CflPATER 7

NATURAL RESOURCE CONSERVATION

AND
MINERAL SUBSTITUTION BV RECOVERING
I- METALS FROM EOL-PC

0^

Improving the quality of human life while living within the

carrying capacity of supporting ecosystems is
sustainability.
Sustainable use of materials has targeted the idea
of dematerialization, converting the "linear path of
m.aterials (extraction, use, disposal in landfill) to a current
material circular flow of materials" as much as possible,
much like recycling and reuse of the waste in nature.
(lUCN/UNEP/WWF- 1991)
 Natural Resource Conservation & Mineral Substitution

CHAPTER - 7

NATURAL RESOURCE CONSERVATION AND MINERAL

SUBSTITUTION BY RECOVERING METALS FROM EOL-PCs

A wide range of components made of metals, plastics and other

substances are contained in electrical and electronic equipments. A personal
computer, which is one of the most commonly used electronic equipments,
contains metals like Iron, Aluminium, Copper, Tin, Cobalt, Gold, Palladium
almost in their pure state etc.

Fig 7.1 Copper mined form EOL- PC

CO2 emissions from mining and production of Copper and precious
metals used in electrical and electronic equipment are estimated at over 23
million tons - 0.1 % global emissions (not including emissions linked to steel.
Nickel or Aluminium nor those linked to manufacturing the devices (Hazards
Coming Up-UN 2010).
7.1 Assessment of Natural Resource Conservation & Mineral substitution
Sustainable use of materials has targeted the idea of dematerialization,
converting the linear path of materials (extraction, use, disposal in landfill) to
a current circular flow of materials as much as possible, much like recycling
and reuse of the waste in nature. This approach is supported by product

Ph.D. Thesis "Recovery of metals from EOL-PC" 122

 Natural Resource Conservation & Mineral Substitution

stewardship and the increasing use of material flow analysis at all levels,
especially individual countries and the global economy. (Product Stewardship
Council, 2009).
Conservation of natural resources by recycling of EOL-PC and
resource recovery from EOL-PC is the best example of circular path followed
towards sustainability.
Recovery efficiency of resources from EOL-PC, is estimated that 38
% Fe, 7.6 % Cu, 1.4 % Al, 0.0012 % Au, 28.77 % Polymer, and 18 % Silica
are recoverable.
To assess the natural resource conservation and mineral substitution by
practicing urban xmnm^surface mining/green metallurgy, during the present
study, extensive field study has been carried out to have first hand information
about consumption of natural resources involved in the production of metals
by traditional metallurgical processes by visiting the following sites:
1. Jindal Steel Works (JSW) Torangallu, Bellary District of Kamataka:
2. National Mineral Development Corporation (NMDC), at Donimalai,
Bellary District, Kamataka State.
3. HINDALCO (earlier INDAL) Indian Aluminium Co, located at
Belgaum, Karantaka State.
4. Hutti Gold Mines Ltd. the only leading Gold Producer of India at
Hutti, Raichur District of Kamataka State.
Detailed study has been done by visiting JSW, and HGML, the process
of extraction of Iron and gold from Primary source is studied, experts were
consulted. (During of the field study, Production Iron and Gold from primary
sources is well documented and presented in the AA^ documentary
(Annexure I and II)
The data generated by field visit has provided most valuable information that
has been used to estimate conservation of natural resources and mineral
substitution by recycling of end of life personal computers.
Ph.D. Thesis " Recovery of metalsfromEOL-PC" 123
 Natural Resource Conservation & Mineral Substitution

Estimation of natural is done based on the characterisation and

recovery efficiency of resources from EOL-PC done during present study.
Calculations are done for one ton as well as extrapolated, assuming that if all
the 56,324 tons of EOL-PCs generated by 2011 are scientifically recycled.
The environmental benefits of recycling are expressed as savings in virgin,
natural resources, saving in energy, reduction in the quantum of Green House
Gases (GHGs), particularly in savings of Carbon dioxide, generation of new
employment etc.
Assessment of conservation of natural resources and mineral
substitution is possible only if a brief comparison between the production of
metals from primary and that from secondary sources is made.

