Melting Temperature Dependent Separations Of Metallic Electronic Wastes Using Centrifugal Forces

1
Melting Temperature Dependent Separations
Of Metallic Electronic Wastes And Wires
Using Centrifugal Forces
Gopi Krishna Mandadi
Department of Mechanical Engineering
04/25/2016

2
Acknowledgements
I would like to thank my advisor and committee chair, Dr. Ramazan Asmatulu,
for his continuous guidance and support throughout this project. I would like to thank Mr.
Ricky Shipman for allowing me to use the Cessna Manufacturing laboratory and also for
his guidance towards this project success. I would also like to thank the Mr. Bryan and Mr.
Matt from the electrical shop, physical plant for their assistance and help in fixing the
Induction heater furnace. I thank Dr. Rajeev Nair and Dr. Abu Asaduzzaman for readily
agreeing to be a committee member. I also I would like to thank Mr. Vamsidhar Patlolla, a
Ph.D. student in mechanical engineering for his guidance and help towards my thesis. Last
but not the least, I am indebted to my friends who have helped me in this research work.

3
Table Of Contents
• Introduction
• Acknowledgement
• Literature review
• Experimental setup
• Results
• Conclusion
• References

4
Introduction
• E-waste is a popular, informal name for electronic products nearing the end of their useful life.
• An emotional increment in the generation and utilization of electrical and electronic equipment’s
(EEEs) with a sharp abatement in their lifespan has prompted the era of expansive amounts of E-
waste.
• This is the quickest developing waste stream in the world with a 3-5% expanding rate for each
year than era of municipal wastes.

5
Classification: Types of E-waste
• Mobile phones
• Computers
• Servers
• Telecom
• TV
• Calculators
• Audio
• Scanners
• Printers
• Air conditioner
• Micro wave
• Washing machine
• Cartridges
• Military electronic
• Mother board
• Alarm
• Sirens
• Automobile catalytic convertor
• Sensor
• CD
• Security device
• Electrical wires

6
Why E - Waste must be Recycled ?
• The developing amount of e-waste from electronic industry is starting to achieve tragic extents. It is
evaluated that the world creates 20-50 million tons every year (Herat 2013). Consumer Electronics
Association (CEA) estimated that an average person owns 24 electronic products.
https://www.youtube.com/watch?v
=dd_ZttK3PuM

7
Contd..
Usage of PC’s for 100 persons [4]

8
Reasons for Recycling Waste
• The driving forces behind recycling e-waste are economic, environmental, public health and data security.
• Electronic devices contain up to 60 different elements, many of which are valuable, such as precious and
special metals, and some of which are hazardous. Precious metals are rare, naturally occurring metallic
elements which traditionally have a higher melting point, and are more ductile than other metals.
• They have a high economic value. Special metals include nickel, nickel base alloys, cobalt base alloys,
titanium and titanium base alloys. Electronic equipment is a primary consumer of precious and special
metals and therefore it is imperative that a circular flow is established in order to recover these metals
and valuable elements. Investments are being made to treat e-scrap and reclaim the valuable metals,
especially as raw materials become more scarce and expensive.

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Concentration Of Metals In Electronics
Electronic Copper (% by weight) Silver (ppm) Gold(ppm) Palladium(ppm)
Television TV Board 10% 280 20 10
Personal Computer
board (PCB)
20% 1000 250 110
Mobile phone 13% 3500 340 130
DVD Player Scrap 5% 115 15 4
Portable audio Scrap 21% 150 10 4
Concentration of metals in electronics (2007)

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E-Waste
• Circuit boards contain the highest value of precious metals in a
computer, as well as most of the heavy metals (United States
Geological Survey (USGS), 2001). The components of a personal
computer have the highest economic value, due to gold plated
connectors, components, pins and transistors:
• Motherboard (main circuit board)
• Peripheral Component Interconnect (PCI) boards
• Random Access Memory (RAM)
• Processor

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Hazardous Metals in E-Waste
• It is estimated that 50-80% of e-waste collected in developed nations is exported to
developing countries such as china, India due to cheap labor and lenient
environmental regulations.
• These developing nations lack the health and safety infrastructure to process and
dispose of materials safely, and consequently workers handle toxic metals without
proper equipment.

12
End of Life Options for E-Waste
• Reuse of functional electronics.
• Refurbishment and repair of electronics
• Reuse and recovery of electronic components.
• End processing for recovering metals.
• Disposal.
 Reuse, refurbishment is the better option out of the above, however it
should be working and must be functional.
 If it is not functional then the best option we have is the recycling. It
allows to collect the precious metals and reduces the effect on
environment.

