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A Review of Current Progress of Recycling Technologies for Metals from Waste


Electrical and Electronic Equipment

Article in Journal of Cleaner Production · April 2016


DOI: 10.1016/j.jclepro.2016.04.004

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Lingen Zhang Zhenming Xu


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Journal of Cleaner Production 127 (2016) 19e36

Contents lists available at ScienceDirect

Journal of Cleaner Production


journal homepage: www.elsevier.com/locate/jclepro

Review

A review of current progress of recycling technologies for metals from


waste electrical and electronic equipment
Lingen Zhang, Zhenming Xu*
School of Environmental Science and Engineering, Shanghai Jiao Tong University, 800 Dongchuan Road, Shanghai 200240, People's Republic of China

a r t i c l e i n f o a b s t r a c t

Article history: The development of the recycling technologies for waste electrical and electronic equipment (WEEE) has
Received 2 November 2015 entered a new stage. The WEEE disposing technologies have evolved from simple disassembly, classifi-
Received in revised form cation and sorting to high value-added utilization technologies. In the past decade, some modified and
3 April 2016
novel technologies have been developed to recover metals from WEEE. This paper focuses on the
Accepted 4 April 2016
Available online 12 April 2016
recycling of metals from WEEE. The recycling principle, separating process, and optimized operating
parameters of existing technologies are summarized and discussed in detail. Based on traditional recy-
cling technologies of WEEE, pyrometallurgical technology and some mild extracting reagent, such as
Keywords:
Recycling technology
chloride medium, ammoniaeammonium and non-cyanide lixiviants can effectively recycle metals.
Waste electrical and electronic equipment Compared with the conventional acid and cyanide leaching, they have vast improvements in aspect of
(WEEE) environmental protection. More than 98% of Cu and 70% of Au can be extracted. In addition, electro-
Metals chemical technology, supercritical technology, vacuum metallurgical technology, etc. are also applied to
Environmental assessment recycle WEEE. The recovery rate of Cu and Pb under optimum conditions is around 84.2% and 89.4%
respectively in supercritical water oxidation (SCWO) combined with electrokinetic (EK) technology.
Vacuum technology has good environmental performance due to its avoiding discharge of waste water.
Other new technologies such as ultrasound technology, mechanochemical technology, and molten salt
oxidation technology have also been tried to recycle metals from WEEE. Regrettably, although many
endeavors to develop recycling technologies have been attempted, these technologies are still relatively
single and limited because WEEE is a complex system. Hence, the shortages and defects of each tech-
nology are discussed from the perspective of technological promotion and environmental protection.
Furthermore, the outlook about the further development of recycling technologies for metals from WEEE
is presented.
© 2016 Published by Elsevier Ltd.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. Selection and classification of research methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3. Traditional methods to recycle metals from WEEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4. Advanced technologies to recycle metals from WEEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1. Pyrometallurgical technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2. Mild extracting technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3. Biometallurgical technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4. Electrochemical technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5. Supercritical technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Acronyms and abbreviations: WEEE, waste electrical and electronic equipment; BFR, bromined flame-retardant; Waste PCBs, waste printed circuit boards; PMO, precious
metals operations; BMO, base metals operations; LIBs, lithium-ion batteries; SCW, supercritical water; BER, brominated epoxy resin; SCWO, supercritical water oxidation;
SCM, supercritical methanol; EK, electrokinetic; XRD, X-ray diffractometer; LCD, liquid crystal display; CRTs, cathode-ray tubes; TCLP, toxicity characteristic leaching pro-
cedure; MSO, molten salt oxidation.
* Corresponding author. Tel./fax: þ86 21 54747495.
E-mail address: zmxu@sjtu.edu.cn (Z. Xu).

http://dx.doi.org/10.1016/j.jclepro.2016.04.004
0959-6526/© 2016 Published by Elsevier Ltd.
20 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

4.6. Vacuum metallurgical technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


4.7. Other novel technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5. Environmental and practical defects of advanced technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6. Perspectives on recycling technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1. Recycling technologies aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2. Environmental protection aspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Supplementary data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1. Introduction advantages, such as less secondary waste and lower energy con-
sumption (He et al., 2006).
With new technological innovation, the replacement of equip- However, WEEE contains not only all kinds of metals, but other
ment is persistently accelerating the occurrence of serious pollu- chemical components which are also quite complicated, such as
tion problem resulting from waste electrical and electronic plastics and brominated flame retardants (BFRs). If WEEE is not
equipment (WEEE). The global amount of WEEE produced and disposed or recovered properly, it will cause serious environmental
disposed is sharply increasing over the past several decades. Ac- pollution and even jeopardize human health (Wang and Xu, 2015).
cording to statistics of Kiddee et al. (2013), 500 million tons of The main hazardous and useful materials of typical WEEE compo-
computers were discarded between 1997 and 2007 in the United nents are shown in Table 3. It has been reported that the occurrence
States and 610 million tons of computers became obsolete in Japan of recycling of WEEE by environment-unfriendly, hazardous and
by the end of 2010. The same statistics indicate more than 1.1 primitive technologies in China has increased in the past decades
million tons/year WEEE are generated in China, particularly from (Ni et al., 2010). Massive amounts of dumping or open burning of
manufacturing industry, end-of-life appliances and imports from WEEE took place in some cities of China.
developed countries (Hadi et al., 2015). Every year, 20e50 million Therefore, research on resource reutilization and safe disposal of
tons of WEEE are generated worldwide and this figure is growing the metals from WEEE has a great significance from the viewpoint
by about 45 million tons/year (Ogunseitan, 2013). of environmental protection. In the initial stage of WEEE recycling,
The waste electrical and electronic products are diverse, simple and rough recovery processes were widely adopted. As
including printed circuit boards (PCBs), television sets, re- shown in Fig. 2, ways of recycling metals from WEEE mainly include
frigerators, computers, cell phones, batteries, etc. Table 1 shows the manual dismantling, hydraulic shaking bed separation, strong acid
main components of typical WEEE, which were first listed in the leaching, etc. The defects of these methods are huge, as they not
Waste Electrical and Electronic Products Recycling Directory by only have low recovery efficiency, but also damage human health
Chinese government in 2011. and environment. Facing the serious issue resulting from crude
WEEE contains a variety of valuable materials, such as metals, recycling of WEEE, the European Union Council passed WEEE
glass, plastics and others. As can be seen in Fig. 1, WEEE is mainly Directive and the Restriction of Hazardous Substances (RoHS)
composed of metals (~60% weight), followed by plastics (~15.21% Directive to limit the harmful composition in electronic products in
weight), and CRT & LCD screen (11.87% weight). January 2003. In the last decade, China has followed the same
Although WEEE accounts for only 3e5% in solid waste, the va- legislative trends and developed WEEE laws and directives
rieties and contents of valuable metals in it are far more than other (Gottberg et al., 2006).
forms of municipal waste (Li et al., 2015). As shown in Table 2, Entering the 1970s, mechanicalephysical separation methods
WEEE such as printed circuit boards, TV scrap has high content of began to be utilized to treat the WEEE (Zhang and Forssberg, 1998).
base metals and the electronic devices such as personal computers Mechanicalephysical separation steps included selectively
and mobile phone scrap contains a large number of precious metals dismantling, crushing and physical separation methods. The
(Akcil et al., 2015; Cui and Zhang, 2008). Therefore, WEEE is worthy
of the name of “urban mine”. According to a survey by Environ-
mental Protection Agency, U.S., compared with primary metals
production, recycling metal resources from WEEE has significant

Table 1
Main components of typical WEEE (He and Xu, 2014).

Typical WEEE Main components

Refrigerator Tubes, liners, condenser, wires, refrigerant


Air conditioner Heat exchanger, motor, compressor,
copper pipe, PCBs, wires, refrigerant
Washer Tub, drain hose, motor, wires, salt waste
Television Deflection yoke, demagnetized coil,
speaker, PCBs, wires, CRTs, LCD
Computer Speaker, battery, storage medium,
PCBs, wires, CRTs, LCD
Cell phones Plastic enclosure, battery, storage
medium, PCBs, wires, LCD
Printer/duplicator Roller, toner, PCBs, wires, toner cartridge
Fig. 1. Typical material fractions in WEEE (Wang and Xu, 2014).
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 21

Table 2
Weight composition and value distribution of metals for different WEEE (Cui and Zhang, 2008).

