END OF LIFE RECYCLING OF PRODUCTS

•Recycle is an important part of the 3R (Reduce,

Reuse, Recyle)
•Not all end-of-life products can be reused

•End-of-life recycling ensures efficient use of

resources and appropriate treatment of
hazardous substances
•Recycling
Energy can considerably
to recycle aluminium reduce
is aboutenergy
5 % of that needed for
needs for
primary production of materials and thus
production.
equivalently
Raw reduce emissions of greenhouse
Materials Product Product
Materials
gases.
Acquisitio
manufact Manufactu Consumpt End-of-life Waste
ure re ion
n

Reuse

Recycle
Source: European Aluminium:“Recycled Content” vs. “End-of-Life Recycling Rate”
WASTE ELECTRICAL
AND ELECTRONIC EQUIPMENT (WEEE)
E-waste such as televisions, household appliances, computers,
mobile phones, photovoltaic panels, etc. is one of the fastest
growing waste streams in the EU.
Because of high concentrations of valuable materials, such as
metals, WEEE is an important resource in circular economy.

COMPOSITION 45
40
• Depends on type, model, manufacturer, 35
manufacture date and age of the equipment. 30
• Plastics, glass, metals. 25
• More than 40 elements in cell phones. 20
• Usually also potentially toxic (hazardous) materials. 15
10
Specific nature of recycling! 5
0
2010 2011 2012 2013 2014 2015 2016

Reuse and recycling rate of e-waste (%)

in EU (28 countries)
 CLASSIFICATION AND LIFESPAN

•There are 6 categories (EU-6) of e-waste

according to WEEE Directive 2012/19/EU.

• Each product of the six e-waste

categories has a different lifetime profile.

Potential value of raw materials

in e-waste
is 55 Billion Euros in 2016 (44.7
https://www.itu.int/en/ITU-D/Climate-Change/Documents/GEM%202017/Global-E-waste%20Monitor%202017%20.pdf
PROCESSES FOR RECYCLING
Mechanical-physical separation

Liberation of materials from their interlocked state physically by comminution

and separation of valuable materials into concentrates.

•Comminution - shredding and screening

•Separation - shape separation, density separation, magnetic separation,

eddy current separation and electrostatic separation

Pyrometallurgical processes

Extraction and purification of metals by processes involving the application of heat.

•Smelting, incineration, combustion, pyrolysis, molten salt, and pyrochemical processes.

Hydrometallurgical processes

Selective leaching of metallic compounds to form a solution from which the metals can
be precipitated and recovered.

•Leaching, precipitation, solvent extraction, and resin ion exchange.

 REFRIGERATORS
Key components/parts:

• Case, thermal insulation, compressor, condenser, evaporator coil, glass shelves.

Primary materials (by scrap value):

• Copper, steel, aluminium, plastics, PUR foam.

Hazardous materials:
3
1% 1% 1%
• %1%polyurethane
Chlorofluorocarbon (CFC), mercury (Hg), polyvinyl chloride (PVC),
(PUR) foam. 3%
7%
Phase 1: Phase 2: 10%
Depollution Shredding and
before shredding separation
• Glass shelves • Steel scrap
60%
• Power cable • PUR foam dust
13%
• Mercury switch • Aluminium/
• Refrigerant and copper
oil • Plastics
• Compressor • Gas
Steel Plastics
Polyurethan Other
Copper Aluminium
PVC (Cables) Glass
Refrigerant Oils

ource: http://eco3e.eu/en/base/refrigerator/
Material composition of a refrigerator
 REFRIGERATORS Disassem
bly
6

4 3 Componen
Draining
ts

8 5
Coolant,
7 Oil,
Shredder
Compress
2 or

1. Manual disassembly 1
Hammer
Phase

mill
2. Draining of the liquid coolant
1

3. Loading onto sealed roller

conveyors Screen
Phase 2

4. Shredding and crushing

5. Screening CFC Magnetic
extraction separation

6. Extraction of CFC‘s
Eddy
7. Magnetic separation PUR dust CFC‘s
Ferrous
currents
metals
separation
8. Eddy currents separation
Non-
ferrous Plastics
metals
ce: http://www.elektrorecycling.sk/technologie/chladiace-zariadenia.html
 Shredded
Refrigerat
CRUSHING AND SCREENING
ors

Hammer mill
Industrial shredder
cut metal and other
materials into smaller
pieces. Plastics
Metals Pulverized foam
Hammer mill further PUR pass through the
foam
reduces the size of screen openings.
the materials. Pieces ofother
PUR foam is materials are
pulverized. retained.
Plastics
Metals

Vibrating screen PUR

foam
 Plastics
Steel SEPARATION
Copper
Aluminiu
m Magnetic separator is
used to remove
pieces of ferrous
metals (steel).
Eddy current
Magnetic
separator is used to
separator
remove pieces of the
t i cs other metals (copper
s r
Pla ppe iu
C o mi n and aluminium),
u
Al m leaving only pieces of
plastics in the last
Steel
product stream.