13
Global Scenario
• If you are throwing your electronics away in regular garbage you are violating
a number of state and federal laws, contributing to global warming, polluting
the environment significantly and contributing to the illness and death of
thousands throughout the world who live and work in landfills, pulling apart
electronics and selling the recyclable parts.

14
Contd.
• In 2001, the Basel Action Network (BAN) led several groups in an
investigation of e-waste processing in China, India, and Pakistan. The
investigation uncovered an entire area known as Guiyu in Guangdong Province,
surrounding the Lianjiang River where about 100,000 poor migrant workers are
employed breaking apart and processing obsolete computers imported primarily
from North America. The workers were found to be using 19th century
technologies to clean up the wastes from the 21st century.
Lianjian River [20]

15
Cont.…
• The United Nations estimated that 41.8 million tons
of e-waste, a broad term that encompasses anything
with an electrical cord or a battery, were dumped
globally in 2014. Of that only 6.5 million tons was
recycled and properly disposed of.
• The U.S. contributed the most to this global
problem, dumping 7.1 million tons and recycling
less than a million tons.

16
E-waste Policy in the U.S.
• Currently there is no U.S. Federal mandate to recycle electronic waste; however
twenty five states have enacted legislation requiring statewide e-waste recycling.
Despite state-wide recycling efforts, it is estimated that 13.6%9 to 26.6%10 to e-
waste is recycled in the U.S.
• According to the U.S. Environmental Protection Agency (EPA) Office of Resource
Conservation and Recovery report “Electronics Waste Management in the United
States through 2009,” 2.44 million short tons were ready for end-of-life
management in 2010 Based on this estimated generation and the aforementioned
U.S. e-waste recycling rates, approximately 332,000 to 649,000 short tons of e-
waste was recycled in the U.S. in 2010.

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• There is a lack of information regarding how much e-waste is generated,
from where and to where it is moving.
• E-waste recycling hotspots have been identified in Asia-Pacific countries
such as China, India, Pakistan and in some African countries such as
Senegal, Ghana and Nigeria.
• Other countries including Mexico, Morocco, Colombia, Peru, Kenya, South
Africa, Senegal, Uganda, Brazil, Cambodia, Indonesia and Thailand are
additional growing destinations for e-waste.
The e-waste trade
Dumping Yards in China [10]

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Literature Review
• Yang et al. used leaching process to initially recover gold fingers
from PCB’s and then implemented hydrometallurgical processing for
gold recovery. It has been reported that hydrometallurgical process
along with thiourea leaching and iodide leaching make more
possible to replace cyanide leaching.
• Jiran cui et al. used pyrometallurgical, hydrometallurgical, and
biometallurgical process and compared the results and concluded
that pyrometallurgical process have greater recovery rates.
• Waldir A. Bizzo et al. used the existing leaching process to analyse
and determine their metal content and characterized them as solid
waste and fuel. It has been reported that concentration of precious
metals (gold and silver) has declined over time

20
Current Techniques
• Pretreatment
 Low Temperature Freezing Method
The United States patent -No. 3990641 came up with
low temperature freezing method to separate the copper and
insulating layer of the waste wires. Low temperature freezing
method is suitable for processing all kinds of wires and cables.
Freezing makes insulation brittle first and shocking separates the
insulation layer and the copper wire.

21
Cont.
Chemical Stripping Method
The method adopts a kind of organic solvent to dissolve insulating
layer of the waste wire to separate the copper wire and insulation layer. Sodium
hydroxide (NaOH) is used as a solvent. The advantage of this method is to get
high quality copper wire, but the disadvantage is that the solvent is difficult to
deal with , and the price of solvent is higher. the development direction of the
technology is to study a cheap practical effective solvent.

22
Cont.
• Shredding & Melting
– copper items stripped by the wire stripping machine needs
to be shredded before packing. Because the entire copper
wire is not so convenient to be transported to the melting
device. When the copper reach the smelting facilities, the
bales are fed into a furnace where they are heated until
they become molten copper. The molten metal is then
poured into casters or molds to form items needed.

