Verma Environmentally Sound Management of E-waste and Practices of Recycling

8/12/2019 Verma Environmentally Sound Management of E-waste and Practices of Recycling

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Presentationon

Environmentally Sound Management of

E-waste and Practices of Recycling/

Recovery of Valuables from E-waste

by

N.K. Verma


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Sustainable development concerns

Electrical and electronic waste (e-waste) is fastest growing wastestreams in the world

Increasing market penetration Replacement market

High obsolence rate (1,46,180 Tonnes for year 2005)

As per Environmental Policy (NEP), there is a need to facilitaterecovery and/or reuse of materials from waste generated from aprocess and or/ from the use of any material, thereby reducing thewaste destined for f inal disposal and to ensure the environmentallysound management of all materials.

The NEP also encourages giving legal recognition and strengtheningthe informal sectors system for collection and recycling of variousmaterials.


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VariousregulationsthatcoverdifferentaspectsofEwasteare:

1. TheHazardousWastes(Management,HandlingandTransboundary

Movement)Rules,

2008.

RegistrationmandatoryforallEwasterecyclersaslistedin

ScheduleIVoftheRule

Transboundarymovement

(export

and

import)

of

Ewaste

regulatedinaccordancewiththeBasel Conventionandwaste

categoriesincludedin ScheduleIIIoftheaboveRule.

2. TheMunicipalSolidWaste(Management&Handling)Rules,2000

forallnontoxiccontents.

LegislationsGoverningEWaste


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Composition of E-Waste

Very diverse compositions and differs in products across different

categories.

More than 1000 different substances, under hazardous and non-hazardous categories

Consists of ferrous (50%) and non-ferrous metals (13%), plastics (21%),

glass, wood & plywood, printed circuit boards, concrete and ceramics,

rubber and other items.

Non-ferrous metals consist of metals like Copper, Aluminium and precious

metals e.g. Silver, Gold, Platinum, Palladium etc.

Presence of Lead, Mercury, Arsenic, Cadmium, Selenium, and hexavalentChromium and Brominated flame retardants beyond threshold quantities in

E-waste makes it hazardous waste.


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CompositionofEwaste

Contd.

Appliances Average

weight

(Kg.)

Fe

%

Weight

Non Fe-

metal

% weight

Glass

%

weight

Plastic

%

weight

Refrigerator

s/freezers

48 64 6 1.4 13

Personal

computers

30 35 9 15 23

TV sets 36 5 5 62 23

Fluorescent

tubes

0.2 0.6 1.4 94 -

Table:AverageWeightandCompositionofSelectedAppliances


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Categorisation ofEWaste

Components which are Building Blocks of EWaste and easily

identifiable and removable are metal, motor/compressor, cooling

plant,

plastic,

insulation

material,

glass,

LCD,

rubber,

electrical

wiring,concrete, transformer, magnetron, textile, circuit board, fluorescent lamp,

incandescent lamp, heating element, thermostat, BFRplastic, batteries,

CFC/HCFC/HFC/HC,externalelectriccablesetc

Large Household

Appliances

Refrigerators, Washing Machines, Microwaves etc

IT & Telecom Appliances Personal Computers, Monitors, Laptops, MobilePhones, etc

Consumer Appliances Television, DVD, Play Stations etc

Threemain

categories

Components


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PossibleHazardousSubstancesinComponents

omponent Possible Hazardous ontent

Cooling ODS

Plastic Phthalate plasticizer, BFR

Insulation Insulation ODS in foam, asbestos,

refractory ceramic fiber

CRT Lead, Antimony, Mercury, Phosphors

LCD Mercury

Rubber Phthalate plasticizer, BFR

Wiring / Electrical Phthalate plasticizer, Lead, BFR

Circuit Board Lead, Beryllium, Antimony, BFRFluorescent Lamp Mercury, Phosphorus, Flame Retardants

Thermostat Mercury

BFR containing

plastic

BFRs

Batteries Lead, Lithium, Cadmium, Mercury

CFC, HCFC, HFC,

HC

Ozone depleting substances

External electric

cables

BFRs, plasticizers

ElectrolyteCapacitors Glycol

Thesubstances

of

most

concern

are the heavy metals such as

lead, mercury, cadmium and

chromium (VI), halogenated

substances

(e.g.

CFCs),polychlorinated biphenyls,

plastics and circuit boards that

contain brominated flame

retardants (BFRs). BFR can give

riseto

dioxins

and

furans

during

incineration.