Electronic waste Content and value distribution for different WEEE (%) (in brackets)

Weight (%) Weight (g/t)

Fe Cu Al Pb Ni Ag Au Pd

TV board scrap 28 (4) 10 (39) 10 (13) 1 (2) 0.3 (5) 280 (6) 20 (25) 10 (6)
PC board scrap 7 (0) 20 (10) 5 (1) 1.5 (0) 1 (1) 1000 (64) 250 (5) 110 (15)
Mobile phone scrap 5 (0) 13 (8) 1 (0) 0.3 (0) 0.1 (0) 1380 (5) 350 (67) 210 (19)
DVD player scrap 62 (17) 5 (35) 2 (4) 0.3 (1) 0.05 (1) 115 (4) 15 (33) 4 (4)
PC mainboard scrap 4.5 (0) 14.3 (6) 2.8 (0) 2.2 (0) 1.1 (2) 639 (2) 566 (81) 124 (8)
Printed circuit boards scrap 12 (1) 10 (19) 7 (4) 1.2 (1) 0.85 (6) 280 (3) 110 (66) e
TV scrap (CRTs removed) e 3.4 (82) 1.2 (9) 0.2 (2) 0.038 (4) 20 (3) <10 (e) <10 (e)
Calculator scrap 4 (1) 3 (12) 5 (6) 0.1 (0) 0.5 (8) 260 (6) 50 (64) 5 (3)
Portable audio scrap 23 (3) 21 (78) 1 (1) 0.14 (0) 0.03 (0) 150 (3) 10 (12) 4 (2)
Typical electronic device scrap 8 (0) 20 (5) 2 (0) 2 (0) 2 (2) 2000 (3) 1000 (87) 50 (2)
E-scrap sample 27.3 (1) 16.4 (22) 11 (5) 1.4 (1) e 210 (2) 150 (65) 20 (4)

Table 3
Main hazardous and useful materials in components of typical WEEE (He and Xu, 2014).

Component Hazardous materials Useful materials

PCBs Heavy metals, brominated flame retardants Glass fiber, resin, copper
Refrigerator cabinet Freon Copper, aluminum, plastic
Toner cartridge Toner aluminum, steel, plastic Aluminum, steel, plastic
CRT Pb (PbO) Glass
LCD panel Liquid crystal, TAC, PVA Glass, In2O3
Wire Polychlorinated biphenyls Copper, aluminum, plastic
Li-ion battery LiPF6 Steel, Al, Cu, Li, Co
NieCd battery Cd Steel, Fe, Ni

Fig. 2. (a) Manual dismantling and (b) hydraulic shaking bed separation to recycle metals in WEEE.

Table 4
A summary of separating situation for the physical separation technologies (Ruan and Xu, 2016).

Physical separation method Character of separation Main advantages and disadvantages

Magnetic separation (MS) Separation of ferrous metals MS was most suitable separating steel or iron but not suitable for
separating of non-ferrous metals
Eddy current separation (ECS) Separation of ferrous and ECS was encouraged to recover non-ferrous metallic particles and
non-ferrous materials hard to separate ferrous metals/other metals
Air current separation (ACS) Separation of light particles Wind velocity, particle size, particle density, etc. were the critical
from heavy particles influences for ACS
Corona electrostatic separation (CES) Separate metallic particles The movement trajectory and collection position of metallic particles
(size from 0.2 mm to 1 mm) in CES were hard to predict and compute
from non-metallic particles

separating situations for the physical separation technologies are particles. Mechanicalephysical separation technologies have ach-
summarized Table 4. ieved good effects in aspect of practice and environmental pro-
The methods of magnetic separation and eddy current separa- tection. They have been adopted by most of the recycling
tion are usually chosen to separate ferrous and non-ferrous metal enterprises in China. An integrated mechanical-physical recycling
22 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

technology for WEEE was established by Xu and his team (Li et al., metals, such as low energy consumption and significant economic
2007; Li and Xu, 2010), including two-step crushing, corona elec- benefits.
trostatic separation, to recover metallic and non-metallic materials Although special advantages come from these technologies,
(Huang et al., 2009a). Eddy current and electrostatic separation defects accompany also. These recycling processes for metals are
methods have achieved recovery for magnetic metals, such as Fe, relatively single, limited, and some methods still have negative
Ni, Co etc (Habib et al., 2013; Jujun et al., 2014; Menad et al., 2013). effects on environment. Therefore, it is necessary to summarize and
Furthermore, non-metal materials from WEEE also achieved recy- discuss in detail the current status of recovery technologies for base
cling as padding (Guo et al., 2010a, b). Fig. 3 shows an automatic and precious metals from WEEE. This paper focuses on the recy-
production line of corona electrostatic separation and eddy sepa- cling of metals from WEEE, reviews features and defects of the
ration equipment. existing technologies. Based on environmental protection and
Regrettably, mechanicalephysical recycling technology for the resource recycling utilization for the metals, some novel and
most of single metal from WEEE cannot achieve effective recycling. environment-friendly ideas are proposed in this article. Meanwhile,
Now, one of the biggest challenges in terms of the recycling tech- the outlook on the further development of recycling technology is
nologies for WEEE is how to further classify and recycle high value- presented for the metals from WEEE.
added metals from WEEE through scientific and effective ways/
methods. 2. Selection and classification of research methods
As a matter of fact, WEEE is a complex system, containing
various organic substances, and metals. Therefore, the methods and Selection and classification of research methods were divided
technologies of recycling metals from WEEE are totally different into three steps:
from technologies of mineral separation. In order to develop and
implement both environmentally friendly and economically viable (1) Selection and classification of literature: the first step of this
recycling processes of metals, a large number of novel technologies research is to conduct literature reviews by a comprehensive
are proposed in recent years and mainly include: pyrometallurgical search on the Scopus, Elsevier and Web of Science database,
technology, mild extracting technology, electrochemical technol- using as key words “WEEE” AND “metals” AND “recycle”
ogy and vacuum metallurgical technology etc (Rocchetti et al., AND “technology” AND “metallurgical” and so forth. The
2013; Weeden et al., 2015). abstracts of the most relevant papers according to their title
Pyrometallurgy has been successfully realized industrialization. were assessed to examine whether they fall under the scope
Its principle involves metals enrichment by smelting and convert- of the study. In addition, already published reviews on
ing, refining and other processes to remove the non-metallic ma- recycling areas of e-waste were identified and utilized to get
terial from WEEE. In this process, the crushed scraps are burned in a available methods and technologies. The literature was
furnace or in a molten bath to remove plastics. The refractory ox- classified according to different recycling technologies,
ides form a slag phase together with some metal oxides (Cui and metals type (base metals and precious metals) and the
Zhang, 2008; Flandinet et al., 2012). Traditional hydrometallurgi- means of pollution control.
cal process is associated with acid or alkaline solutions to solubilize (2) Selection and classification of recycling technologies: for
crushed WEEE. This process is called leaching. But in recent decade, traditional recycling technologies, such as pyrometallurgical
hydrometallurgical technology has begun to pay more attention to and hydrometallurgical technology, we chose the technolo-
environment-friendly recycling metals. Some mild leaching agents gies which had prominent improvement in the aspects of
and modified technologies are proposed, which offer more exact, environmental protection. In addition, some new/novel
relatively low construction costs and a certain recovery rate of technologies in recent decades were also focused. These
metals with their suitability for small scale applications. In recent technologies had great significance for recycling metals in
years, extensive studies and practices have been carried out on the view of pollution control and recovery efficiency. They
recycling metals from WEEE by vacuum metallurgical technology included biometallurgical technology, electrochemical tech-
which separates and recycles materials through several kinds of nology, supercritical technology, and vacuum metallurgical
means like vacuum evaporation, vacuum sublimation (Zhan and technology etc.
Xu, 2009, 2011, 2012), vacuum reduction (He et al., 2014), vacuum (3) Evaluation of technological processes: these methods/tech-
pyrolysis (Zhou and Qiu, 2010; Zhou et al., 2011), etc. Vacuum nologies were classified into seven specific categories to
metallurgical technology has some advantages on the separation of facilitate their analysis and evaluation. We focus on each