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Cont.
• Two other process that are currently in existence
are
– Melting at a copper smelter along with copper ore
• At a copper smelter, the scrap copper and alloy components are
loaded into the furnace which is then fired up. The copper ore is
fed into the furnace along with the required amount of limestone
and sand. Oxygen and air are supplied and when the mix has
become molten, it is then tapped into rectangular molds.
– Melting along with a proportion of copper ingots at a
dedicated copper recycling plant

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Experimental Setup
• A workpiece that can hold various weight samples and which can bear the
higher temperatures have to be manufactured.
• Complete experimental setup is as shown fig.

25
Pro-E Design
Solid Base Perforated Basket Closing capBearing

26
Cont.…
• Boring
Boring is the process of enlarging a hole that has already been drilled (or
cast), by means of a single-point cutting tool (or of a boring head containing several
such tools)
0.7cm
1.8cm
FinalInitial
1.4cm 3.6cm

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Drilling
Drilling is a cutting process that uses a drill bit to cut a hole of circular
cross-section in solid materials. The drill bit is a rotary cutting tool, often
multipoint.
• A drill bit size of 1.1 cm has been used.
• Holes are drilled through half way of the workpiece.
• Holes are drilled throughout the circumference of the workpiece at
an interval of 22.50.

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Closing caps
Welding is a materials joining process which produces coalescence of
materials by heating them to suitable temperatures with or without the
application of pressure or by the application of pressure alone, and with or
without the use of filler material.
• After drilling the holes on the surface, on one of the closing caps of the
workpiece, an external solid surface is inserted which is going to be on the
top hand side of the workpiece. And that surface holds the workpiece when
a centrifugal force is applied with the help of a drill machine.

29
Machining
• A solid base is created at the bottom in which the workpiece is placed so
that the workpiece will be in a static when centrifugal force is being
applied. And also a large diameter hole that fits the bearing is bored in the
solid surface.

30
Cond…
• A gear is installed in to the grooved
hole on the solid surface for an easy
rotation when centrifugal is being
applied.
• An external shield for the collection
of molten metal is

31
Experimental setup
Drill Machine
Shield
Solid Base
Workpiece

32
Cont..
• After manufacturing the workpiece induction heater is need to setup
with an electrical supply and water supply.
• There are 2 water inlets and 3 water outlets that needs to be
plugged with water pipes.
• A ¾ manifold for water outlet is used and 2-1 manifold is used for
water inlet.
• A 8 gauge wire is used for electrical supply.

33
Water Fittings
¾ manifold 2-1 manifold

34
Electrical Setup
Electric cables Insulation box

35
Induction Heater Furnace
Induction Heater furnace.

36
Experiment
• Electrical wires of different types such as copper wires, aluminum wires,
solder, steel, high strength alloys, nickel plated conductors, tinned
conductors etc. can be chosen for the recycling. Copper wires, electrical
wires and solder are chosen for this experiment. Solder wires do not have a
PVC material insulated on the metal whereas the copper wire and
aluminum wire has a PVC material insulated on the meatal.
Aluminum wire Copper wires Solder metal

37
Samples
• 5 g samples including solder, aluminum and copper
wires without PVC at low speed.
• 10g samples including solder, aluminum and
copper wires without PVC at low speed.
• 15 g samples including solder, aluminum and
wires with PVC at low speed.
copper wires with PVC at low speed.
wires without PVC at high speed.
• 10g samples including solder, aluminum and
copper wires without PVC at high speed.
wires with PVC at high speed.
copper wires with PVC at high speed.

38
Weighing Scale
• Experimental part begins with the weighing of required samples and
shearing the PVC (cap material) on the wires for aluminum and copper
wires. Starting with Samples of 5g each i.e. copper wire 5g without PVC
material, 5g of aluminum without PVC material and 5g of solder is
weighed.

39
E-Scrap
• All the materials that are weighed are fed into the workpiece.
• Later the feeding, the workpiece is closed with a cap.

40
Workpiece Heating
• Now, The work piece is heated and allowed to reach melting points of
certain metals such as for the solder the melting point is 183 0 C, so the
workpiece is allowed to reach the temperature of 200 0 C.

42
Extracting the Metal
• After it reaches to the melting point of the solder the
heating is stopped and shield is placed around the
work piece and drill machine is used as an external
force for the application of centrifugal force.