Eddy current iu
in
separator l um m
A

per
Plastics C op
LARGE EQUIPMENT
• Typical includes: washing machines,
clothes dryers, dish-washing machines, Disassem
bly
electric stoves, large printing machines,
copying equipment, and photovoltaic
panels. Compone
Shredder
• Large household appliances currently nts

make up over 20 % of WEEE (9.1 Mt

globally) Hammer
• Content of about 90 % metals per mill
weight
Magnetic
Recycling technologies used for separatio
n
large domestic appliances are
similar to recycling of Eddy
refrigerators. Ferrous currents
metals separatio
n

Non- Plastics
ferrous and
metals residues
SMALL EQUIPMENT
• Typical includes: vacuum cleaners, microwaves,
ventilation equipment, toasters, electric kettles,
electric shavers, scales, calculators, radio sets,
video cameras, electrical and electronic toys, small
electrical and electronic tools, small medical
devices, small monitoring and control instruments
• Small equipment currently make up almost 38 % of
WEEE (16.8 Mt globally)
• The most complicated WEEE stream for
recycling

Mechanical-physical processing – separation of metals

and plastics
Thermal treatment (pyrometallurgical processes) –
recovery of metals
Hydrometallurgical treatment – recovery of metals
Electrochemical treatment – refining steps
 PRINTED CIRCUIT BOARDS (PCBs)
Key components/parts: Board (non-conductive and conductive layers),
electronic components

Primary materials (by scrap value): Gold, palladium, copper, silver

Hazardous materials Toxic metals (e.g. As, Cd, Cr, Pb, Hg), brominated
flame retardants (BFRs)

Methods for recovery of valuable materials

• Hydrometallurgical leaching

• Feprocessing
Pyrometallurgical Cu Al Pb Sn Ni Pd Au Ag
(wt. (wt. (wt. (wt. (wt. (wt. (pp (pp (pp
%) %) %) %) %) %) m) m) m)
PC mainboard 4.5 14.3 2.8 2.2 1.1 124 566 639
Mobile phone 5 13 1 0.3 0.5 0.1 210 350 1380
TV board 28 10 10 1 1.4 0.3 10 20 280

Typical Cu primary ore contains Typical gold ore grade

about 0.5 wt. % Cu is about 6 ppm. Concentrates
ce: https://www.sciencedirect.com/science/article/pii/S092134491830288X
contain about 500 ppm Au.
 PRE-TREATMENT (HYDROMETALLURGY) Disassem
bly

•Disassembly
Electronic
Base
• Manual (labor intensive), componen
board
ts
• automated (melting of solder joints).

•Size reduction (optional) : Shredding

• Shredding, crushing and grinding.

•Enrichment (optional) – separation: Crushing

• Size and shape, magnetism, electric conductivity

(eddy current, corona electrostatic or triboelectric
Grinding
separation), density.

•Chemical pre-treatment
Magnetic
• Solder mask dissolving, solder dissolving, organic separation
swelling, supercritical depolymerization, resin
dissolving.
Ferrous Electric
metals separation

Non-
Non-
ferrous
metals
metals

Pre-
Purificati Recover
treatme Leaching
on y
nt
ce: https://www.sciencedirect.com/science/article/pii/S092134491830288X
 LEACHING OF METALS (HYDROMETALLURGY)
•Transfer of metals from solid materials to a solution

•Traditional leaching methods

• Leaching of base and precious metals using mineral acids.
 Mineral acids only - H2SO4, HNO3, HCl and aqua regia (HCl:HNO3 = 3:1, v/v).
 Using mineral acid and oxidant - metals with high reduction potentials.
 Multi-stage leaching – selective leaching of metals.
• Cyanide-based leaching of precious metals

•Mild leaching methods

• Thiourea leaching of precious metals – acid or alkaline thiourea
• Thiosulfate leaching of precious metals (S2O32−)
• Thiocyanate leaching of precious metals
• Halide leaching of precious metals
• Ammonia-ammonium leaching of base metals

•Novel leaching methods

• Chelating leaching of base metals
• Ionic liquid leaching of base metals
• Supercritical leaching of base and precious metals

Pre-
Purificati Recover
treatme Leaching
on y
nt
ce: https://www.sciencedirect.com/science/article/pii/S092134491830288X
 PURIFICATION AND RECOVERY (HYDROMETALLURGY)
•Purification – removal of harmful substances from solutions

•Recovery – precipitation of the dissolved metals and their recovery in

solid form.