7.2 Production of Iron from EOL-PC v/s Iron from primary resources:
Based on the field study at Jindal Steel Works (JSW), Thoranagallu,
Bellary District of Kamataka, it is observed that Iron from iron ore, is
produced by the well known Blast Furnace route, and also, by the most
modem method called COREX process (Direct Reduced Iron). There are only
two other places in the world i.e.. South Korea and South Africa, which use
this COREX technology to produce Iron from the ores.
Results obtained during the present study Based on the characterisation
study, and recycling efficiency, it is estimated that, recycling of EOL-PC
produces, 38% Iron by processing one ton of EOL PCs. To produce one ton
of Iron requires 6 tons of Iron ore, (Fig 7.2), one ton of coal/coke (Fig 7.3) and
1.2 tons of basic fluxes. In addition, it requires 5.8 kJ of energy to transport
ore (through conveyer belt), 0.6 kJ for smelting, 3.3 cubic meter of water, and
1500 man hours and at the end of the process, one ton of pig iron, 0.6 ton of
slag is also obtained.
Concentrated iron ore is reduced to Iron using coal/coke at high
temperature maintained in the furnace; fluxes added react with non fusible
PhD. Thesis "Recovery of metals from EOL-PC" 124
 Natural Resource Conservation & Mineral Substitution

impurities producing fusible slag as the byproduct. Molten iron with several
nonmetals and metals and dissolved oxides of Sulphur and nitrogen is impure
and is called Pig iron. This is further refined to get steel by the well known,
Linz and Donawiz (L.D).Process.
Besides, plant scale production of Iron and Steel from primary
resources requires a vast land (limited resources) for establishment of
processing plant (Fig7.4 and 7.6), huge capital investment, technically
qualified, skilled and experienced human resource. There is life risk while
collecting molten metal coming out of the furnaces (Fig.7.5). In the latest
Corex process for the production of Iron, emission of pollutants like oxides of
Sulphur and Nitrogen though can be minimized, can not be completely
avoided.

Fig. 7 .2. Iron ore ready for transport

Fig.7.3 Coke source of enenrgy and reducing agent.

Ph.D. The.sis "Recovery of metals from EOL-PC 125

 Natural Resource Conservation & Mineral Substitution

1n

Fig. 7.4 COREX Plant at JSW Fig. 7.5 Working at the

Blast furnace: risky operation

Fig.7.7 describes a comparative account of process of production of Iron &

steel from primary ores and that from secondary source. Table 7.1 explains the
conservation of natural resources and mineral substitution by recovering Iron
and steel from the EOL-PC as secondary source. By recovering Iron by
recycling one ton of EOL-PC, one can save 0.6 ton of ore, 0.38 ton of coke,
0.45 ton of basic flux, 1.2J of energy, 1.2 cubic meter of water, 570 man
hours, and 0.2 ton of slag.

Ph.D. Thesis "Recoveiy of metals from EOL-PC" 126

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 Natural Resource Conservation & Mineral Substitution

7.3 Resource Conservation by recovering Aluminium from EOL-PC:

HINDALCO (earlier INDAL) Indian Aluminium Co, located at

Belgaum, Karantaka State where primary production of Aluminium from
naturally occurring Bauxite is practiced by the well known Bayer's Process
followed by Hall-Herolt Electrolytic Process. In the Bayer's process, ground
Bauxite (Fig 7.8) ore is treated with strong solution of hot Caustic Soda in
huge special barrels arranged in series for obtaining (Fig.7.9) Aluminum oxide
through leaching and later collected as solid Alumina (Fig.7.10). The major
raw materials for the production of Al are Bauxite and electricity. Ferric Oxide
naturally present in the Bauxite remaining in the form of solid residue is called
"Red mud" (Fig 7.12). For every ton of Aluminium produced, 3.2 tons of red
mud is produced which has negative impacts on the environment. Alumina
with molten cryolite to reduce m.p., in presence of little Calcium fluoride is
electrolyzed at about 960°C to get Aluminium (Hall-Herolt process). The
process is most energy demanding, requires vast land, heavy capital
investment and vast land (Fig.7.11) and is highly polluting due to the
byproduct produced -red mud.
For one ton of Al to be produced from the primary source, 6 ton of
Bauxite,37.7 kg of Lime,78 kg of Caustic Soda,O.Il m2 filter cloth, 0.234 kg
of synthetic flocculants, 158 kW of power,123.5 kg of boiler oil,85 kg of kiln
oil and 2.77 MLD of water are required. The unwanted byproducts which
are threat to the environment are Red mud 1.73 ton and 10.6 ton of Carbon
dioxide.
On the contrary, in the recovery of Aluminium from EOL-PC as
secondary source, it is only direct collection of Aluminium components
mainly used as heat sink in SMPS, CRT monitor etc. and simply remelting.
Which is least energy demanding, no capital investment, no vast land required
and pollution levels are nil.

