Yuchen He and
Zhenming Xu*
Shanghai Jiao Tong University, School of Environmental Science & Engineering, Shanghai, 200240, China. E-mail: zmxu@sjtu.edu.cn
First published on 24th December 2014
Waste electric and electronic equipment (WEEE) usually contains many recoverable and valuable elements, including gold and copper. Primitive technologies, such as aqua regia leaching and calcination, are still widely used in China, which has caused serious pollution in local environments. Chlorination is a feasible alternative for the recovery of metallic elements due to the higher dissolution rate, non-polluting character and selective leaching of different metals by controlling the redox potential. In the present study, an efficient and less-polluted chlorination process to recycle gold and copper from waste PCBs was investigated. This work is based on a physical processing with a crush–pneumatic separation–corona electrostatic separation dealing with waste PCBs, which provided the raw material for chlorination process. The influence of different pretreatments and experimental parameters was studied. The result showed that more than 90% of copper could be selective recovered by controlling the Eh of leaching solution from 400 to 800 mV. The supercritical process had a better effect with a leaching yield of metallic elements over 99% percent, for both gold and copper. The ball milling process had different influence on gold and copper based on milling time. The leaching yield of copper increased with increase in ball-milling time. For gold, there was an optimal time around 10 min at 20 s−1 frequency of milling. The leaching yield of gold could reach more than 99% after a pretreatment with ball milling for 10 min when the leaching time was 90 min, the leaching temperature was 40 °C and the initial concentration of sulfuric acid was 100 g L−1. This study could contribute significantly to metallic element recycling of high value-added WEEE and provide technological parameters for industrial application in the future.
Hydrometallurgy is widely used in gold extraction.6 Cyanidation process is the most frequently used method in conventional hydrometallurgy.7 However, this process could not achieve the selective leaching of copper and gold8 and has environmental-related disadvantages such as a highly toxic effluent.9 As shown in Fig. 1, in China, primitive technologies are still widely used in family-run workshops to recover gold from PCBs. The electrolytic process has a high cost that prevents the application to small-scale treatments. The leaching process with aqua regia could produce large amount of strong acid waste liquid, which results in serious pollution of the local environment.10–12
Due to the higher dissolution rate,13 non-polluting character14,15 and selective leaching of different metals by controlling the redox potential, chlorination is a feasible alternative method for gold recovery.16,17 Thus far, some research efforts have used chlorination as an alternative method. Donmez B. et al.18,19 have studied the chlorination leaching of gold from decopperized anode slime. The extraction yield can reach more than 90%. Baghalha13 used chloride/hypochlorite solutions in the leaching of oxide gold ore, which reached 67% gold extraction in 4 h. Nam K. S.20 used chloride/hypochlorite to recover gold from tailings and reached 80% gold extraction. The studies indicate that raw material played a big role in the chlorination leaching. However, few studies focused on the chlorination leaching of gold from PCBs.
Moreover, pretreatment is an important method to improve the leaching yield and purity of metal. However, traditional pretreatment methods, such as roasting, acid leaching, alkaline leaching and bio-oxidation,3 will generate large amounts of waste water or highly polluting gas.20,21 Different from refractory gold ores, there is no sulfide or carbonate in PCB. Thus, oxidation is not the key process in the pretreatment of PCBs. Hence, ball milling as a physical method with low pollution and cost should be taken into consideration in the pretreatment process. In recent years, supercritical water (T ≥ 374 °C, P ≥ 22.1 MPa) has become known as an environment-friendly method in many academic sectors. As the dissociation constant (Kw) for water is about three orders of magnitude higher at the critical point,22 supercritical water is both a strong acid and alkali. It is an ideal pretreatment method due to the utilization of a non-toxic reactant.23,24 There are many influencing factors in chlorination processes such as temperature, reaction time, acidity, chloride concentration, and agitation rate. Some of the influencing factors should be investigated for the optimization of the gold leaching process.
In this work, we try to establish an efficient and less-polluted process to selectively recycle gold and copper from metal concentrate, which comes from waste PCBs after a crushing–electrostatic separation process. The objectives of this research are as follows: (1) to evaluate the effectiveness of crushing and supercritical water pretreatment on gold and copper recovery; (2) to evaluate the effectiveness and feasibility of the selective leaching of gold and copper by a chlorination process and optimize the experimental parameters to increase the leaching yield.
Au | Cu | Al | Fe | Ni | Pb |
---|---|---|---|---|---|
0.2339 | 20.78 | 0.8529 | 0.1424 | 0.1478 | 0.0868 |
In this experiment, sodium chlorate was taken as the chlorinating agent. The reagents used in this study (NaClO3, NaCl and H2SO4) were of analytical grade, and the solutions were pre-made separately.
