Biotechnological strategies for the recovery of valuable and critical raw materials from waste electrical and electronic equipment (WEEE) - A review

Critical raw materials (CRMs) are essential in the development of novel high-tech applications. They are essential in sustainable materials and green technologies, including renewable energy, emissionfree electric vehicles and energy-efficient lighting. However, the sustainable supply of CRMs is a major concern. Recycling end-of-life devices is an integral element of the CRMs supply policy of many countries. Waste electrical and electronic equipment (WEEE) is an important secondary source of CRMs. Currently, pyrometallurgical processes are used to recycle metals from WEEE. These processes are deemed imperfect, energy-intensive and non-selective towards CRMs. Biotechnologies are a promising alternative to the current industrial best available technologies (BAT). In this review, we present the current frontiers in CRMs recovery from WEEE using biotechnology, the biochemical fundamentals of these bio-based technologies and discuss recent research and development (R&D) activities. These technologies encompass biologically induced leaching (bioleaching) from various matrices,biomass-induced sorption (biosorption), and bioelectrochemical systems (BES).

A novel bioreactor system for simultaneous mutli-metal leaching from industrial pyrite ash: Effect of agitation and sulphur dosage

Simultaneous multi-metal leaching from industrial pyrite ash is reported for the first time using a novel bioreactor system that allows natural diffusion of atmospheric O₂ and CO₂ along with the required temperature maintenance. The waste containing economically important metals (Cu, Co, Zn & As) was leached using an adapted consortium of meso-acidophilic Fe²⁺ and S oxidising bacteria. The unique property of the sample supported adequate growth and activity of the acidophiles, thereby, driving the (bio) chemical reactions. Oxido-reductive potentials were seen to improve with time and the system's pH lowered as a result of active S oxidation. Increase in sulphur dosage (>1g/L) and agitation speed (>150rpm) did not bear any significant effect on metal dissolution. The consortium was able to leach 94.01% Cu (11.75% dissolution/d), 98.54% Co (12.3% dissolution/d), 75.95% Zn (9.49% dissolution/d) and 60.80% As (7.6% dissolution/d) at 150rpm, 1g/L sulphur, 30°C in 8days.

Synergistic effect of biogenic Fe3+ coupled to S° oxidation on simultaneous bioleaching of Cu, Co, Zn and As from hazardous Pyrite Ash Waste

Pyrite ash, a waste by-product formed during roasting of pyrite ores, is a good source of valuable metals. The waste is associated with several environmental issues due to its dumping in sea and/or land filling. Although several other management practices are available for its utilization, the waste still awaits and calls for an eco-friendly biotechnological application for metal recovery. In the present study, chemolithotrophic meso-acidophilic iron and sulphur oxidisers were evaluated for the first time towards simultaneous mutli-metal recovery from pyrite ash. XRD and XRF analysis indicated higher amount of Hematite (Fe₂O₃) in the sample. ICP-OES analysis indicated concentrations of Cu>Zn>Co>As that were considered for bioleaching. Optimization studies indicated Cu - 95%, Co - 97%, Zn - 78% and As - 60% recovery within 8days at 10% pulp density, pH - 1.75, 10% (v/v) inoculum and 9g/L Fe²⁺. The productivity of the bioleaching system was found to be Cu - 1696ppm/d (12% dissolution/d), Co - 338ppm/d (12.2% dissolution/d), Zn k 576ppm/d (9.8% dissolution/d) and As - 75ppm/d (7.5% dissolution/d). Synergistic actions for Fe²⁺ - S° oxidation by iron and sulphur oxidisers were identified as the key drivers for enhanced metal dissolution from pyrite ash sample.

An integrated biological approach for treatment of cyanidation wastewater

The cyanidation process has been, and still remains, a profitable and highly efficient process for the recovery of precious metals from ores. However, this process has contributed to environmental deterioration and potable water reserve contamination due to the discharge of poorly treated, or untreated, cyanide containing wastewater. The process produces numerous cyanide complexes in addition to the gold cyanocomplex. Additionally, the discharge constituents also include hydrogen cyanide (HCN) - metallic complexes with iron, nickel, copper, zinc, cobalt and other metals; thiocyanate (SCN); and cyanate (CNO). The fate of these complexes in the environment dictates the degree to which these species pose a threat to living organisms. This paper reviews the impact that the cyanidation process has on the environment, the ecotoxicology of the cyanidation wastewater and the treatment methods that are currently utilised to treat cyanidation wastewater. Furthermore, this review proposes an integrated biological approach for the treatment of the cyanidation process wastewater using microbial consortia that is insensitive and able to degrade cyanide species, in all stages of the proposed process.