Fig. 3. (a) An automatic production line of corona electrostatic separation and (b) eddy separation equipment.
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 23

category of method/technology to further search in data- process is most important process for pyrometallurgy. The two
bases. A filtered work of literature for a certain technical basic and widely applied smelting processes include flash smelting
process was carried out. And then, according to the ideas, and bath smelting. Flash smelting employs oxygenated gas to
devices and results of experiments in literature, we selected promote autogenous conditions while bath smelting depends on
representative examples from each recycling technology to the roasting and smelting steps, and reaction occurs in a molten
summarize and review. Finally, some shortages and im- pool containing both melts and slag phases (Montenegro et al.,
provements of these recycling processes were proposed from 2013). Some advanced smelting equipments have been used in
relevant research papers, review papers and some produc- pyrometallurgy, such as Outokumpu flash smelting, Noranda
tion processes. Hence, this paper reviewed representative reactor system and Mitsubishi continuous smelting (Kucharski
and innovative technologies to clarify current progress of et al., 2014; Moskalyk and Alfantazi, 2003). The next step is con-
recycling metals in WEEE. verting process. In the copper converters, matte can be obtained
from the converting unit by blowing in air from tuyeres. This step
can oxidize the iron sulfide and convert copper sulfide to metallic
3. Traditional methods to recycle metals from WEEE copper. The last procedure is refining units with the purpose to get
high purity copper in the reverberatory or rotary furnaces
Traditional methods of recycling WEEE are incineration, hy- (Hagelüken, 2006). The pyrometallurgical process of recycling
draulic shaking bed separation and acid leaching process. For copper in WEEE is shown in Fig. 4.
incineration process, WEEE is directly burned in the blast furnace. An application for pyrometallurgical process to recover metals
The product in the blast furnace contains 70e85 wt.% black copper. from WEEE was practiced at the Boliden Ltd. Ro €nnskår Smelter,
This black copper is fed into the converter to be oxidized and then is Sweden. The schematic diagram for the Ro € nnskår Smelter is shown
reduced in the anode furnace. The recovered anode copper can be in Fig. 5a. More than 100,000 t of e-scraps including WEEE were fed
further purified in H2SO4 electrolyte with other elements, such as into Kaldo Furnace every year (Cui and Zhang, 2008). The e-scraps
Ni, Zn, and Fe (Kang and Schoenung, 2005). The hydraulic shaking can be fed into the process in different steps according to their
bed separation was widely used for recycling metals in waste PCBs purities. Some e-scraps containing high content of copper were fed
in the past. Crude copper particles can be obtained by this process. into converting process directly, but low grade e-scraps were fed
However, this process generates huge amounts of waste water and into Kaldo Furnace. And further the mixed copper alloys produced
residues (Huang et al., 2009a). If not handled properly, waste water in Kaldo Furnace were sent to the converting process to recover
and residues can cause serious secondary pollution. In addition, it is metals (Cu, Ag, Au, Pd, Ni, Se, and Zn). The dusts containing Pb, Sb,
hard to recover other metals except copper, and non-metal mate- In and Cd were sent to other operations to further recover (Cui and
rials cannot be recycled. Zhang, 2008; Ek and Olsson, 2005; Isaksson and Lehner, 2000).
Traditional hydrometallurgy processes are acid leaching to
recover metals (Watling, 2013). HNO3/HCl/HClO4 is used as leach-
ing solvent to extract metals such as Cu, Pb, Zn, etc. from WEEE. In
the past, nitric acid was also used in combination with hydrochloric
acid in the form of aqua regia for non-selective and aggressive
digestion of base and precious metals (Cu, Pb, Zn, Ag, etc.) from
WEEE (Bas et al., 2014; Castro and Martins, 2009; Sheng and Etsell,
2007). Cyanide leaching precious metal Au has been used for more
than one century due to the selectivity and stability of dicyanoau-
rate complex (Kulandaisamy et al., 2003; Quinet et al., 2005). The
cyanide as leaching agent has a major issue, its toxicity, that may
cause environmental and workers safety problems if used
improperly. These traditional methods are not only inefficient but
also greatly damaging to the environment. In recent years, on the
basis of traditional technologies, some advanced recycling tech-
nologies are put forward and have gained considerable progress.

4. Advanced technologies to recycle metals from WEEE

4.1. Pyrometallurgical technology

Pyrometallurgical technology has been significantly improved in


terms of the recycling technologies and the treatment of pollutant.
Pyrometallurgy can successfully realize industrialization, including
a series of steps, such as dismantling, smelting in a plasma arc
furnace, drossing, sintering, melting and reactions in a gas phase at
high temperatures. In this process, the crushed scraps containing
metals (including base and precious metals) are burned in a high
temperature furnace, and then the metals are volatilized by a
chemical reaction or by heat, and impurities are converted into slags.
Generally, WEEE needs to be treated firstly through the
mechanicalephysical pretreatment: dismantling main parts;
shredding/grinding processes for size reduction, liberation of
components, etc. And then, enriched metals are smelted in furnaces Fig. 4. A schematic flow sheet showing recycling copper in WEEE by pyrometallurgy
and coarse metal ingot can be obtained. In most cases, smelting processes.
24 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

Another application for pyrometallurgical process was the plant technology (Ghosh et al., 2015). Some mild leaching agent for hy-
of Umicore integrated smelter and refinery. This process mainly drometallurgy was proposed, such as leaching process of chlorinate
focused on recovery of precious metals from WEEE including Ag, (He and Xu, 2015), ammoniaeammonium (Koyama et al., 2006; Sun
Au, Pt, Pd, Rh, Ru and Ir. The schematic diagram for the Umicore et al., 2015; Xiao et al., 2013) and non-cyanide lixiviants for leaching
Smelter is shown in Fig. 5b. Its procedures included: firstly, WEEE Au (Akcil et al., 2015), etc.
was pretreated (i.e. dismantling, shredding and physical process- Several chloride-based leaching processes were developed and
ing) and then the precious metals operations (PMO) were smelted presented at the lab/pilot scale. A chloride medium
in an Isa Smelt furnace. Almost all other metals were concentrated (HCleCuCl2eNaCl) to extract copper were utilized. Cupric ion
in the slag after smelting; thirdly, the slag was further treated at the (Cu2þ) acting as an oxidant can form stabilization of cuprous (Cuþ)
base metals operations (BMO). The base metals were the byprod- when a suitable ligand such as chloride ion (Cl) was added to
ucts from the PMO which were subjected to electrolytic refining to sulfate solution (Yazici and Deveci, 2015). Cu2þ also might present
gain high purity base metals, such as copper (Le Ret and Briel, 2011; as chloro-complexes ðCuCl2n n Þ in chloride solutions (Yazici and
Tuncuk et al., 2012). Deveci, 2013). The equations of reactions are described:
A crushing-pyrometallurgical process of waste fluorescent
lamps was applied by Nomura Kohsan in Japan (the flow sheet as
shown in Fig. 5c). This process concentrated on the extraction of Cu0 þ Cu2þ /2Cuþ
base metals, rare earth metals and mercury in the recycling of Cuþ þ nCl /CuCl1n
n
(1)
fluorescent lamps. The waste fluorescent lamps were calcinated in Cu0 þ Cu2þ þ 2Cl /2CuClðsÞ ðDG298 K ¼ 41 kJ=molÞ
vertical calcinatory and then underwent refining process to get rare Cu0 þ Cu2þ þ 4Cl /2CuCl
2 ðDG298 K ¼ 25 kJ=molÞ
earth metals and mercury (Yufeng et al., 2014).
The results showed that increasing the initial concentration of
Cu2þ to 79 mmol/l can improve the extraction of metals with
4.2. Mild extracting technology almost complete extractions (98%) for Cu at a leaching period of
more than 120 min. Yazici and Deveci (2013, 2015) used
Modified and new hydrometallurgical technologies have H2SO4eCuSO4eNaCl leaching system to extract the metals from
becoming a hot spot of recent researches. They are more targeted waste PCBs. The effect of initial concentration of cupric (0.5e7.5 g/l
towards metals recovery or pretreatment, easier to control chemical Cu2þ), chloride (4.7e46.6 g/l Cl) and temperature (20e80  C) on
reaction, and make relatively less pollution than pyrometallurgical the leaching of copper was investigated. The results demonstrated