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1st level treatment

2nd level treatment

3rd level treatment

All the three levels of e-waste treatment are based on material flow. The material flows

from 1st level to 3rd level treatment. Each level treatment consists of unit operations,

where e-waste is treated and out put of 1st level treatment serves as input to 2nd level

treatment. After the third level treatment, the residues are disposed of either in TSDF or

incinerated. The efficiency of operations at first and second level determines the

quantity of residues going to TSDF or incineration.

Input e-waste

Output i.e. recovered

materials

Disposal

1st level

Treatment

2nd level

Treatment

3rd levelTreatment

Disposal

The first step towards

environmentally sound

management of E-Waste is

to remove hazardous

substances as well as

recyclable components.

Environmentally Sound E-waste Management and Treatment

The second step involves

unit operations such as

hammering, shredding and

process of separation using

various techniques.


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First Level TreatmentInput: E-waste items like TV, refrigerator and Personal Computers (PC)

Unit Operations: There are three units operations at first level of E-waste treatment

Decontamination : Removal of all liquids and Gases

Dismantling -Manual/Mechanized Breaking

Segregation

All the three unit operations are dry processes, which do not require usage of water.

Decontamination

The first treatment step is to decontaminate e-waste and render it non-hazardous. This

involves removal of all types of liquids and gases (if any) under negative pressure, their

recovery and storage.Dismantling

The decontaminated e-waste or the e-waste requiring no decontamination are dismantled

to remove the components from the used equipments. The dismantling process could be

manual or mechanized.

SegregationAfter dismantling the components are segregated into hazardous and non-hazardous

components of E-waste fractions to be sent for 2nd level treatment.

Output of First Level Treatment

Segregated hazardous wastes like CFC, Hg Switches, batteries and capacitors Decontaminated E-waste consist ing of segregated non-hazardous E-waste like plastic, CRT, circuit

board and cables


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Input: Decontaminated E-waste consisting ofsegregated non hazardous wastes like plastic,

CRT, Circuit Board and Cables

Unit Operations: There are three unit operations at

second level of E-waste treatment

HammeringShredding

Special treatment processes comprising of

CRT treatment consisting of separation offunnels and screen glass.

Electromagnetic separation

Eddy current separation

Density separation using water

Second Level Treatment


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Treatment of Gas Discharge lamps

Gas discharge lamps are defined as lamps in which light

is produced by an electrical discharge through a gas.

The discharge can either be through gases (such as

xenon, neon and carbon dioxide) or through metal vapour

such as mercury or sodium.

The treatment process for fluorescent lamps involves

shredding followed by separation into glass, metal and

powder (which contains mercury). The separation

process should be designed to prevent fugitiveemissions of mercury vapour or dust.


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Third Level Treatment

Carried out mainly to recover ferrous, non-ferrous metals including precious metals,

plastics and other items of economic value

Input/ Output and Unit Operations in 3rd Level Treatment

Input/ E-waste residues Unit Operation/ Disposal/ Recycling

Technique

Output

Sorted Plastic Recycling Plastic Product

Plastic Mixture Energy Recovery/ Incineration Energy Recovery

Plastic Mixture with FR Incineration Energy Recovery

CRT Breaking/ Recycling Glass Cullet

Lead Smelting Secondary Lead Smelter Lead

Ferrous metal scrap Secondary steel/ iron recycling Iron

Non Ferrous metal Scrap Secondary copper and aluminum smelting Copper/ Aluminum

Precious Metals Au/ Ag separation (refining) Gold/ Silver/ Platinum and

Palladium

Batteries (Lead Acid/ Ni MH and Li

ION)

Lead recovery and smelting

Remelting and separation

Lead

CFC Recovery/ Reuse and Incineration CFC/ Energy recovery

Oil Recovery/ Reuse and Incineration Oil recovery/ energy

Capacitors Incineration Energy recovery

Mercury Separation and Distillation Mercury


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Plastic RecyclingThree different types of plastic recycling options

Chemical recycling

Mechanical recycling

Thermal recycling.

New raw materialsPelletized and new

productsAlternative fuel

Mixed plastics

Chemical recycling Mechanical recycling Thermal recycling/re-use

Refinery or metal

smelter

Shredding,

identification

and separation

Power generator or

cement kiln

The two major types of plastic

resins

Thermosets

Thermosets are shredded

because they cannot be re-

melted and formed into new

products

Thermoplastics

Thermoplastics can be re-

melted and formed into new

products

Thermal Recycl ing/

Re - use Process

In thermal recycling process,plastics are used as fuel for energy

recovery. Since plastics have high

calorific value, which is equivalent

to or greater than coal, they can be

combusted to produce heat energy

in cement kilns.


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Chemical Recycling ProcessThe different steps in this process are given below.