Combined oxidative leaching and electrowinning process for mercury recovery from spent fluorescent lamps

In this paper, oxidative leaching and electrowinnig processes were performed to recovery of mercury from spent tubular fluorescent lamps. Hypochlorite was found to be effectively used for the leaching of mercury to the solution. Mercury could be leached with an efficiency of 96% using 0.5M/0.2M NaOCl/NaCl reagents at 50°C and pH 7.5 for 2-h. Electrowinning process was conducted on the filtered leaching solutions and over the 81% of mercury was recovered at the graphite electrode using citric acid as a reducing agent. The optimal process conditions were observed as a 6A current intensity, 30g/L of reducing agent concentration, 120min. electrolysis time and pH of 7 at the room temperature. It was found that current intensity and citric acid amount had positive effect for mercury reduction. Recovery of mercury in its elemental form was confirmed by SEM/EDX. Oxidative leaching with NaOCl/NaCl reagent was followed by electrowinning process can be effectively used for the recovery of mercury from spent fluorescent lamps.

A greener approach for resource recycling: Manganese bioleaching

In view of unremitting diminution of mineral resources, rising energy economics along with increasing global consumption of Manganese (Mn), development of environment friendly technologies for tapping alternate sources of Mn has gained importance lately. Mn recovery from mining residues using conventional approaches is extremely expensive due to high capital and energy costs involved. However lean grade ores present in millions of tons awaits the development of competent and cost effective extractive process. Mn recovery by biomining with diverse microbes is thereby recommended as a superior and green alternative to the current pyro metallurgical techniques. The synergistic effects of different factors are known to influence microbial leaching of mineral ores which includes microbiological, mineralogical, physicochemical and process parameters. Bacterial bioleaching is mostly due to enzymatic influence, however fungal bioleaching is non enzymatic. Genomic studies on microbial diversity and an insight of its metabolic pathways provides unique dimension to the mechanism of biomining microorganisms. The extraction of Mn has a massive future prospective and will play a remarkable role in altering the situation of ever-decreasing grades of ore. This review aims to encompass the different aspects of Mn bioleaching, the plethora of organisms involved, the mechanisms driving the process and the recent trends and future prospects of this green technology.

Copper and cobalt recovery from pyrite ashes of a sulphuric acid plant

The pyrite ashes formed as waste material during the calcination of concentrated pyrite ore used for producing sulphuric acid not only has a high iron content but also contains economically valuable metals. These wastes, which are currently landfilled or dumped into the sea, cause serious land and environmental pollution problems owing to the release of acids and toxic substances. In this study, physical (sulphation roasting) and hydrometallurgical methods were evaluated for their efficacy to recover non-iron metals with a high content in the pyrite ashes and to prevent pollution thereby. The preliminary enrichment tests performed via sulphation roasting were conducted at different roasting temperatures and with different acid amounts. The leaching tests investigated the impact of the variables, including different solvents, acid concentrations and leach temperatures on the copper and cobalt leaching efficiency. The experimental studies indicated that the pre-enrichment via sulphation roasting method has an effect on the leaching efficiencies of copper and cobalt, and that approximate recoveries of 80% copper and 70% cobalt were achieved in the H2O2-added H2SO4 leaching tests.

Recovery of vanadium from spent catalysts of sulfuric acid plant by using inorganic and organic acids: Laboratory and semi-pilot tests

Catalysts are used extensively in industry to purify and upgrade various feeds and to improve process efficiency. These catalysts lose their activity with time. Spent catalysts from a sulfuric acid plant (main elemental composition: 5.71% V2O5, 1.89% Al2O3, 1.17% Fe2O3 and 61.04% SiO2; and the rest constituting several other oxides in traces/minute quantities) were used as a secondary source for vanadium recovery. Experimental studies were conducted by using three different leaching systems (citric acid with hydrogen peroxide, oxalic acid with hydrogen peroxide and sulfuric acid with hydrogen peroxide). The effects of leaching time, temperature, concentration of reagents and solid/liquid (S/L) ratio were investigated. Under optimum conditions (1:25 S/L ratio, 0.1 M citric acid, 0.1 M hydrogen peroxide, 50°C and 120 min), 95% V was recovered in the presence of hydrogen peroxide in citric acid leaching.