€nnskår Smelter; (b) plant of Umicore and (c) recycling process of fluorescent lamps (Cui and Zhang, 2008; Tuncuk et al., 2012; Yufeng et al.,
Fig. 5. Schematic diagram for (a) Ro
2014).
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 25

that the extraction of metals had significantly improved with extraction and extraction rate of Cu can reach approximately 100%.
increasing temperature and Cu2þ concentration. The Cl/Cu2þ For thiourea acid leaching process, 20 g/l of CS(NH2)2, 6 g/l of Fe3þ,
molar ratio was importance for the extraction process, because Cl 0.5 M H2SO4 were founded as optimal conditions for Au extraction
and Cu2þ had a strong interaction in leaching process. and extraction rate of Au exceeded 70%.
The method of ammoniaeammonium leaching has superiority On the basis of leaching Au by acidic thiourea in the presence of
in terms of selectivity towards copper (Liu et al., 2009). An ferric iron, a modified hydrometallurgical technology was proposed
ammoniaeammonium sulfate and chloride systems were used to for selective recovery of Cu, Ag, Au and Pd from waste PCBs. Firstly,
recover Cu from waste PCBs. Ammoniaeammonium salt solution through two consecutive sulfuric acid leaching steps in the pres-
containing Cu(I) and Cu(II) ammine complexes were used as the ence of H2O2 as oxidizing agents, more than 99% of copper was
leaching agent. The process consisted of two stages: leaching and dissolved. The 2nd leaching step was acidic thiourea in the pres-
purification. In the stage of leaching, Cu in the waste PCBs was ence of ferric iron as oxidizing agent to leach the solid residue,
oxidized by Cu(II) to form Cu(I)eammine complex ions, resulting which 85.76% Au and 71.36% Ag was achieved. The leaching of Pd
from the decreased oxidationereduction potential during the and remained Au from the solid reside of 3rd leaching step was
leaching. The leaching reaction can be expressed as: performed in NaClOeHCleH2O2 leaching system, and then palla-
dium and gold were precipitated by sodium borohydride. 100% of
þ
Cu þ CuðNH3 Þ2þ
4 /2CuðNH3 Þ2 (2) Pd and Au of what was in the chloride leachate were precipitated by
using 2 g/l sodium borohydride (Behnamfard et al., 2013).
The Cu(II)eammine complex significantly enhanced the leach- Thiocyanate is also an effective lixiviant for gold in acidic con-
ing rate of Cu (leaching rate >95%). In the stage of purification, an ditions. The thiocyanate system has been considered to effectively
electro-winning technology had been proposed to recycle Cu in the dissolve and recycle gold and silver from gold-bearing WEEE. One
Cu(I)eammine complex ðCuðNH3 Þþ 2 Þ (Koyama et al., 2006; Oishi important characteristic of the thiocyanate ion is that it can form
et al., 2007). They focused on the leaching mechanism and stable and soluble complexes of aurothiocyanate ðAuðSCNÞ 2 Þ, and
behavior of copper by electro-winning. Lim et al. (2013) tried to use aurithiocyanate ðAuðSCNÞ 4 Þ (Li et al., 2012b). The equations of re-
NH3/NH4Cl with oxidants CuCl2 leaching to recover metals Cu from actions are as follows:
alloy obtained from smelting reduction process of mobile phone
PCBs. It was observed that 98% Cu can be leached under the 2SCN þ Au ¼ AuðSCNÞ
2 þe

(5)
following conditions: 2 kmol/m3 NH4Cl and 5 kmol/m3 NH3 solu- 4SCN þ Au ¼ AuðSCNÞ
4 þ e 

tion, 0.1 kmol/m3 CuCl2 at 30  C.


In order to overcome the disadvantages of cyanide leaching In sulfuric acid solutions with ferric as oxidizing agent, thiocy-
precious metals, considerable efforts have been made to research anate presents and gold dissolves according to reaction:
for non-cyanide systems. Hence, several non-cyanide lixiviants
have been proposed and are regarded as being the most realistic Au þ 2SCN þ Fe3þ ¼ AuðSCNÞ
2 þ Fe

(6)
substitutes in recent years, such as thiourea (Li et al., 2012a), The mechanism of dissolution of gold by ferric-thiocyanate so-
thiosulfate (Chandra and Jeffrey, 2005; Ha et al., 2010; Jeffrey and lution was considered as an auto-reduction process, namely, ferric
Brunt, 2007). was spontaneously reduced to ferrous while oxidizing SCN. This
Thiourea ((NH2)2CS) used as a gold extracting agent for WEEE oxidation was considered through forming several intermediate
has shown significant advantage due to its high rate of leaching, species, in particular (SCN)3 and (SCN)2, which acted both as ox-
lower toxicity and eco-efficiency (Gurung et al., 2013; Ubaldini idants and as complex for gold (Li et al., 2012c, d, e).
et al., 1998; Vinh Hung et al., 2010; Wronski and Luczak, 2010). Followed by above studies, the leaching of gold has been studied
The content of leaching of gold is contingent upon careful optimi- by the combining method of thioureaethiocyanate, using ferric
zation and control of pH, redox potential, thiourea concentration, sulfate as oxidant (Yang et al., 2011). The gold leaching was higher
and leaching time. The reaction follows the equation: than either ferric-thiocyanate or ferric-thiourea solutions respec-
þ tively. The explanation was that the synergistic effect was attrib-
Au þ 2SCðNH2 Þ2 /Au SC½NH2 2 2
þ e (3) uted to the formation of a mixed ligand complex Au(SC
[NH2]2)2SCN.
In addition, the combination of lixiviants can produce a syner-
Recently, some organic acids are introduced as environment-
gistic effect. The effect was evident using ferric sulfate as the
friendly leaching reagents. For example, citric acid and hydrogen
oxidant for leaching Au (Broadhurst and Dupreez, 1993; Li and
peroxide, DL-malic acid or other extraction agents as leaching re-
Miller, 2007). The gold leaching reaction in acid thioureaeferric
agents were introduced to leach cobalt and lithium from lithium-
sulfate solution can be represented by the following reaction:
ion batteries (LIBs) (Jha et al., 2013; Li et al., 2010a, b). Extraction
þ agent as PC-88A, D2EHPA, and Cyanex 272 were used to separate
Au þ 2SCðNH2 Þ2 þ Fe3þ /Au SC½NH2 2 2
þ Fe2þ (4)
and purify the metals (Chen et al., 2011; Dorella and Mansur, 2007;
The conclusion showed that the ferric ion presented in acidic Swain et al., 2006, 2007; Xu et al., 2008). Separation of base and
thiourea solutions can significantly affect the reaction kinetics of precious metals from WEEE using environment-friendly, low cor-
gold cementation. The leaching rate of gold depended on ferric rosive leaching reagents, such as NH3$H2O/KI for Pd, Pt (Dawson
concentration; ferric ion increased significantly the redox potential and Kelsall, 2007), and (NH4)2S2O3/CuSO4/NH4OH/O3-Cl for Ag,
of the solutions, but the leaching rate kept constant with time when Au was also widely investigated (Oh et al., 2003; Vinals et al., 2006;
thiourea concentration was below 12 g/l and ferric was above 0.1 g/l Vinh Hung et al., 2014; Zhang and Zhang, 2013). Supplementary
(Birloaga et al., 2013). Birloaga et al. (2014) utilized two chemical data Table S1 summarizes main processes and reactions of modi-
leaching systems to recycle the base and precious metals from fied hydrometallurgical technologies to recycle precious metals Au.
waste PCBs, that is, the first step was the leaching system of sulfuric
acid with hydrogen peroxide, meantime thiourea with the ferric ion 4.3. Biometallurgical technology
in sulfuric acid medium was used as the second step. The results
indicated that 2 mol/l H2SO4 (98% w/v), 5% H2O2, 25  C, 1/10 S/L Biometallurgical process is well used in mineral processing as an
ratio and 200 rpm were founded as optimal conditions for Cu alternative technology for recovering metals from very low-grade
26 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