Mixed plastics

waste

Depolymerization

< 400 0c

Hydrogenation 2 (Gasphase)

Hydrogenation 1

(liquid phase)

Petrochemical

processes

HCL

Condensation

H2< 100 bar Hydrogenation

bitumen


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Mechanical Recycling Process

Sorting

Shredder

(Size reduction)

Magnetic separation


Air separation

Resin identification

Extrusion

Pelletizing

Metals, fluff, fines

Ferrous metals

Nonferrous metals

Labels, films

Sorting

Shredder

(Size reduction)

Magnetic separation


Air separation


Extrusion

Pelletizing

Sorting

Shredder

(Size reduction)

Magnetic separation


Air separation


Extrusion

Pelletizing

Metals, fluff, fines

Ferrous metals

Nonferrous metals

Labels, films

Process flow diagram for themechanical recycling of post

consumer plastics

Shear-shredder and hammer mills - for size reduction andliberation of metals (coarse fraction)

Magnetic separators for ferrous metals separation,

Eddy current separators for non ferrous metals separation.

Air separation system for separation of light fractions such

as paper, labels and films.


Hydro cyclones separation technique

Plastic fractions are separated using density

separation technique, which is made more effective by

enhancing material wettabili ty.

Turboelectric separation techniquePlastic resins are separated on the basis of surface

charge transfer phenomena. This technique has been

found to be most effective for materials with a particle

size between 2-4 mm.

High accelerator separation techniqueFor de-lamination of shredded plastic waste, which is

further separated by air classification, sieve and

electrostatics.

X-ray fluorescence spectroscopy

For identifying heavy metals as well as flame-

retardants.

Af ter identif ication and sorting of dif ferent resins, they are

extruded and palletized.


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Lead RecoveryReverberatory furnace and blast furnace are used to recover lead from e-waste fraction.

Metals Recycling

Non Ferrous Metals (Out put of 2nd Level Treatment) are recovered in metal recovery facilit ies.

Processes flow for secondary lead recovery

Pretreatment

Reverberatoryfurnace

Blast furnace

Relining

Hard Pb

Reductant

Soft Pb(99.98% Pb)

75-85% Pb

Reductant Slag

Reverberatory furnace is charged

with lead containing materials and

reductants. In this furnace, the

reduction of lead compounds is

carried out to produce lead bullion

and slag. Lead bullion is 99.9%

while slag contains 60-70% lead.

Lead is recovered from the slag by

charging it in blast furnace along

with other lead containing

materials and fluxing agents likeiron and limestone

Hard lead is recovered from the

blast furnace, which contains 75-

85 wt. % Pb and 15-25 wt. % Sb.

Slag contains 1-3% lead. Slag

contains CaO, SiO2 and FeO.


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Copper Recovery

Electrolytic Refinery

Pretreatment

Blast furnace

Converter

Anode Furnace Reductant

Anode Cu: - 98.5 wt% Cu

Reductant

Black Cu: 70 85 wt% Cu

Low grade scrap (10-40 wt% Cu)

Blister Cu: 95 wt% Cu

Precious Metals

Cathode Cu: 99.99 wt% Cu

E-waste fraction containing Cu is fed into a blast furnace,

which are reduced by scrap iron and plastics to produce

black copper . Black copper contains 70-85 wt. % copper.

Sn, Pb and Zn are also reduced as gas fumes.

The black copper is fed into converter and oxidized using air

or enriched oxygen to produce blister copper having 95 wt. %

purity. Sn, Pb and Zn are removed, while Fe is removed as

slag.

Blister copper and scrap Cu are melted and reduced by coke

or wood or waste plastic in anode furnace. Other less noblemetal are oxidized and removed f rom blister copper. Sulfur is

also removed from the anode furnace.

Recovered anode copper is further purified in electrolytic

process where it is dissolved in H2SO4 electrolyte with other

elements such as Ni, Zn and Fe. The pure copper 99.99 wt. %

is deposited on the cathodes.

The by-products of copper recovery process and slag are

reused for roof shingles, sand blasting and ballasts for

railroads. The anode slime from electrolytic process is used

for precious metal recovery. The entire secondary recovery of

Cu uses only one-sixth of the energy that would be required

to produce Cu from ore.


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Precious Metals Recovery

Copper anode slime

Leach

Smelter

Silver

Gold, Platinum,

Palladium

Anode slime

Silver electrolytic refining

The anode slime from copper electrolytic process is used

for precious metal recovery.

Anode slime is leached by pressure.

The leached residue is then dried and, after the

addition of fluxes, smelted in a precious metals

furnace. Selenium is recovered during smelting.