PhD. Thesis "Recovery of metals from EOL-PC" 129

 Natural Resource Conservation & Mineral Substitution

Fig 7.8: Bauxite ore unloaded at HINDACO-

Aluminium Factory, Belgaum

For one ton of EOL-PC recycled as secondary source for Al, one can save
0.084 ton of Bauxite, 37.7 kg of Lime, 1.092 of Caustic Soda, 0.00154 ml
filter cloth, 0.0038 kg of synthetic flocculants, 2.212 kW of power, 1.73 kg of
boiler oil, 1.19 kg of kiln oil and 0.0388 MLD. The unwanted byproducts
which are threat to the environment are Red mud 0.02422 ton and 0.148 ton of
Carbon dioxide.

!N4CV.
Fig 7.9 Plant to produce Alumina (Bayer's Process.)

Ph.D. Thesis "Recover\' of metals from EOL-PC" 130

 Natural Resource Conservation & Mineral Substitution

Fig. 7.10 Calcined Aluminium Hydroxide- Alumina

Fig. 7.11 A view of HINDALCO-Factory (Hall-Herolt Process)

Ph.D. Thesis "Recovery oj metals from EOL-PC" 131

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 Natural Resource Conservation & Mineral Substitution

7.^ Resource Conservation by recovering Gold from EOL-PC

Gold is one of the most sought-after metals found in a computer's
printed wiring boards and other circuit boards of PCs. Mainly because of its
malleability, ductility and chemical inertness. Fortimately gold occurs in its
native state but in deep mines and that too in small quantities.
The process of extraction of gold from gold ore is complicated,
involves risk of entering in to deep mines to get the ore, and also of handling
cyanide. The process carried out at Hutti Gold Mines of Kamataka mines is
explained as under.
Gold ore occurring in deep mines, at a depth of about 2500-3000 feet
belovs^ the ground is hoisted to the ground level. The hard gray quartz bearing
gold is crushed and ground to fine powder of about minus 200 mesh. This is
repeatedly washed with water on an inclined plane over which woolen
blankets are kept. Native Gold particles of size more than 40 microns are held
back on the blanket. These blankets are immersed in a tank filled with water.
Heavy gold particles settle at the bottom. Solid residue rich in Gold is then
subjected for gravity separation using Wilfley Table where, free gold particles
are held back and lighter impurities are throvm away. Free gold so collected
is then subjected fox panning to get impure non saleable gold.
Gold particles of size less than 40 microns present in the slurry is then
subjected for cyanidation, using Hydrogen peroxide and oxygen of the air as
oxidizing agents. After 36 hours, gold in the combined state becomes Sod.
Aurocyanide complex. At HGML, traditional Merrill-Crowe Zinc
Precipitation method is replaced by "Carbon In Pulp - CIP" (Fig.7.1^) is
practiced using activated coconut charcoal to adsorb Soda. Aurocyanide at pH
7 and at room temp. Gold loaded Charcoal is further heated with Caustic soda
at a temp.95° C, gold desorbs. Solution rich in Gold is further subjected to
electro wiiming. Gold deposits over steel wool.

Ph.D. Thesis "Recovery of metals from EOL-PC" 137

 Natural Resource Conservation & Mineral Substitution

Cathode with gold deposition is mixed with impure gold collected by panning
and then smelted using suitable fluxes to get gold bullion. The entire process
practiced in HGML is explained in Fig.7.l5
The process uses limestone, bleaching powder to neutralize cyanide,
sufficient energy for hoisting of the ore from deep mines to the ground level,
crushing and pulverizing the ore, smelting etc.
The huge residue left behind after the extraction of gold is dumped as
Gold Ore Tailing (GOT) (Fig. 7.I7) which is causing envirormiental problems.
How long these mines will be able to supply us gold, one day even
these mines will be declared dead. Then one has to depend on the secondary
sources like EOL-PCs to provide us gold and other valuable metals
Once PC reaches its end of life, becomes a secondary source of not
only gold but also silver and copper. Components like Processor, SD RAM,
various connects have gold, and silver coated pins. Mother board and many
other circuit boards (daughter boards) also contain precious metals concealed
and embedded in the heavy polymer like bakelite, epoxy etc. These precious
metals are difficult to be retrieved by physical methods. Above mentioned
precious metal rich subassemblies are size reduced and sent to UMICORE
Precious Metal Refinery, Belgium for the recovery of precious metals. After
standard sampling procedure, "concentrates" are fed along with the concerned
ore and metals are recovered.
By chemical analysis results and characterisation study, it is found that
one ton of P-III model EOL-PC contains 12 gm of gold.
To assess conservation of natural resources and mineral substitution,
process of recovery of gold from EOL-PC is compared with that practiced in
Hutti Gold Mines Ltd. (HGML), of Kamataka State, only leading gold
producer in India. During the field study on an average, a rich grade gold ore
contains about 4 g/w of gold for every ton of ore processed. On the contrary,
fortunately in 'surface mining/urban mining/green mining there is no risk of

Ph.D. Thesis "Recovery of metals from EOL-PC" 138

 Natural Resource Conservation & Mineral Substitution

deep mining operations, no crushing, no pulverization, no use of adsorbent etc

are observed.
Following (Tab!e7.3) explains the extraction of gold from gold ore
which helps in comparing the process practiced to recover gold from EOL-PC.

