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Resources 2014, 3 173 The preprocessing steps including sorting, dismantling, crushing and liberation will isolate metals, alloys and other valuables from complex e-waste material. A part of the technical difficulties during the smelting and refining processes can be minimized during the stage of liberation. The isolation of PMs from e-waste is challenging because of their interlinkage with other metals in the PCBs. For example, in the computer boards, PMs are in contact with other metals, connectors, solders, and hard disc drives. In ceramics they coexist in multilayer capacitors, integrated circuits (ICs), and with plastics in PCBs tracks, interboard layers and ICs. Although preprocessing using mechanical techniques separates the major metal fractions, approximately 20% is retained by plastics and other composite materials. This results in the loss of about 7% to 42% of copper and 43% to 93% of PMs. Assuming a 20% loss of PMs from PC boards and cell phones, this represents an overall loss of $1300/ton [20]. Currently in Australia, few companies are recycling e-waste. There is an opportunity to improve and optimize the current mechanical processing technology to minimize metal loss, especially PMs. Moreover, an optimized preprocessing will recover the aluminum and iron fractions that are lost during the direct smelting in integrated plants. 6.4. Technical Barriers—Knowledge of Process Thermodynamics One of the barriers affecting the potential of e-waste recycling is the underpinning knowledge of smelting and refining process. It is decisive to have the knowledge of feed material composition, its possible reactions and final product [62]. The recovery of PMs from e-waste using technology similar to their natural ores is challenging. When processing natural ores, the relationship between PMs and other accessory metals is well understood and investigated. However, for e-waste recycling using conventional metallurgical routes, the knowledge on the behavior of complex input materials is not well understood. To extract small quantities of PMs from e-waste, thermodynamic knowledge of more than one BMs including copper, lead, nickel and zinc is required. Australia is a world leader in the mineral and mining industry and possesses the capability of copper, lead, zinc and PM processing. There is an opportunity to optimize the existing non-ferrous extraction processes to recycle e-waste and recover PMs. 6.5. Lack of Integrated Smelting and Refining Facility Globally, integrated smelting and refining facilities are successfully operating for e-waste recycling. In these plants, e-waste is blended with a feed material composed of Cu concentrates or waste (scrap and dust, etc.) from metallurgical processes. Smelting technologies based on copper and lead are commonly employed in these integrated plants. Therefore, the recovery of PMs is high with minimal generation of wastes. Such integrated smelting and refining facilities can be installed in Australia similar to the Umicore, Rönnskär and Noranda processes overseas. Australian technical expertise in the primary BM production and mineral processing is an opportunity for e-waste recycling. However, primary BM smelters have closed or are closing (Mount Isa Mines Copper Smelter, Brisbane) in Australia. The main contributing factors for the closing of copper smelting and refining operations are higher operating cost and over-capacity in the global market. This is a significant barrier for e-waste recycling in Australia. Currently, it is cheaper toPDF Image | Metal Extraction Processes for Electronic Waste
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