ores and concentrates (Watling, 2006). However, most of applica- and minimal chemical usage. Some researchers reported this
tions of the biometallurgy for recovering WEEE are still in a labo- technology to recover metals from WEEE.
ratory scale. There are two main fields of biometallurgy for recovery Kim et al. (2011b) developed a process of electro-generated
of metals, namely bioleaching and biosorption. chlorine to carry out the leaching of metals from waste PCBs. The
Bioleaching is technically feasible by the use of bacteria-assisted technology of electro-generated chlorine has the advantage of
reaction to extract base metals such as Cu, Ni, Zn, Cr and precious leaching precious metals because of acquiring high oxidation po-
metals from WEEE such as Au, Ag in current results of laboratory tential (Kim et al., 2011b). Fig. 6a shows the schematic diagram of
scale. For bioleaching, acidophilic group of bacteria plays an separate reactors consisted of an electrolytic cell for chlorine gen-
important role in bioleaching of heavy metals such as Acid- eration. Two cathodes and anodes were used and hydrochloric acid
ithiobacillus ferrooxidans, Acidithiobacillus thiooxidans, Leptospir- was poured into the leaching reactor. Anode reaction can be rep-
illum ferrooxidans, and Sulfolobus sp (Debaraj and Rhee, 2010; Liang resented by the following equation:
et al., 2010; Panda et al., 2015). For example, Wang et al. (2009) used
bioleaching processes to mobilize metals from waste PCBs. The 2Cl ¼ Cl2 ðelectrode surfaceÞ þ 2e (7)
bacteria A. ferrooxidans and A. thiooxidans were grown and accli-
mated in waste PCBs and then used as bioleaching bacteria to sol- And the dissolution of gold reaction as:
ubilize metals. The results demonstrated that all the percentages of
Cu, Pb, and Zn solubilized into the leaching solution from PCBs. The Au þ Cl þ 3=2Cl2 ðaqÞ ¼ AuCl
4 ðaqÞ DG298 K
concentration of PCBs should be controlled under the range from ¼ 27:04 kcal=mol (8)
7.8 to 19.5 g/l. Under 7.8 g/l of the concentration of PCBs, the
dissolution rates of Cu are 99.0%, 74.9%, 99.9% at 0.5e1.0 mm of
sieve fraction at 9 d of leaching time by the pure culture of Au þ 3=2HClO þ 3=2Hþ þ 5=2Cl ¼ AuCl
4 þ 3=2H2 O DG298 K
A. ferrooxidans, the pure culture of A. thiooxidans, and mixed culture ¼ 33:29 kcal=mol
of A. ferrooxidans and A. thiooxidans, respectively. Similar studies
also showed the leaching content of Cu increased when the amount They found that the content of leaching of gold was increased
of the ferrous ion increased in the solution up to 7 g/l with A. fer- with increasing of temperature and initial concentration of chlo-
rooxidans (Yang et al., 2009, 2014). Karwowska et al. (2014) evalu- rine, and was favorable even at low concentration of acid. But the
ated the possibility of bioleaching Zn, Cu, Pb, Ni, Cd and Cr from leaching of copper was different, that is, leaching increased with
waste PCBs by using a culture of sulfur-oxidizing bacteria and a increasing of concentration of acid and decreasing of temperature.
mixed culture of biosurfactant-producing bacteria and sulfur- In total leaching process, 97% copper was dissolved and the re-
oxidizing bacteria. The results showed that 48% Zn and 93% Cd were covery rate of gold was 93% in the separate reactor. A combined
dissolved in both media. For Ni and Cu, a better effect was obtained reactor (Fig. 6b) with simultaneous Cl2 generation and metal
in the acidic medium with a removal rate of 48.5% and 53% leaching which can circulate and reuse chloride ion without addi-
respectively. Pb was removed with very low effectiveness (below tional supplementation, was compared with the separate reactor
0.5%). for the recovery effect of metals (Kim et al., 2011a). It was observed
Biosorption process is a physico-chemical and metabolism- that the leaching rate of Cu increased with increase in current
independent process resulting in the removal of substances from density, temperature and time in both reactors. The dissolution of
solution by biological materials (Gadd, 2009). The properties of Cu was about 20% and 25% in the combined and separate reactor
certain types of inactive or dead microbial biomass materials also respectively with the copper leaching rate gradually diminished.
allow them to bind and concentrate metal ions from industrial ef- This result may be attributed to the surface area of copper forming
fluents and aqueous solutions. Biosorbents are prepared from CuCl(s) with increasing of leaching time. And the leaching effi-
different microorganisms including bacteria, fungi, algae, actino- ciency of copper was lower in the combined reactor than that of the
mycetes, yeasts and some biowaste materials on precious metal separate reactor due to the change of electrode reactions.
biosorption. Au(III) was successfully recovered as metallic gold Similarly, a mediated electrochemical oxidation was proposed to
nanoparticles using dead biomass of the brown alga Fucus ves- recover copper and separate a rich gold residue from waste PCBs
iculosus by the study of Mata et al. (2009). The results indicated that (Fogarasi et al., 2013, 2014). The process was also carried out by
the brown alga F. vesiculosus can recover and reduce Au(III) to Au(0). employing two different types of reactors coupled in series, ac-
The greatest gold uptakes were obtained at initial pH values be- cording to the experimental setup from Fig. 6c. One was a leaching
tween 4 and 9, with an optimum at pH 7. The marine alga reactor with a perforated rotating drum to dissolve base metals,
Sargassum natans and the fungal cells of Aspergillus niger, Mucor and the other one was a divided electrochemical reactor for the
rouxii and Rhizopus arrihus were also found to take up precious regeneration of the leaching solution with the parallel electro-
metals like gold (Das, 2010). Tasdelen et al. (2009) investigated winning of copper. In the experiment, the electrolyte with 0.3 mol/l
recovery of gold from synthetically prepared diluted gold-bearing HCl and different concentrations of FeCl3 was prepared with waste
solutions of 50 ppm using DEAE-cellulose, a common biopolymer PCBs. Cu in electrolytes HCl and mediators FeCl3 can be generated
derivative. The results demonstrated that gold can be effectively through electrochemical reaction. And Fe3þ can regenerate through
recovered using excessive amounts of DEAE-cellulose (at DEAE- the anodic oxidation. The electrochemical reactors connected in
cellulose/Au weight ratios of 400 and above) and recovery rate of series can allow the simultaneous generation of Fe3þ and dissolu-
gold was found to be over 99%. Table 5 lists some recycled efficiency tion of metals without supplementation of the leaching agent. The
of base and precious metals by bioleaching and biosorption. process was evaluated through the dissolution efficiency, current
efficiency and specific energy consumptions. A 99.04 wt.% high
purity Cu at a current efficiency of 63.84% was gained at a leaching
4.4. Electrochemical technology of laboratory scale, and specific energy consumption of 1.75 kW h/
kg cooper. Electro-oxidation leaching copper in sulfuric acid solu-
Electrochemical process is promising technology and offers tion was also studied for metal powders from waste PCBs (Ping
unique method to recover base and precious metals from WEEE et al., 2009). The experiment tried to recover base metal copper
due to high environmental compatibility, high energy efficiency by leaching process using H2SO4, NaCl, CuSO4 and the air. In the
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 27

Table 5
Recovery of base and precious metals by bioleaching and biosorption (Das, 2010; Ghosh et al., 2015).

Microorganisms Recovery rate (%)

Bioleaching Thiobacillus thiooxidans þ T. ferrooxidans Cu, Ni, Al, Zn >90%


Aspergillus niger Cu, Sn 65%
Penicillium simplicissimum Al, Ni, Pb, Zn >95%
Acidithiobacillus ferrooxidans Cu 81.6%
Acidiphilium acidophilum (ATCC 27807) Cu 3.6%, Ni 86% Zn 40.8%
Sulfobacillus thermosulfidooxidans þ acidophilic heterotroph (AlTSB) Ni 81%, Cu 89%, Al 79%, Zn 83%
Chromobacterium violaceum Au 68.5%
A. ferrooxidans Cu 99%
A. ferrooxidans Cu 99%
A. ferrooxidans þ A. thiooxidans genera Acidithiobacillus and Gallionella Cu 96.8%, Al 88.2%, Zn 91.6%
Sulfobacillus thermosulfidooxidans þ Thermoplasma acidophilum Cu 95%
Acidithiobacillus thiooxidans Cu 98%

Adsorbents Max of adsorption quantity (mmol/g)

Biosorption Algae
Fucus vesiculosus Au, 0.35
Dealginated seaweed waste Au, 0.4
Chlorella vulgaris Au, 0.5
Sargassum natanss Au, 2.1
Chlorella vulgaris Au, 0.5
Fungi
C. cladosporioides strain 1 Au, 0.4
C. cladosporioides strain 2 Au, 0.5
Fomitopsis carnea Au, 0.48
Cladosporium cladosporioides Au, 0.5
Aspergillus niger Au, 1
Rhizopus arrhizus Au, 0.8
Bacteria
Streptomyces erythraeus Au, 0.03
Desulfovibrio desulfuricans Pd 1.2, Pt 0.32
Desulfovibrio fructosivorans Pd 1.0, Pt 0.17
Others
Chemically modified chitosan Au 3.4
Bisthiourea derivative of resins Au 3.63
Thiourea derivative of chitosan Pt 2.0
Chitosan derivatives Pt 3.2, Pd 3.5