The parameters in a gold-leaching experiment were optimized, including initial concentration of sulfuric acid, reaction time and temperature. The parameter settings in the optimization experiment are presented in Table 2.
Time | Temperature | Initial acidity |
---|---|---|
a t (min): leaching time; T (°C): leaching temperature; C (g L−1): initial concentration of sulfuric acid. | ||
t = 30, 60, 90, 120, 180, 240, 300; T = 40; C = 150 | T = 30, 40, 50, 60, 70; t = 120; C = 150 | C = 50, 100, 150, 200, 250; T = 40; t = 120 |
The flowchart of leaching process is shown in Fig. 3.
The metallic elements' leaching yield (R) is calculated by the following equation:
![]() | (1) |
Fine crushing time (min) | Dx(10) (μm) | Dx(50) (μm) | Dx(90) (μm) |
---|---|---|---|
a Where Dx(n) is the particle size at the cumulative frequency of n%. | |||
0 | 14.7 | 325 | 1490 |
10 | 8.56 | 177 | 639 |
30 | 5.69 | 86.5 | 338 |
60 | 5.14 | 60.6 | 242 |
The leaching experiments were conducted with 10 g of metal concentrate with different ball milling times. The results are presented in Fig. 4.
As shown in Fig. 4, with increasing ball milling time, the leaching yield of copper increased from 77.06% to 97.54%. The leaching yield of gold increased from 48.25% to 89.98% after a 10 minute ball milling. However, the leaching yield of gold decreased from 89.98% to 43.75% when the ball milling time increased from 10 minutes to 60 minutes.
To improve the separation rate of gold and copper, an experiment using two-stage leaching with controlled redox potential was conducted for the particles with 10 min ball milling. After the typical run, the residue and sulfuric acid were added back into the reactor for another 8 h leaching at a range from 400 to 600 mV. The result showed an additional 6.99% of copper was leached out from residue.
As shown in Fig. 5, the supercritical process had the advantage of higher leaching yield of metallic elements. Both the leaching yield of gold and copper could reach more than 99%.
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Fig. 6 Surface morphology of different particles (800× magnification): (a) raw material; (b) particles after 10 minute ball milling; (c) particles after supercritical process. |
However, Fig. 6 also shows that the particle surface was totally different after the supercritical process. Due to the change of dissociation constant at the critical point, supercritical water became a strong oxidizing agent. Supercritical water is a solvent used to recycle organic polymers due to its low viscosity, high mass transportation coefficient, diffusivity and solubility. On the one hand, the supercritical process changed the surface morphology of particles. On the other hand, the non-metal parts of PCBs were resolved into low molecular weight organic matter after the supercritical process, which meant a more complete separation of metal and non-metal parts. Hence, the leaching yield of metallic elements increased after the supercritical process. However, the supercritical process demands high energy consumption due to the reaction conditions of high temperature and pressure, which might hamper industrial application.
The separation rate of copper could reach over 90% after the result of two-stage leaching. However, the results also indicated that the reaction rate in the second stage leaching had a significant decline due to the decrease of leachable metal. Hence, leaching multiple times was not an efficient way to increase the separation rate and leaching yield of metallic elements without changing other experimental conditions.
As shown in Fig. 11, with increase in leaching time, neither Al nor Fe showed an evident change in leaching yield where the fluctuation was less than 3%. However, both Al and Fe showed a significant increase of leaching yield with increase in leaching temperature. Compared with Fig. 8, it was the same trend as that for copper. Fig. 11(c) indicates that Fe was more sensitive to the change of acidity of solution.
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Fig. 10 Eh–pH diagram for: (a) Au–Cl–H2O system (25 g L−1 NaClO3, 75 g L−1 NaCl and 0.29 g L−1 Au); (b) Cu–Cl–H2O system (25 g L−1 NaClO3, 75 g L−1 NaCl and 25.96 g L−1 Cu). |
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Fig. 11 Leaching yield of Al, Fe, Ni and Fe under different experimental conditions: (a) time; (b) temperature; (c) initial concentration of sulfuric acid. |
The leaching yield of Pb was significantly higher than that for other metals. Due to the low solubility of PbSO4, Pb was hardly leached in the first-stage leaching process. Fig. 11(b) and (c) showed that the temperature and acidity had an influence on the leaching yield of Pb with an optimized leaching condition. However, the influence was limited. The leaching yield of Ni did not have an evident change in different experimental conditions. Furthermore, the concentration of Ni was low in the leaching liquor L2. Hence, the interaction between Pb, Ni and gold was not the main factor influencing the leaching efficiency of gold.
The results proved that the interaction of gold and other metals leaching was evident in high temperature. The competitive relationship of gold and other base metals would result in a decrease of gold leaching yield with increase in temperature. However, as the amount of these metals was considerably less than the amount of copper, the interaction was very limited in the leaching system, particularly at low temperatures.