43
Recovered Metal
• By the action of centrifugal force the metal that is melted hits the wall
surfaces of the workpieces and as there are holes drilled throughout the
circumference of the workpiece, the molten metals is forced out of the
workpiece and collected in the shield at bottom.
Recovered Solder
Solder

44
Recovered Metal
• Similarly the experiment is further continued and allowed the workpiece to
reach the melting point of aluminum which is 660.30 C and then again the
drill machine is attached to the workpiece and centrifugal force is applied
and the aluminum metal is recovered.
Aluminum recovered
Aluminum

45
Recovered Metal
• Experiment is further continued, but as we fed 3 types of metals into the
workpiece and out of which we have taken out the two metals which are
aluminum and solder, all the left over material in the workpiece is copper
and their residues. So further heating is to just make sure the copper metal
is completely burnt and keeping no traces of other metals.
Copper Residues
Copper Metal

46
Measure of Recovered Metal
• Recovered metals are weighed and the percentage of recovery is
calculated.

47
E- Scrap
• Similarly, experiment is carried out for the high
speeds and different weight samples. Also,
further experiments includes the PVC material
on the wires and burning them to recover the
metals.
Aluminum Wire
Solder
Copper Wire

48
Conversion
• To keep the comparison same between without PVC and with PVC
samples, conversion factor of insulated material is calculated.
Material 5g 10g 15g 20g
Aluminum 7.0271 14.0542 21.0813 28.1084
Copper 17.98 35.96 53.94 71.92

49
Workpiece Heating
Smoke due to
burning of PVC

51
Recovered metals
Aluminum RecoveredSolder Recovered

53
Results And Discussions
• Metals are recovered by heating process and the collected samples are
weighed and compared with the original values and the percentage of metal
recovered is calculated.
S.
No
Solder Recovery
(%) Low Speed
Aluminum
Recovery (%) Low
Speed
Copper
Recovery (%)
Low Speed
1 96.13848719 97.31426578 99.24096478
2 96.73573603 98.25139183 100.7921999
3 98.38726017 98.02434644 100.0399042
4 98.93716059 97.16130794 99.55209348
5 95.89335207 97.63796477 99.78634535
Percentage Recovery Of 5g Samples
Without Cap Low Speed
percentage recovery of 5g samples
without cap High Speed
S.
No
Solder
Recovery (%)
HIGH Speed
Aluminum
Recovery (%)
High Speed
Copper
Recovery (%)
High Speed
1 98.89348134 98.63857214 102.2958531
2 98.62140946 98.86288621 100.8116046
3 97.08064792 99.00033256 100.5539754
4 98.67584142 99.08471509 100.712671
5 97.13957094 99.25144573 100.7695788

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10g Samples Without cap
S. No
Solder recovery (%) Low
speed Aluminum recovery (%) Low speed Copper recovery (%) Low speed
1 87.38761775 98.99979849 100.0002924
2 98.67364225 97.19985345 100.0000068
3 98.51829214 97.99983542 100.0000258
4 98.91830852 98.30788884 100.000079
5 98.55990439 97.99987582 100.0000472
S. No
Solder recovery (%)
HIGH speed
Aluminum recovery (%) High
speed
Copper recovery (%) High
speed
1 88.0595058 98.14729145 106.6323502
2 98.25876064 98.92451899 102.1095135
3 99.07396088 99.29885629 100.5047667
4 99.23220898 99.03540535 100.5013778
5 99.48756368 98.19198828 100.8065393
Percentage Recovery Of 10g Samples Without Cap Low Speed
Percentage Recovery Of 10g Samples Without Cap High Speed

57
15gm Without PVC
S. No
Solder recovery (%)
Low speed
Aluminum recovery (%) Low
speed
Copper recovery (%) Low
speed
1 96.77589949 97.41466938 101.9423497
2 97.82605842 96.19371225 100.8101622
3 97.65933401 98.79287765 100.9131542
4 98.18895142 98.85580488 100.967604
5 98.09560184 98.79330607 101.2527128
S. No
Solder recovery (%)
HIGH speed
speed
speed
1 95.96780425 97.45363093 107.9811586
2 96.60701169 98.03592988 105.1598013
3 99.04508936 98.69272424 102.6069117
4 99.27079968 98.54485799 102.4541163
5 99.45247338 98.75633808 103.4352881
Percentage Recovery of 15g Samples Without Cap Low Speed
Percentage Recovery of 15g Samples Without Cap High Speed

59
20g Samples Without PVC
S. No
speed
speed
speed
1 94.9927058 95.19322914 103.738916
2 93.50108124 96.74508618 102.48265
3 94.34259749 95.62392213 104.5125
4 94.20766044 95.76492465 104.031094
5 94.27843506 96.36286393 104.594802
S. No
Solder recovery (%) HIGH
speed
Aluminum recovery (%)
High speed
speed
1 96.89348134 96.63857214 104.2958531
2 95.62140946 97.86288621 103.8116046
3 96.08064792 98.00033256 103.5539754
4 96.67584142 96.08471509 102.712671
5 95.13957094 97.25144573 104.7695788
Percentage Recovery of 20g Samples Without Cap Low Speed
Percentage Recovery of 20g Samples Without Cap High Speed