leaching system, chloride ion was taken as complex agent, and for organics (Matsumoto and Oshima, 2014; Xiu et al., 2015; Zhu
Cu2þ, air were taken as oxidants. The result showed that the et al., 2012).
leaching rate of copper can reach 100%. Oishi et al. (2008) improved Li and Xu (2015) applied supercritical water (SCW, Tc ¼ 374  C,
this process. The impurities in the solution were removed by sol- Pc ¼ 22.1 MPa) to decompose brominated epoxy resin (BER) from
vent extraction using LIX 26, and the purified Cu(I) solution was waste memory module and environmental friendly recover metals.
electro-won in a diaphragm cell. Fig. 7a shows the schematic diagram of the semibatch-type reactor.
Electrorecycling is a technology which utilizes minimal chemi- Experiments were carried under external-catalyst-free with tem-
cal input to dissolve and recover metals on a cathode for further peratures 350e550  C, pressures 25e40 MPa, and reaction times
processing (Lister et al., 2014). The advantage of this process is that 120e360 min in a semibatch-type reactor. The results showed that
use a single electrochemical cell to maximize energy efficiency. A BER could be quickly and efficiently decomposed under SCW con-
diagram of the electrorecycling system is shown in Fig. 6d. The dition, and the recovery rate of metal reached 99.80%. The mech-
electrorecycling process generated oxidizing agents at anode to anism was possibly free radical reaction.
dissolve metals from the scrap matrix meantime dissolved metals Supercritical methanol (SCM, Tc ¼ 240  C, Pc ¼ 8.09 MPa) to
were reduced at the cathode. The electrochemical cell configured a simultaneously recover polymers and metals from waste PCBs was
trough with the cathode solution. EepH diagrams and the data of conducted by Xiu and Zhang (2010). Their study focused on the
metal dissolution were presented for anticipated conditions in the characteristics of both oils and solid products obtained from the
electrorecycling system. In their work, two stages of electro- SCM treated waste PCBs. Fig. 7b shows the schematic diagram of
recycling were proposed. Firstly Cu, Sn, Ag and magnet materials the chemical recovery process from waste PCBs using supercritical
using Fe3þ were dissolved in sulfate and then Pd and Au were methanol. The waste PCBs were put into the reactor with methanol
dissolved using Cl2 in a HCl solution. Over 95% Cu and Ag were of appropriate volume. After SCM reaction, the liquidesolid
recovered, but the recovery rate of Au and Pd was low. mixture in products was filtered by a membrane filter with pore
size 1.0 m. High concentrations of Cu (34%), Fe (7.9%), Sn (7.9%), Pb
4.5. Supercritical technology (6.3%) and Zn (2.6%) were found in most of the solid products when
waste PCBs were concentrated effectively after SCM treatment. A
In recent years, supercritical technology is introduced as an rotary evaporator was used to recover the solvent methanol, and
environment-friendly method to decompose organic polymers and then the oil and gas products were also recovered. Besides super-
recycle metals due to its special properties, such as low viscosities, critical methanol, other supercritical fluids were also employed for
high mass transport coefficient, high diffusivity, and high solubility the recycling of waste PCBs. Sanyal et al. (2013) used supercritical
28 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

Fig. 6. Schematic diagram of (a) separate reactor consisted of an electrolytic cell for chlorine generation; (b) combined reactor consisted of an electrolytic cell for chlorine gen-
eration; (c) a mediated electrochemical oxidation; (d) electro-recycling system (Fogarasi et al., 2014; Kim et al., 2011a, b; Lister et al., 2014).

CO2 as solvent with an additional small amount of water to recover 4.6. Vacuum metallurgical technology
copper foil, glass fiber and polymer in waste PCB.
A technology of supercritical water oxidation (SCWO) combined In recent years, vacuum metallurgical technology has been
with electrokinetic (EK) process was developed to recover metals applied to recover metals from WEEE because of no waste water
(Xiu et al., 2013, 2015; Xiu and Zhang, 2009a, b). In the process, the pollution. The separation of metals is based on the difference of
PCBs were pretreated in supercritical water, and then subjected to vapor pressure of these metal elements at the same temperature
EK process (Fig. 7c, d). Xiu et al. used this technology to recover Cu, (as shown in Fig. 8a). Under the guidance of separation crite-
Pb (Xiu and Zhang, 2009b) and to prepare Cu2O nanoparticles (Xiu rion, different metals can be successfully separated and recycled
and Zhang, 2012) from waste PCBs. In the SCWO treatment exper- from several waste PCBs. Vacuum distillation of metals is
iments, the sample and distilled water were employed, and considered to need to experience four crucial processes, namely,
hydrogen peroxide (H2O2, 30 wt.%) was used as the source of ox- heat transfer, evaporation, mass transfer and condensation.
ygen. The EK process relied upon an electric field with 20 ml of Volatile metals in interior of the melt spread to the surface and
1 mol/l HCl solutions added to the SCWO-treated waste PCBs. The arrive at the boundary layer. The temperature and pressure of
metal ions or ionic complexes were formed and migrated to the volatile metals is Tv and Pv. And then the metals begin to
cathode or anode. Experimental results showed that supercritical evaporate. They are condensed at condensation wall, which the
water oxidation (SCWO) process was strong enough to decompose temperature and pressure of volatile metals decrease to Tk and
the organic compounds of waste PCBs, and XRD spectra indicated Pk. Fig. 8b shows the process of metal from volatilization to
that copper and lead were oxidized to CuO, Cu2O and PbO2. In the condensation. In the process, the rates of volatile metals can be
EK process, Cu and Pb can form complexes with Cl and the com- described different mathematics model (Bird et al., 2002; Li
plexes can be positively charged, negatively charged or uncharged et al., 2013).
(MeClþ, MeCl2 (aq), MeCl3 and MeCl2 4 ). The recovery percentages Zhan and Xu (2008, 2009, 2011, 2012) carried out a series of studies
of copper and lead under optimum SCWO þ EK treatment condi- on recycling metals fromwaste PCBs by vacuum separation, using the
tions were around 84.2% and 89.4% respectively. self-made vacuum furnace (as shown in Fig. 9a). The study indicated
Highly uniform and monodisperse Cu2O nanoparticles were that Cd can be evaporated preferentially, and subsequently Zn can be
gained successfully from waste PCBs in EK process. The average size separated as a result of their huge vapor pressure gaps. Mixed metal
of Cu2O nanoparticles decreased from 49.5 to 18.2 nm when current particlesofZn,Cddirectsublimatedbysolidstateandsurfaceoxidation
density increased from 10 to 20 mA/cm2, and the size uniformity of film can hamper this evaporation process. The separation of Pb was
nanoparticles was improved significantly at a higher current den- more difficult because the PbeBi alloy was formed with a low vapor
sity. Up to 90 wt.% of Cu in waste PCBs could be recovered as Cu2O pressure.AndPbwasalsofoundinthesoldersofwastePCBsduetoform
nanoparticles under optimized condition. of PbeSn alloy.
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 29

Fig. 7. Schematic diagram of (a) semibatch-type SCW reactor; (b) SCM recovery process; (c, d) SCW combined with EK process (Li and Xu, 2015; Xiu and Zhang, 2009b, 2010, 2012).

Fig. 8. (a) Migration process of the metals from the melt; (b) relationship between the saturation pressure and temperature of metals.

Vacuum metallurgy can also be used to get metal nanoparticles. quenching of the Bi-vapor flow produced particles with narrow size
Synthesis of bismuth nanoparticles was systematically investigated distribution. In contrast, counter flow quenching resulted in early
following mechanism of aerosol nucleation, condensation and particle formation and broad particle residence time distributions
coagulation. Fig. 9b shows a schematic of the jet aerosol flow producing particles with a wide size distribution. Bismuth nano-
condenser unit. Bismuth vapor was produced in an externally particles were synthesized through this process, which average
heated tube flow condenser containing a crucible with the Bi melt. diameter was about 12e37 nm (Wegner et al., 2002). On the basis
Transport of the vapor in an argon carrier gas jet was followed by of Karsten Wegner's study, Xing and Zhang (2011) investigated a
rapid quenching with second argon streams (in a diluter) and by novel process for lead nanopowder synthesis from the waste
particle collection on a filter. The results showed that rapid cathode ray-tube funnel glass.
30 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

Fig. 9. Schematic illustration of (a) vacuum distillation recovery system; (b) aerosol flow condenser with its Inconel pipe; (c) vacuum-chlorinated separation system; (d) vacuum
pyrolysis process (Ma et al., 2012; Xing and Zhang, 2011; Zhan and Xu, 2009; Zhou and Qiu, 2010).

