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Resources 2014, 3 166 The Precious Metals Operation (PMO) focuses on the recovery of PMs from copper matte smelting, leaching and electrowinning. The feed from e-waste and other industries is smelted in an IsaSmelt furnace. The plastic and organic constituents partially replace coke as a reducing agent and a source of energy during smelting. PMs are segregated mainly in the copper bullion and the rest in the lead slag. Copper is leached out from the copper bullion and recovered by an electrowinning process. The residue of the copper electrowinning process is further treated at a PMs refinery for the recovery of PMs. The second recycling process at Umicore is called the Base Metals Operation (BMO) that treats by-products from PMO. Figure 5 shows the affinity of PMs with BMs, and simplified Umicore process organization. The main processing units in BMO are a lead blast furnace, lead refinery and special metals plant. The oxidized lead slag and third party residues high in lead are treated in the lead blast furnace that produces impure lead bullion, nickel speiss, copper matte and depleted slag. The Harris process (lead refinery) is used to refine lead bullion that contains fewer PMs. Pure lead, sodium antimonite and special metals (indium, selenium and tellurium) are produced during the Harris process. Bismuth and tin are sold to dedicated companies to produce pure metals. At Umicore’s Olen plant, nickel is leached out from nickel speiss as sulfate. The remaining residue is treated at a PMs refinery for further recovery of metals [60,61]. Figure 5. Principle input-output streams for Umicore’s integrated metals smelter and refinery where Cu/Pb/Ni is used to segregate precious and special metals [61]. Reprinted with permission from AMS, 2006. The Umicore’s integrated metals recovery process is coupled with an efficient emission controlled system that meets European and Flemish environmental control requirements. The flue gases controlling and monitoring system is schematically shown in Figure 6. The process exhaust gases are cooled for the recovery of energy and are cleaned using special techniques including bag house filters, electrofilters and scrubbers. Sulfuric acid is produced from SO2 that is generated from sulfur in the feed material. Toxic gases including NOx and SO2 are continuously monitored from both stacks over the period of smelting process to avoid environmental pollution. Intensive water sprinkling is used to control diffused emission from stockyards and roads. Further pollution-controlled measures are dust-free drum/bag shipping and handling, sampling procedures, storage of critical materials, and emptying of containers. Consequently, the emissions of dust, metals, gases and dioxins are well below the European and Flemish legal environmental requirements [60,61].PDF Image | Metal Extraction Processes for Electronic Waste
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