61
5g Samples With PVC
S.no
speed
speed
speed
1 96.3981462 95.44621639 102.1795485
2 95.9696824 97.32100351 103.6982523
3 97.9448529 96.53079901 103.3552624
4 97.5549214 97.53256425 102.3686813
5 97.661928 97.49257296 102.792179
S.no
Solder recovery (%)
High speed
speed
speed
1 96.5526581 97.16631351 106.279914
2 96.8745722 94.27287328 107.202756
3 95.5577763 96.76269752 106.0993794
4 96.3567355 94.72578795 107.5379049
5 97.2138365 94.58424128 106.982931
Percentage Recovery of 5g Samples With Cap Low Speed
Percentage Recovery Of 5g Samples With Cap High Speed

63
10g Samples With PVC
S.no
Solder recovery (%)
Low speed
Low speed
speed
1 92.6307147 94.74527464 103.5756547
2 95.19278868 93.2706595 105.6023362
3 95.19521404 94.63244383 103.8294695
4 94.41624862 92.17918276 104.5960853
5 93.22480131 93.17244604 104.4316428
S.no
Solder recovery (%)
HIGH speed
High speed
speed
1 96.8423219 94.44365029 103.0089546
2 92.3142846 94.12613445 105.5944654
3 95.8230883 95.8591443 101.6632694
4 94.1187557 92.68395708 102.6535641
5 94.0960554 94.02725386 103.7070149
Percentage Recovery of 10g Samples With Cap High Speed

65
15g Samples with PVC
S. No
Solder recovery (%)
Low speed
speed
speed
1 91.62945311 88.24994046 103.5756547
2 89.19002741 89.69882272 105.6023362
3 92.05756539 91.72398749 103.8294695
4 88.54890916 91.47039019 104.5960853
5 88.19590983 88.92116712 104.4316428
S. No
Solder recovery (%)
HIGH speed
speed
speed
1 92.750475 93.174818 110.027927
2 90.593454 93.90464 110.1983181
3 92.286784 92.114485 109.3294309
4 93.920315 94.556955 105.7078773
5 92.088539 95.501658 105.0190731
Percentage Recovery Of 15g Samples With Cap High Speed

67
Effect of Speed
• All the experiments are attempted at high and low speeds and the variations
are clearly drawn and almost all the samples with the high speed are
resulted in greater metal recovery rates when compared with the low speed
samples. So speed of the spin has greater effects on the metal recovery
rates.

68
Effect of Time
• Heating of the workpiece beyond the melting point of the metal results in
mixture of the metals i.e. if a solder is heated beyond its melting point and
if the temperature reaches the melting point of the any other metal then that
metals gets melted and it mixes with the already melted solder.

69
Variations Due To Area of The Workpiece
• High weight samples have the low recovery rates when compared with the
low weight samples. And the area of the workpiece corresponds to the
recovery rates.

70
Effect of PVC material on metal recovery rates
• PVC material insulated on the wires are high in
weight which results in less metal recovery

71
Conclusion
• Burning of metals in open environment is reduced.
• Uncontrolled heating processes are completely eliminated.
• Metal recovery rates are high compared to the other processes that are
presently using.
• By smelting process that are presently in existence have given a 86% metal
recovery rates, where as the current process have a recovery rates of 90%.
• All recovery techniques that are presently in existence will be able to
recover one metal at a time and for the other kind of metal another
technique has to applied.

72
Cont.
• Even though 100% recovery is not happened, but on
each and every sample the recovery rate is more than
90%, which is a clear indication of the greater
recovery rates.
• Metal recovery depends on various factors like RPM,
weight of the sample, uniform heating, and time rate.
• A new design is created for the recovery process and
the design has reflected in great recovery rates.

73
• Easily available wire metals are chosen for the experimentation.
• Induction furnace that was used is a 15kw induction heater furnace, more
kW machine would give greater results and metals with high melting points
can also be recovered easily.
• Insulated material (PVC) extraction involves complex steps to recover yet
not an impossible process, so the possibilities of PVC before extracting the
metals has to studied.
Future Work

74
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