Au+ + e− → Au, E0 = 1.691 V | (2) |
Au3+ + 3e− → Au, E0 = 1.498 V | (3) |
AuCl2− + e− → Au + 2Cl−, E0 = 1.113 V | (4) |
AuCl4− + 3e− → Au + 4Cl−, E0 = 0.994 V | (5) |
2Au + 3Cl2 + 2Cl− → 2[AuCl4]− | (6) |
As sodium chlorate was the chlorinating agent in this experiment, the reactions in the leaching solution can be described as following equations:
2ClO3− + 12H+ + 10e− → Cl2 + 6H2O, E0 = 1.468 V | (7) |
ClO3− + 6H+ + 6e− → Cl− + 3H2O, E0 = 1.45 V | (8) |
The chemical equation indicates that the gold ion could only exist in solution after the formation of complex ions with chloride ion, as the complex ion decreased the electrode potential of gold from 1.498 V to 0.994 V. The leaching solution should be in an acidic condition, and the hydrogen ions would be consumed in the leaching process.
The typical Eh–pH diagram for the Au–Cl–H2O system (25 g L−1 NaClO3, 75 g L−1 NaCl and 0.29 g L−1 Au) and the Cu–Cl–H2O system (25 g L−1 NaClO3, 75 g L−1 NaCl and 25.96 g L−1 Cu) used in this study are shown in Fig. 10 (calculated by HSC Chemistry 7.0).
The information from Au–Cl–H2O system model indicated that, gold in the leaching solution is mostly stable as an AuCl4− complex and that the stability zone for AuCl32− is narrow. Generally speaking, when the Eh of solution is between 900 mV and 1500 mV, and the pH of solution is below 8, the gold can be leached into solution as the AuCl4− complex. However, if the Eh potential is too high (e.g., above 1200 mV) and the pH of solution is above 5, the gold chloride will convert to a more stable Au(OH)3.27 Hence, to maintain gold in the solution, the leaching condition should be controlled with the 800–1200 mV Eh range and the pH below 4. The Cu–Cl–H2O system model showed that, when the Eh of solution is above 0 mV and the pH of solution is below 4, copper can be leached into solution. The lower pH and higher Eh were better for the leaching of copper. The selective leaching of cooper could be achieved if the Eh of leaching solution were controlled between 0 to 800 mV, and the pH of solution is below 4.
Fig. 10 shows that the gold and copper had a competitive relationship in the leaching system. Due to the complicated composition of PCBs, the leaching yield of gold will be influenced by copper and the other metallic elements remained in the residue. As presented in chemical reaction formula eqn (7), with increase in time, the H+ in the leaching solution would be expended and the emission of Cl2 might occur due to the open system. As a result, the concentration of chlorinating agent will decrease and the pH of solution would increase, which had a greater influence on the leaching of gold due to the stability of AuCl4−. The Au3+ in leaching solution would tend to convert to Au(OH)3 under this condition, which resulted in a significant decreasing of leaching yield of gold and an increasing of leaching yield of copper after 180 min leaching.
Generally speaking, the increase in temperature would accelerate the reaction rate and present as an increase in leaching yield of metallic elements. However, as the leaching system was not closed, if the leaching temperature was too high, the gas emission of Cl2 would increase, which would lead to the decrease in concentration of chlorate and in the leaching yield of gold. When the temperature increased from 50 °C to 70 °C, the temperature had a more significant influence on the leaching of metal, which resulted in a recovery in the leaching yield of gold at 70 °C, as shown in Fig. 8. Due to the competitive relationship of metallic elements in the leaching system, the leaching yield of gold was influenced by the leaching of other metallic elements such as copper at the same time. Hence, the leaching yield of gold decreased within a certain range of temperature.
Chlorate exists in many forms in aqueous solution. The acidity of the solution played a big role in the amount of different forms present. Due to the high standard electrode potential of gold, the gold leaching process was more sensitive to changes in the form of chlorate. As shown in Fig. 10, if the pH of the leaching solution is too high, the gold chloride would tend to be converted to Au(OH)3. However, if the pH of the leaching solution is too low, the solubility of Cl2 would decrease due to the movement of solubility equilibrium in the direction of producing gas, which resulted in the decrease in chlorinating agent and led to the decreased leaching yield of gold. Moreover, a lower pH had a positive influence on the leaching of copper. As the concentration of chlorinating agent was not the main influencing factor, the leaching yield of copper would increase continuously with the increase in acidity, which would have a negative influence on the leaching of gold resulting from the competitive relationship. Hence, there is an optimal condition for gold leaching at around 100 g L−1 of sulfuric acid.
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Fig. 12 The flowchart of chlorination leaching process for the selective recovery of gold and copper. |
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c4ra16231e |
This journal is © The Royal Society of Chemistry 2015 |