•Pa
-»A,.
H T^Wt^tMr/.
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1 \
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Fig. 7.16 Carbon in Pulp (CIP) Fig.7.17 Gold Ore TaiUng (GOT) dumped
Plant at Hutti Gold Mines,

to get about 4 gm of gold, 0.5kg of NaCN, 2.5 kg of lime,0.03 kg of lead

acetate,33 units of power to hoist the ore from deep mines to the ground
level,45 units to crush the ore, another 45 units to operate Wilfley table to
collect free gold size more than 40 microns, 0.08 kg of coconut charcoal, 0.3
kg of various fluxes,2.5 kg of bleaching powder to neutralize cyanide, and
3000 litres of water are required. While extracting 4 gm of gold, almost the
same amount of tailings left over will be threat to the environment and
occupies space.

Ph.D. Thesis "Recover}' of metals from EOL-PC 139

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 Natural Resource Conservation & Mineral Substitution

7.6 Conservation of natural Resources by Recycling Glass

• In EOL-PC weight of CRT monitor is 39%
• 56,324 MT of EOL-PC = 22,171MT of Monitors
• Based on the present characterisation study of EOL-PC monitor
contains 4L65% CRT glass (panel glass. Frit glass and Front glass)
• There fore the quantity of CRT glass from 22,171 MT of monitors is
41.65x22.172 = 9235.65 MT.
100
Natural resources like silica (sand), lead oxide, Barium oxide and
Strontium oxide, that can be conserved if 9235.65 MT CRT glass cuUets
are recycled for the production of new CRT is presented in the following
Table 7.5.
Table 7.5 Resources conserved by recycling of CRT glass
Resource Panel glass Funnel glass Remarks
Silica 5818 MT 5080 MT Conserved
Lead oxide 184MT 1350 MT Conserved
Barium oxide 877.4 MT 290 MT Conserved
Strontium oxide 712 MT 323.25 MT Conserved

7.7 Conservation of natural Resources by Recycling Plastics

Plastics recovered from EOL-PC can be recycled at least six times and
help in conserving natural resources like oil, reduce emission of Green House
Gases (GHG) and unnecessary space occupied if stored without recyling.
Based on the present resource recovery efficiency of EOL-PC, about
28 % comes from a variety of recyclable plastics. Quantity of Plastics that
can be recovered from 56,324 MT of EOL-PC is 15,770.72 MT. The
following Table 7.6 explains the other benefits of recycling of polymer.

Ph.D. Thesis "Recovery of metals from EOL-PC" 142

 Natural Resource Conservation & Mineral Substitution

Other Impacts on Ecology by recyling of Plastics from EOL-PC

> Reduces water usage by about 90%
> Reduces energy consumption by 70%
> Developed countries are unable to recycle Plastics, and end up in
incineration for energy recovery.
Table 7.6 Resources conserved and other benefits by recycling of Plastics
Sl.no Resource Required for fresli Conserved by recycling
production/ton 15,770.72 MT of
Plastics
1. Oil 3080 litres. 48571600 litres
2. Landfill space 30CFT 47310 CFT
3. C02 2.5 times reduced
4. NOx 1.3 times reduced
5. SOx 1.3 times reduced

7.^ Annual resource recovery in Bangalore city by recycling EOL-PC

In Bangalore city armually 15000 PCs become obsolete. This
corresponds to about 476 MT. Major Resources that could be recovered from
476 MT EOL-PCs are, Fe 180 MT, Cu,36.17 MT, Al,6.664 MT, Ag,0.25138
MT, Pd 0.01560 MT,Au,0.005712 MT and nonmetals like. Polymer 134.6 MT
and Silica 85.68 MT as shown in Table 7.7.