Current scenario of chalcopyrite bioleaching: a review on the recent advances to its heap-leach technology

Chalcopyrite is the primary copper mineral used for production of copper metal. Today, as a result of rapid industrialization, there has been enormous demand to profitably process the low grade chalcopyrite and "dirty" concentrates through bioleaching. In the current scenario, heap bioleaching is the most advanced and preferred eco-friendly technology for processing of low grade, uneconomic/difficult-to-enrich ores for copper extraction. This paper reviews the current status of chalcopyrite bioleaching. Advanced information with the attempts made for understanding the diversity of bioleaching microorganisms; role of OMICs based research for future applications to industrial sectors and chemical/microbial aspects of chalcopyrite bioleaching is discussed. Additionally, the current progress made to overcome the problems of passivation as seen in chalcopyrite bioleaching systems have been conversed. Furthermore, advances in the designing of heap bioleaching plant along with microbial and environmental factors of importance have been reviewed with conclusions into the future prospects of chalcopyrite bioleaching.

A review of metal recovery from spent petroleum catalysts and ash

With the increase in environmental awareness, the disposal of any form of hazardous waste has become a great concern for the industrial sector. Spent catalysts contribute to a significant amount of the solid waste generated by the petrochemical and petroleum refining industry. Hydro-cracking and hydrodesulfurization (HDS) catalysts are extensively used in the petroleum refining and petrochemical industries. The catalysts used in the refining processes lose their effectiveness over time. When the activity of catalysts decline below the acceptable level, they are usually regenerated and reused but regeneration is not possible every time. Recycling of some industrial waste containing base metals (such as V, Ni, Co, Mo) is estimated as an economical opportunity in the exploitation of these wastes. Alkali roasted catalysts can be leached in water to get the Mo and V in solution (in which temperature plays an important role during leaching). Several techniques are possible to separate the different metals, among those selective precipitation and solvent extraction are the most used. Pyrometallurgical treatment and bio-hydrometallurgical leaching were also proposed in the scientific literature but up to now they did not have any industrial application. An overview on patented and commercial processes was also presented.

Precious metal recovery from waste printed circuit boards using cyanide and non-cyanide lixiviants--A review

Waste generated by the electrical and electronic devices is huge concern worldwide. With decreasing life cycle of most electronic devices and unavailability of the suitable recycling technologies it is expected to have huge electronic and electrical wastes to be generated in the coming years. The environmental threats caused by the disposal and incineration of electronic waste starting from the atmosphere to the aquatic and terrestrial living system have raised high alerts and concerns on the gases produced (dioxins, furans, polybrominated organic pollutants, and polycyclic aromatic hydrocarbons) by thermal treatments and can cause serious health problems if the flue gas cleaning systems are not developed and implemented. Apart from that there can be also dissolution of heavy metals released to the ground water from the landfill sites. As all these electronic and electrical waste do posses richness in the metal values it would be worth recovering the metal content and protect the environmental from the pollution. Cyanide leaching has been a successful technology worldwide for the recovery of precious metals (especially Au and Ag) from ores/concentrates/waste materials. Nevertheless, cyanide is always preferred over others because of its potential to deliver high recovery with a cheaper cost. Cyanidation process also increases the additional work of effluent treatment prior to disposal. Several non-cyanide leaching processes have been developed considering toxic nature and handling problems of cyanide with non-toxic lixiviants such as thiourea, thiosulphate, aqua regia and iodine. Therefore, several recycling technologies have been developed using cyanide or non-cyanide leaching methods to recover precious and valuable metals.