Lin and Qiu (2011) tried to use the vacuum reduction technology to and 1 Pa with 30 wt.% carbon addition for 30 min and the recovery
recover Pb in waste lead storage battery. They recovered Pb from two rate of indium could reach to 90 wt.%. On the basis of vacuum
parts: metallic grids and lead pastes. The results showed that Pb could carbon-reduction, an efficient rough vacuum-chlorinated separa-
be satisfactorily recycled. Similarly, the vacuum reduction technology tion method was proposed for the recovery of indium from waste
also was used to recover Pb (about 20e30% PbO) (Me ar et al., 2006) in LCD panels. NH4Cl was used as the chlorinating agent. Fig. 9c shows
cathode-ray tubes (CRTs). Chen et al. (2009) studied lead recovery the schematic illustration of the vacuum-chlorinated separation.
efficiency, optimizing of this process and the evaluation of environ- The results indicated that the reaction condition of vacuum-
mental safety of the product. A reaction equation was shown: chlorinated metallurgy was easier than the reaction of vacuum
carbon-reduction. The reactions can be expressed by follows the
PbO þ C ¼ PbðgÞ þ COðgÞ equation:
(9)
DGT ¼ 289; 427  481:88T þ 2RT ln pð328  885  CÞ
The experimental condition was that temperatures were In2 O3 þ 6HCl ¼ 2InCl3 þ 3H2 OðgÞ (11)
600e1000  C, vacuum pressures were 10e10,000 Pa, carbon adding The weight ratio of NH4Cl to glass powder and the optimum
amounts were 0e9%, and holding times were 0.5e6 h, respectively. particle size were confirmed as 1:2 and less than 0.13 mm, at 400  C
Lead, with a purity of 99.3%, was successfully separated and respectively. Indium chloride was successfully recovered from the
recovered. The test of Toxicity Characteristic Leaching Procedure waste LCD panels using this method. The recovery rate of indium
(TCLP) indicated that lead from the foam glass leached at optimum and the purity of indium chloride were 98.02 and 99.50% respec-
conditions was below the regulated value. Besides, the waste tively (Ma et al., 2012).
NieCd batteries recycling were also investigated (Huang et al., Pyrolysis technology can be considered as an alternative tech-
2009b, 2010). nology of recycling WEEE in recent years. Pyrolysis can remove
For the recovery of rare and precious metals from WEEE, He non-metallic materials from WEEE, and then metals can be recov-
et al. (2014) adopted coke powder as the reducing agent to get ered (Alston et al., 2011; Hall and Williams, 2006). Zhou and Qiu
metallic indium from discard liquid crystal display (LCD) panels. (2010) and Zhou et al. (2011) have introduced two-step vacuum
In2O3 can be reduced to metallic indium under high temperature pyrolysis processes to recycle metals from waste PCBs. One process
condition with reducing atmosphere. The reactions can be was to separate the solder of the waste PCBs firstly, which was
expressed by follows the equation: molten in the heated diesel oil and separated by centrifugal sepa-
ration; and then use vacuum pyrolysis to recover the waste PCBs
In2 O3 þ 3C ¼ 2InðsÞ þ 3COðgÞ (10)
without solder. The other process pyrolyzed the waste PCBs under
The experiment for the recovery of indium from waste LCD vacuum condition firstly; and then the obtained pyrolysis residue
power showed that the best parameters were confirmed as 1223 K was heated under vacuum to recover the solder by centrifugal
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 31

separation. The vacuum pyrolysis was carried out on the self-made increasing of ultrasound energy were reached at 93.76% and 2.07%
equipment, as shown in Fig. 9d. The equipment consisted of elec- respectively (Huang et al., 2011; Xie et al., 2009).
tromotor, reactor, rotating drum, temperature controlled furnace, The mechanochemical method can make technically feasible the
cold trap, vacuum pump, etc. The rotating drum was designed recycling of metals from some specific wastes, such as CRTs funnel
especially to recover solder from waste PCBs. In pyrolysis process, glass. Tan and Li (2015) provided a systematic review of the utilization
the solder of waste PCBs was separated and recovered when the of mechanochemistry in metal recycling the wastes from the effect of
temperature range was 400e600  C, the rotational speed was mechanochemical methods to discuss the physicochemical changes,
maintained at 1000 rpm, and the rotating drum was rotated for reactions occurred during these processes, and analyze its mecha-
10 min. The recovered solder can be reused directly. The pyrolysis nisms (as shown in Fig. 10b). Mechanochemical technology can be
residues containing other metals, glass fibers and other inorganic used as a means of pretreatment, and then hydrometallurgical
materials still need further treatment. technology to recycle metals. Through this way, the recovery rate of
metal was significantly higher than ordinary hydrometallurgy.
Molten salt oxidation (MSO) technology to recover metals in
4.7. Other novel technologies
waste PCBs has been proposed and this method was efficient for
recovering a copper-rich metallic fraction (Flandinet et al., 2012).
Some new technologies such as ultrasound technology
Molten salts and specifically molten KOHeNaOH eutectic was used
(Fengchun et al., 2009), mechanochemical technology (Chen et al.,
to dissolve glasses, oxides and plastics in waste PCBs without
2010), and combination with pyrometallurgy and hydrometallurgy
oxidizing the most valuable metals. The molten salt was selected a
technology (Havlik et al., 2010, 2011) also have been tried to recycle
mixture of hydroxides, specifically NaOHeKOH, with eutectic
metals from WEEE.
composition (Tmelting ¼ 170  C). The experimental setup, as shown
The technology of ultrasound was applied in recycling metals.
in Fig. 10c, consisted of a stainless steel cell and gas inlet through by
Recover the copper and iron from waste PCBs sludge by ultrasoni-
pure argon and iron melting-pot. Crushed waste PCBs samples
cally assisted acid leaching. The ultrasonically assisted leaching
were placed in an iron melting pot containing the salt. Non-metallic
experiment device is shown in Fig. 10a. Sample was pretreated
components, such as fiberglass, epoxy resin were dissolved in the
firstly, which was put into a beaker with water and 30% of H2O2, and
molten KOHeNaOH eutectic at 300  C. The metallic fraction which
stirred at a speed of 300 rpm for 60 min at room temperature
contained copper and all the precious metals, was recovered with
(25  C). Lime was put into sample and then the slurry was filtered.
no dissolution or melting phenomena.
The solution of pH was adjusted to below 1.5. The result demon-
A combined pyro-hydrometallurgical method to treat the prin-
strated that this method can effectively separate copper from iron,
ted circuit boards from used computers was studied for copper and
which the leaching rates of copper and iron were enhanced with

Fig. 10. Schematic illustration of (a) ultrasonically assisted leaching technology; (b) mechanochemical technology; (c) molten salts leaching technology; (d) combined pyro-
hydrometallurgical technology (Flandinet et al., 2012; Havlik et al., 2011; Tan and Li, 2015; Xie et al., 2009).
32 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