Table 7.7 Estimated Annual Resource recovery from EOL-PC in Bangalore

Sl.no Resource % Resource recovery in (MT) Bangalore from

476 MT of EOL-PC Annually
1. Fe 38 180.8
2. Cu 7.6 36.17
3 A! 1.4 6.664
6. Au 0.0012 0.005712
7. Polymer 28.77 0.005712
8. Silica 18 85.68

Ph.D. Thesis "Recovery of metals from EOL-PC" 143

 Natural Resource Conservation & Mineral Substitution

7.Q Economics of Recycling of EOL-PC

Based on the present buying of EOL-PC and selling of resources recovered to
the down stream vendors in Bangalore City, economics of PC recycle and
sustainability is presented in the following Table 7.7 This estimation helps in
making proposals for recycling of EOL-PCs

If recycling of EOL-PC is taken as business in Bangalore city, one

should have the knowledge of the recyclables that can be easily reclaimed
and sold to the down stream vendors. Further, how are the EOL-PCs
purchased for recycling (from the MNCs or any organization), logistics,
wages paid to the dismantlers. As of mid 2011 it is reliably learnt the
approved recycler will purchase one ton of EOL-PC at Rs.35, 000/-, about Rs.
3000/- should be spent on logistics. Wages for dismantlers is about Rs. 9300/-
Thus, a recycler has to invest Rs.47, 300 for every ton of EOL-PC.
After dismantling, Fe, Al, Cu and Polymer are sold to the down stream
vendors at Rs.l5/-, Rs 90/-, Rs. 300/-, and Rs.l5/- per kg respectively. For the
recovery of concealed metals and precious metals, circuit boards are sold at
Rs.l75/- per kg. Total income is Rs. 48,260/- Net profit, therefore is Rs.960/-
Therefore the business is just sustainable but environmental benefits are of
paramount importance

Table 7,8 Economic viability of Recycling of EOL-PC. in Bangalore City

Sl.no Resource Recovery Selling Income per Buying rate (in Rs.) for
efficiency rate per ton recycling and other
% kg expenditure/ton.
1 Fe 38 Rs.15/- 5700=00 EOL-PC 35,000/-
2 Al 1.4 Rs.90/- 1260=00 Logistics 3000/-
3 Cu 7.7 Rs.300/ 23,100=00 Salary and 9300/-
others
4 Polymer 28 Rs.15/- 4200=00 Liabilities Not taken in
account
5 Circuit 8 Rs.175/ 14,000=00
Board
Total 48,260 =00 47,300=00

Ph.D. Thesis "Recovery of metals from EOL-PC" 144

 Natural Resource Conservation & Mineral Substitution

7/0 Results and Discussion:

Metals like Fe, Al, Cu, Ag, Au can be economically and profitably
recovered almost in their pure state right at room temperature. Polymers and
leaded glass can be recycled by blending with virgin material. Above all,
environmental benefits are of prime importance. Recycling of EOL-PC
• Helps conservation of natural resources and mineral substitution.
• Life span of existing natural resources can be extended.
• No ore tailing are left behind.
• For every ton of EOL-PC recycled, while 38% Iron is recovered, one can
save 0.6 ton of ore, 0.38 ton of coal, 0.45 ton of basic fluxes,2.81 kJ of
energy, 1.2 cubic meter of water, 570 man hours saved and prevents 0.2
ton of slag formed.
• By recycling one ton of EOL-PC, 14 kg of Al is recovered and savings are
immense. Mainly, one can save,0.084 ton of Bauxite,0.5278 kg of lime,
1.092 kg of NaOH, 2.212 kW of energy, 2.92 kg of boiler oil,0.0388 MLD
of water and significantly, O.02422 ton of red mud and emission of 0.1485
ton of Carbon dioxide can be avoided.
• One ton copper recovered from EOL-PC avoids 110 ton of ore tailing,
• No risk of deep mining operation and collecting the molten metal.
• In India, Gold deposits are available only in Hutti Gold Mines in
Karantaka. Savings on natural resources by recovering gold from EOL-PC
gains great significance. By recycling one ton of EOL-PC, while
recovering 12 g of gold, mainly we can save 1.5 kg of NaCN,7.5 kg of
lime, totally 1269 units of power, 9000 litres of water, 7.5 kg of bleaching
powder, almost 3 tons of dumping of ore tailing can be avoided.
• By recycling polymers, ever depleting petroleum reserves can be saved
and hence foreign exchange.

Ph.D. Thesis "Recovery of metals from EOL-PC" 145

 Natural Resource Conservation & Mineral Substitution

Recyling of leaded glass not only saves sand, oxides of alkali and alkaline
earth metals and repeated use of lead also. Depleting reserves of sand can
be conserved.
If collection methods are effectively done for every ton of EOL-PC one
can earn Rs. 960/-, thus in large scale, recycling of EOL-PC would be a
sustainable business.
Generates employment to the local people.

Ph.D. Thesis "Recovery of metals from EOL-PC" 146