•Various methods:
• Chemical precipitation – displacement reaction (more active metal
replaces less active metal in solution)
 Cementation – Fe replaces Cu; base metals replace precious metals.
 pH adjustment, using other chemicals for precipitations
• Solvent extraction (metals are passed from the leach solution into
extraction solution and the two phases are then separated).
• Activated carbon adsorption - Au and Ag recovery from cyanide
leaching solutions.
• Ion exchange by resin – comparable to adsorption with activated
carbon often with higher adsorption and recovery rates
• Electrodeposition – utilization of simple electric device with
minimal chemicals input – environmental point of view.

Pre-
Purificati Recover
treatme Leaching
on y
nt
ce: https://www.sciencedirect.com/science/article/pii/S092134491830288X
 PYROMETALLURGY (PCBs)
•Pre-treatment (dismantling of electronic components, grinding)

•Incineration
• Aerobic conditions – organic components are thermally decomposed and
combusted at high temperature.
• Glass-fibers and metal oxides (recycled by physical separation methods).

•Pyrolysis
• Thermochemical decomposition of organic resins in anaerobic conditions.
• Pyrolysis products (oil and gasses) and residues (glass fibers and metals)

•Plasma
• Decomposition of organic matter to gasses and melting of glass fibers.
• Gasses, vitreous body (molten glass fibers), metals.

•Molten salt
• Molten salt (stable and inert) is used to separate liquid or solid-state metal
products at high temperature.

Pyrometallurg
Physical
Pre-treatment ical
separation
processing
ce: https://www.sciencedirect.com/science/article/pii/S0921344917302409
Present Scenario of E-waste
Recycling in India
 90-95% e-waste recycling in non-formal sector

Non-formal sector
 PCBs are treated in primitive methods to remove
components & value metals
 Burning cables to recover copper & unwanted materials
in open air
 Leaching of heavy metals/ chemicals into landfills
and incinerator hazardous
 Recovery yield is poor (~10-20%)- loosing precious
metals

• 5-10% e-waste is recycled in formal sector

Formal sector
• Segregating, disassembling to recover:
structural metal parts, cables, Printed Circuit
Board (PCB), glass components etc.
• Limited PCB treatment or Exported them for further
process to recover precious metals
 Potential Materials Recovered from E-
waste
Recovered Items Recycling Option Used
1. Small & large Dismantling, Recovered materials
Hazardous waste Plastics Precious Metals Structural parts

structural metal Segregation, Smelting can be sold at market

parts, heat sinks, Available with local price
Ferrous metal smelters
2. Ferrite & ceramic
components Non ferrous
metal scrap mainly Cu &
Al
3. Glass components
4. Precious metal scrap, PCBs Exported/ High end
with IC Chips, electronic imported Technology
components and connectors Required Indigenous High value
technology developed: extracted Precious
Smelting + Hydro- metals can be sold
metallurgy + Electro-
chemical Process
5. Small & large low value/ dealt in Value added master
structural plastic informal sector batch made
parts, flame retardants Indigenous high value
plastic Technology extracted metals
6. Cables and wires Developed
7. Hazardous wastes like CFC, Indigenous Extracted metals
Mercury (Hg) Switches, CRT, Technology to be sold to
and capacitor Developed market
8. Hazardous wastes like High end imported High value
batteries specially Technology Required extracted Precious
Lithium ion Indigenous metals can be sold
technology
developed:
 Technology Developed for Extraction of
Metals

◉ Processing technology successfully developed for recycling and

reuse of electronic waste

o Pulverization, physical separation, chemical leaching etc.

o Pilot Plant level demonstration done to recover precious
metal from 1 Metric Tonnes of e-waste with a recovery rate
of 95%.
o Commercialization
NML, Jamshedpur

◉ Printed circuit boards processing technology was successfully

developed & demonstrated

o Depopulation, pyrolysis, calciner, chemical leaching etc.

CMET, Hyderabad & E-parisara, Bangalore

 Dismantling and Segregation

Initial Process

Electronic Printed Circuit

Products Boards

Segregated
Components
 PCB Recycling

Physical
Separation
(Magnetic, Gravity,
Electrical)
Populated PCB Pulverized PCB

Chemical
Leaching
Cu, Au
Ag Pd
metals
fractions

Cu, Au Ag, Pd M
e
t
a
NML, Jamshedpur- process l

R
 PCB Recycling

Oil
Depopulator Pyrolysis
Gas

Populated
Depopulated Solid
PCB
PCB

Chemical Calcinations
Leaching & & Smelting
Electrolysis

Metal Recovery Materials

CMET, Hyderabad & E-Parisara, B’lr- process

 Printed circuit
Precious boards Depopulation
metals (10kg/hour)
Environmental sound PCB
Anode mud Recycling Technology: 100Kg Shredding
processing
capacity (20kg/hour)
(5kg/batch)
 Prototype systems developed