The remaining material from smelter is caste into

anode and undergoes electrolysis to form high-purity

silver cathode and anode gold slime.

The anode gold slime is further leached and high puritygold, palladium and platinum are recovered.


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State E-Waste(Tonnes) (2004-05)MAHARASHTRA 20271

TAMIL NADU 13486

Andhra Pradesh 12780

Uttar Pradesh 10381

West Bengal 10059

Delhi 9729

Karnataka 9119

Gujarat 8994

Madhya Pradesh 7800

Punjab 6958

Total 1,09, 577

MajorEWasteGeneratorStates


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Ewaste

Facilities

Uttaranchal

Jharkhand

Chattisgarh

01

01

02

04

02

01

01


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Registered E-Waste Recyclers

S.No. Name Registered Capacity(Tonnes)

01. M/s Attero Recycling Pvt. Ltd., Roorkee, Uttrakhand 12,000 MTA

02. M/s Eco Recycling Pvt. Ltd. Andheri(East), Mumbai 3,600 MTA03. M/s Earth Sense Recycle Pvt.Ltd. Hyderabad, Andhra

Pradesh

1,800 MTA

04. M/s Earth Sense Recycling Pvt. Ltd. Gurgaon 1,200 MTA

05. M/s K. G. Nandini, near Bangalore Karnataka 7,200 MTA06. M/s E-Parisara Pvt.Ltd.,Bangalore Karnataka 1,800 MTA

07 M/s Earth Sense Recycling Pvt. Ltd. Mumbai 360 MTA

08 M/s TIC Ltd, Noida 1,000 MTA

09 M/s Ash Recyclers, Bangalore Karnataka 120 MTA10 M/s Trishiraya Recyclers, Ltd, Chennai 740 MTA

11 M/s Tess Amm Ltd, Chennai 30, 000 MTA

12 M/s NewPort Computer Services (India) Private Limited,

Bangalore

500 MTA

Total 60,320 23


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Recycling Practices Adopted

S.No. Name of the unit Description

01. M/s Attero Recycling Pvt. Ltd., Roorkee, Uttrakhand Manual dismantling, automated

segregation and metal recovery

through electrolytic process.

02. M/s Eco Recycling Pvt. Ltd. Andheri(East), Mumbai Automated dismantling and

segregation. No CRT cutting

03. M/s Earth Sense Recycle Pvt.Ltd. Hyderabad, Andhra Pradesh Manual dismantling and CRT cutting

04. M/s Earth Sense Recycling Pvt. Ltd. Gurgaon Manual dismantling and CRT cutting

05. M/s K. G. Nandini, near Bangalore Karnataka Automated dismantling and

segregation

06. M/s E-Parisara Pvt.Ltd.,Bangalore Karnataka Manual dismantling and CRT cutting

07 M/s Earth Sense Recycling Pvt. Ltd. Mumbai Manual dismantling and CRT cutting

08 M/s TIC Ltd, Noida Manual dismantling, CRT cutting and

mechanized CRT crusher

09 M/s Ash Recyclers, Bangalore Karnataka Manual dismantling and re-furbishing

10 M/s Tr ishiraya Recyclers, L td, Chennai Manual d ismantl ing, segregat ion and

CRT cutting

11 M/s Tess Amm Ltd, Chennai Automated dismantling and

segregation

12 M/s NewPort Computer Services (India) Pr ivate L imited, Bangalore Manual dismantl ing and segregat ion24


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MATERIAL RECEIVING

SEGREGATION

DISMANTLING

SEGREGATION

Separation of Metals-

Steel,Copper,

Aluminium, Mild Steel.

Separation

of Plastics-

Grade-I,

Grade-II &

Grade-III

Separation

of Printed

Circuit

Boards

Separation of

CRTSeparation

of Batteries

Packing

Storing

Recycling

Shredding

Recycling

of Plastics

Packing

Fugitive dust separation

by pulse jet bag filter and

cyclones

Separation of

Hazardous like

tungsten, electron

gun, Dust

Storing

Forwarding

for Precious

Metal

Extraction

Sendingto TSDF

Storing

Forwarding to

TSDF for

Disposal

Separation

of Funnel

glass

Storing

Separation

of frontGlass

Removal of

Phosphorus

Removal of

Tie

Glass

recycling

Forwarding to the

CRT Manufacturers

for recycling

A TYPICAL PROCESS FLOW CHART FOR RECYCLING

OF E-WASTE

Disposal by TSDF

Storing

Recycling


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Thank You!

Documents

Verma Environmentally Sound Management of E-waste and Practices of Recycling