tin extraction. The samples after thermally pretreated were leached further promotion. On the one hand, vacuum metallurgical tech-
in the solution of 1 mol/l HCl at 80  C. Fig. 10d is the apparatus for nology has obvious advantages for low boiling point, high satura-
thermal treatment and the leaching apparatus. The results showed tion vapor pressure base metals separation, such as Zn, Pb, and Cd.
that the significant increase trend of the copper extraction for On the other hand, the separation effect for rare and precious
burned samples compared with unburned samples. After burning metals which have low saturated vapor pressure such as Au, Ag
process, metallic copper changed into the copper oxides. The cop- through vacuum distillation method is not perfect. In addition,
per oxides were well leached in the hydrochloric acid, and this is whether it can meet the industrial standard for metal purity after
the reason why the cooper was leached out from burned samples. the separation should be investigated. There are also some theo-
Unlike copper, after burning, SnO2 can be formed and was mini- retical issues waiting for further research before its industrial
mally leached in HCl. Hence, the leaching had not too much application, according to the review of Zhan and Xu (2014). Table 6
changed before and after burning process (Havlik et al., 2010, 2011). shows the status of these technologies of recycling metals from
WEEE.
5. Environmental and practical defects of advanced In fact, almost all efforts from new technologies aim to achieve
technologies better cost-effectiveness, environmental promotion and sustain-
ability. With the continuous improvement and development of
As described in Section 4, all of these methods and technologies recycling technologies, the researchers have begun to focus on new
have been improved and upgraded on the basis of traditional technologies which have small harm to the environment and hu-
methods. man. As a result, some combinative recycling technologies should
Pyrometallurgy can recycle some base metals such as Cu, Pb, Zn, be put forward to improve recycling of the metals from WEEE.
etc., and these metals can be gained with high purity through
smelting, refining process. Advanced pyrometallurgical technology 6. Perspectives on recycling technologies
firstly adds the mechanicalephysical pretreatment of WEEE. In
addition, it pays great attention to the treatment of waste gas 6.1. Recycling technologies aspect
during metals smelting and refining processes. However, although
pyrometallurgy has been improved furthest, some pollution prob- After a decade of effort, the recycling technologies for metals
lems are still inevitable. For example, atmosphere pollution resul- from WEEE have gained obvious improvement. However, it is no
ted from fine particles PM2.5 and PM10 or the release of some toxic deny that current technologies still have some challenges for
gas, such as dioxins and furans should be considered. Moreover, the further promotion. For example, these new and novel recycling
equipments are expensive, consume a vast amount of energy, and processes for metals are relatively single and dispersed. They are
not suit for small and medium-sized enterprises. Moreover, the difficult to independently and efficiently separating metals from
equipments are expensive, consume a vast amount of energy, and WEEE.
not are suitable for small and medium-sized enterprises. More There are three considerations that ought to be noticed and
importantly, the pyrometallurgical technology has limitations in ensured for the future recycling technology innovation: (1) Tech-
recycling the single metal from rare and precious metals. nologies in the future should be prepared to face commercializa-
Some modified hydrometallurgical technologies, such as mild tion, and suit for small and medium-sized enterprises in terms of
extracting technology, electrochemical technology are designed investment or equipment; Further research should focus on the
with the main purpose to solve the problem of the single metal development of pilot scale tests to generate operational and cost
recycling, and it has good performance in terms of recovery ratio data with the ultimate aim of commercialization; (2) Single tech-
and purity. However, there are still some defects and shortages to nology cannot solve all the problems because WEEE is a compli-
be improved. Take non-cyanide leaching methods to recover cated system. So, recycling technologies would be more varied, and
precious and valuable metals for example. Most of non-cyanide technology should be integrated according to the physical and
lixiviants are low cost and environment-friendly, but has low chemical properties of all kinds of WEEE; (3) Future technologies
chemical stability with low metal recovery. In addition, for thiourea should own high separation efficiency, recovery rate and greater
leaching, an above 90% recovery rate can be gained in a short sustainability.
leaching time, yet the thiourea consumption would be too high and
very expensive compared to cyanide lixiviant. Biometallurgy has 6.2. Environmental protection aspect
too many limitations: Certain microorganism treats specific metal;
and the kinds and content of recycling metal by biometallurgy also As reviewed above, developed and modified technologies can
are limited. Electrochemical technology is an environment-friendly successfully recover base metals, such as Cu, Pb, Zn, Cd and precious
technology, but the sludge generating through this process is metals, such as Au, Ag. Advanced recycling methods and technol-
hazardous waste. Disposing of sludge is complicated and difficult. ogies also have been improved and upgraded comparing with
For supercritical technology, although it can effectively decompose traditional methods in aspect of environmental protection. How-
organic substances from WEEE, remaining metals mixture still ever, some methods still have negative effects on the environment.
need to be further separated through hydrometallurgical technol- There are three considerations that ought to be noticed and
ogy or other technologies. In addition, generated liquid phase and ensured for the future recycling technology innovation: (1) Well-
gas through supercritical process also have a negative impact on designed pretreatments like removing plastics, papers, irons, etc.
environment to a certain extent. For example, liquid phase contains are necessary. For example, a mechanicalephysical technology as
a significant number of phosphated compounds and phenol the means of pretreatment is a must procedure to separate the
derivatives. metal and non-metal, in order to avoid the generation of toxic gases
The environmental and economic benefits of vacuum metal- such as PCDD/Fs and residues resulting from non-metals in WEEE;
lurgical technology for recycling WEEE have been validated. In (2) Enterprise or government should advocate the use of “green”
some industrial practices, gas flow can be effectively controlled and reagent in recycling processes/technologies to reduce pollution of
no waste water discharge or dust emission occurs. This technology waste water; (3) Comprehensive resource utilization as far as
is an environment-friendly and promising method for recycling possible for both metals and non-metals in WEEE should be the
metals from WEEE. However, it still needs to be improved for target in recycling processes/technologies.
L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36 33

Table 6
Status of all kinds of technologies of recycling metals from WEEE (Akcil et al., 2015; Cui and Zhang, 2008; Hadi et al., 2015; Tan and Li, 2015; Zhan and Xu, 2014).

Recycling technology State of recovery Species and effect of recovery metals Advantages of environmental Disadvantages of
metals and technological aspect environmental and
technological aspect

Pyrometallurgical technology Pure solid metals Almost all metals; high recovery rate Totally-commercial; owing Vast cost of investment; fine
some dust chamber and particles pollution; consuming
exhaust gas treatment plant a vast number of energy;
difficult to recovery of precious
metals
Mild extracting technology Solution Almost all metals; recovery rate Low toxicity; simple and easy High cost of some reagent;
related to the reagents and accessibility; relative low some reagents could result in
reaction condition environment damage waste water pollution; semi-
commercial
Biometallurgical Technology Solution Only for a few specific metals; Environment-friendly; low cost High selectivity of metals (only
considerable recovery rate of investment for a few specific metals, such as
for Cu, Zn, Au, etc. Cu, Zn, Au); no industrialization
Electrochemical technology Pure solid metals Only for specific metals; High recovery efficiency; low Waste water and residue
high recovery rate cost of investment; mature pollution; low
technology industrialization;
Supercritical technology Solid mixture Almost all metals; high High recovery efficiency; low Failure to recycle single metal;
of metals recovery rate cost of investment; low waste oil and waste gas
environment damage pollution; low industrialization
Vacuum metallurgical technology Solid single metal Only for high vapor pressure metals; Environment-friendly; short Relative high cost of
high recovery rate technological process investment; low
industrialization; immature
technology
Other metallurgical technologies Solid mixture Need to combined with other Environment-friendly; low cost Failure to recycle single metal;
(ultrasonical, mechanochemical of metals/solution technologies to recycle metals of investment no industrialization
technology, etc.)

7. Conclusions recycled metals from WEEE in aspect of recovery ratio and envi-
ronmental protection. The leaching rate of base metal Cu from
On the one hand, the WEEE can cause serious environmental WEEE can reach 98%. In the non-cyanide leaching precious metals
problems if not be treated properly. On the other hand, WEEE Au systems, thiourea, thiocyanate and combining method of
contains considerable quantities of metal resources. Therefore, thiourea-thiocyanate can form stable and soluble complexes of
developing the novel technologies to recycle the metals from WEEE AuðSC½NH2 2 Þþ 2
2 , Au(SCN) , Au(SC[NH2]2)2SCN, etc. to extract Au
is of great significance from both economy and environment per- and extraction rate of Au exceeded 70%. In addition, some novel and
spectives. Current status of recovery technologies for metals from new technologies, such as supercritical technology, vacuum
WEEE is summarized and discussed in detail in this review. metallurgical technology, ultrasound technology, etc. were put
Based on traditional recycling technologies of WEEE, pyromet- forward in past decade and had also obtained quite satisfactory
allurgical technology and hydrometallurgical technology have been results in terms of recycling base and precious metals from WEEE.
significantly improved in recent years. Some modified and mild For example, exceeding 80% Cu in PCBs can be recycled by super-
extracting technologies, such as leaching process of chlorinate, critical technology. Vacuum metallurgical technology can success-
ammoniaeammonium and non-cyanide lixiviants can effectively fully separate Cu, Pb, Zn, etc. metals in PCBs.

E-scrape
(Cu, Fe, Al, Au, Ag,
Mechanical and physical technology Metals separation technology of past
Magnetic
In, Y, Eu ) Metals (Fe, Co,
Metals (Fe, Co, Ni )
Eddying separation Ni, Cu, Al, Au,
Automatic Ag, Y, Eu ) Precious Metals
Nonmagnetic Incineration
dismantling Magnetic (Au, Ag, Pt etc)
Metals (Cu, Al,
separation
Au, Ag, Y, Eu ) Heavy metals
Corona electrostatic Nonmetals Dissipated metals
separation rare earth metals Acid leaching
process
Multistiage crushing

Metals separation technology of now and future


Pyrometallurgy
Mind extracting technology
Precious Metals
(Au, Ag, Pt etc)
Vacuum-metallurgy
Heavy metals
Dissipated metals
rare earth metals
Electrometallugy
Supercritical technology

Others Technologies
(Biological, Physical, etc)

Fig. 11. A schematic flow sheet showing an integrated recycling technology to recycle the metals from WEEE.
34 L. Zhang, Z. Xu / Journal of Cleaner Production 127 (2016) 19e36

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leaching followed by adsorption using biosorbent prepared from persimmon
tannin. Hydrometallurgy 133, 84e93.
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