Experimental design and process analysis for acidic leaching of metal-rich glass wastes

The removal of iron, titanium and aluminium from colourless and green waste glasses has been studied under various experimental conditions in order to optimize the process parameters and to decrease the metal content in the waste glass by acidic leaching. Statistical design of experiments and ANOVA (analysis of variance) were performed in order to determine the main effects and interactions between the investigated factors (sample ratio, acid concentration, temperature and leaching time). A full factorial experiment was performed by sulphuric acid leaching of glass for metal removal. After treating, the iron content was 530 ppm, corresponding to 1880 ppm initial concentration of Fe(2)O(3) in the original colourless sample. This result is achieved using 1M H(2)SO( 4) and 30% sample ratio at 90(o)C leaching temperature for 2 hours. The iron content in the green waste glass sample was reduced from 3350 ppm initial concentration to 2470 ppm after treating.

Biodegradation of cyanide containing effluents by Scenedesmus obliquus

Biological degradation of cyanide has been shown a viable and robust process for degrading cyanide in mining process wastewaters. Several algal cultures can effectively degrade cyanide as carbon and/or nitrogen source for their growth. In this study, cyanide effluent degradation by Scenedesmus obliquus was examined. Gold mill effluents containing WAD cyanide concentration of 77.9mg/L was fed to batch unit to examine the ability of S. obliquus for degrading cyanide. Cyanide was reduced down to 6mg/L in 77h. Microbial growth and metal uptake of Zn, Fe and Cu was examined during cyanide degradation. The cells well adapted to high pH and the effluent contained cyanide and the metals. It is important that Zn level reduced down 50%, of the starting concentration. pH was kept at 10.3 to prevent loss of cyanide as HCN, due its volatile nature. The bio treatment process was considered to be successful in degrading cyanide in the mine process water.

Heterogeneous catalytic degradation of cyanide using copper-impregnated pumice and hydrogen peroxide

The main objective of this research was to investigate the oxidative destruction of free cyanide with hydrogen peroxide and copper-impregnated pumice as a heterogeneous catalyst. Original or copper-impregnated pumices added alone were not effective adsorbents of negatively charged cyanide ions due to incompatible surface interactions. Peroxide and original pumices added together were also ineffective in removing cyanide. However, for all of the three natural pumices tested with various particle size fractions, the use of copper-impregnated pumices and peroxide together significantly enhanced both the initial rate and extent of cyanide removal. Although copper-impregnated specific surface area was the major factor affecting the rate and extent of cyanide destruction for a particular pumice source with similar surface chemistries, the type of surface chemistry (i.e., specific functional groups) within different pumice sources also appears to be a very important factor. Lower rates and extents of cyanide removals were observed at pH 11 compared to pH 8 probably because of the negative impacts of alkaline conditions in terms of scavenging peroxide and forming more negatively charged pumice surfaces. Both the initial rate and ultimate extent of cyanide removals were generally higher at a temperature of 20 degrees C compared with those found at 10 degrees C. The use of copper-impregnated pumice as a light, cheap, readily available, natural, and porous heterogeneous catalyst either in completely mixed/suspended or fixed-bed reactor configurations may be an effective treatment technology for cyanide removal from solution. This new approach may minimize downstream metal removal problems experienced in conventional cyanide oxidation technologies.

Destruction of cyanide in gold mill effluents: biological versus chemical treatments

In gold mining, cyanide has been the preferred lixiviant worldwide since 1887. Although cyanide can be destroyed and recovered by several processes, it is still widely discussed and examined due to its potential toxicity and environmental impact. Biological treatment of cyanide is a well-established process and has been commercially used at gold mining operations in North America. Biological treatment processes facilitate growth of microorganisms that are essential for the treatment. The present review describes the advances in the use of biological treatment for the destruction of cyanide in gold mill effluents.

Microbial destruction of cyanide wastes in gold mining: process review

Microbial destruction of cyanide and its related compounds is one of the most important biotechnologies to emerge in the last two decades for treating process and tailings solutions at precious metals mining operations. Hundreds of plant and microbial species (bacteria, fungi and algae) can detoxify cyanide quickly to environmentally acceptable levels and into less harmful by-products. Full-scale bacterial processes have been used effectively for many years in commercial applications in North America. Several species of bacteria can convert cyanide under both aerobic and anaerobic conditions using it as a primary source of nitrogen and carbon. Other organisms are capable of oxidizing the cyanide related compounds of thiocyanate and ammonia under varying conditions of pH, temperature, nutrient levels, oxygen, and metal concentrations. This paper presents an overview of the destruction of cyanide in mining related solutions by microbial processes.