 Demonstration plant
established
Electro-refining  Flue gases are treated in a secondary
Calcination
(5kg Cu/day) burner and the dioxin and furnas (100kg/day)
contents within admissible emission
limit of CPCB
Smelting
(150kg/day)
Refining of copper
(150kg/day)
 Metal Extraction from PCB Recycling:
Demonstration Plant
C-MET Hyderabad EPPL Bangalore

Status:
ToT ready up till black
copper & also precious
metal

End user:
Copper smelters, E- waste
recyclers

Capacity: 300 TPA

Capacity: 30 TPA
1000Kg PCB (35MT e-
100Kg PCB (3.5MT e-waste) /batch waste) /day
 Metal Extraction from PCB Recycling:
Demonstration Plant
C-MET Hyderabad

E-Waste Demo Plant at C-MET

Hyderabad

Electro-Refining unit Anode Mud

(5kg/day Deposition rate) Leaching Unit
 Metal Extraction from PCB Recycling:
Demonstration Plant
EPPL Bangalore

Ingots of Black copper

Indigenously designed and

fabricated low cost furnace for
smelting of PCBs.
 Metal Extraction from PCB Recycling:
Demonstration Plant
EPPL Bangalore

Scaled up Electrolysis of Anode

Copper to 99.9 % pure copper,
collection of precious metals rich anode Ingots of fire
slime refined copper
 Typical Potential Materials from e-
waste:
Demonstration
* E-waste mixture (Desktop, Plant
laptop, refrigerator, TV, Washing machine etc.) 35MT
a. Ferrous (iron & steel) : 13.80 MT
b. Non ferrous ( Cu, Al, Pb, Sn (39%)
etc) : 10.20 MT
c. Plastics: (29%)
d. Glass: 8.00 MT
e. PCB:a., b. and d. to be sold to smelter based (23%)
on their market value
2.00
c. and MT
e. would be processed
(06%)
* Li-ion battery mixture (of mobile, laptop, tubular batteries etc. 10MT
1.00 MT
a. Aluminum: (03%)
1.50 MT (15%)
b. Copper : 1.00 MT (10%)
c. Cobalt: 1.80 MT (8%)
d. Lithium: 0.18 MT (2%)
e. Plastic: 0.90 MT (9%)
f. Carbon: 2.00 MT (20%)
g. Electrolyte: 1.90 MT (19%)
h. Steel, Nickel, 0.72 MT (7%)
others: a., b. c. d. e and h would be
recovered
 Technology developed for E-waste Plastics
• 7 categories of plastics
(ABS, HIPS, PC, PP,
PVC, nylons,
Epoxy, phenolic, Polyesters
etc.) Segregated in 3 Types:

o Homogenous type Type

1: (76%): housing, mouse
etc.. Processing
technology developed to
convert these plastic to
Master batch for value
added product, gained
virgin properties,
Process patented. TOT in
progress
o Heterogenous type: Type
2 (20.5%): connectors,
catridge,
etc., & Type 3
(3.5%):
Thermoset plastics
containing BFR, fillers &
 Technology developed for E-waste Plastics
CIPET, Bhubaneswar

Grinding, washing
mechanical recycling
Collection, segregation/
identification of plastics Blending with additives &
fillers for properties
optimization
 Other Materials Processed : Demonstration
Plant

• All types of wires/ connectors

• CFL / Fluorescent Tube

• Rare earth materials from Phosphors (Yttrium,

Europium etc.)

• Rare earth materials from Neodymium (Nd) from Hard

disc
SMART PHONE LIFE CYCLE
• Nearly 60% of the WEEE stream consists of seven ferrous and non-ferrous
metals such as iron (Fe), copper (Cu), aluminum (Al), lead (Pb), gold (Au),
silver (Ag), platinum (Pt) and palladium (Pd). Gramatyka et al. stated that the
typical metal scrap comprises 20% copper (Cu), 8% iron (Fe), 4% tin (Sn),
2% nickel (Ni), 2% lead (Pb), 1% zinc (Zn), 0.02% silver (Ag), 0.1% gold (Au)
and 0.005% palladium (Pd) metals .
• Printed circuit boards, popularly known as printed circuit boards (PCBs),
are the backbone of most electronics and they are generally composed of
metals, ceramics and polymers. Even though they contribute only to 6% of
the weight of WEEE, they are the main carriers of valuable metals. According
to Cui and Zhang, the precious metal content in telephones and PCBs is about
70%, while it is about 40% in TV boards and DVD players

• A typical computer PCB contains 250 g/ton Au and 20 wt.% Cu, while a
mobile phone contains 350 g/ton Au and 13 wt.% Cu,
• Metals could be recycled by conventional mechanical, pyrometallurgical,
hydrometallurgical and bio/hydrometallurgical processes or a combination
of these techniques,