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Project Proposal Feasibility Study Metallic Joules
Sam Allison, Annelle Eben, Allyson Hofman, Joe Mohan
Engr339/340 Senior Design Project
Calvin College
12 Nov 2011
ii
© 2012, Team Metallic Joules and Calvin College
iii
Table of Contents 1 Executive Summary
2 Introduction 1.1 Project Overview
1.2 Design Norms
1.2.1 Stewardship 1.2.2 Integrity
1.2.3 Caring
1.2.4 Love 3 Project Management
3.1 Team Organization
3.2 Schedule
3.3 Method of Approach 4 Project Background Information
4.1 What is E-waste?
4.2 Recycling Mandates 4.3 Novel Plasma technology
5 Design Constraints
5.1 Client Communication and Relationship 5.2 Project Scope
5.3 Requirements
6 Equipment Research
6.1 Filter Types 6.2 Reactors
7 Elemental separation Research
8 Process Proposal 8.1 Acid Washing
8.2 Process specific details
8.3 Revenue estimates
9 Business Plan 10 Conclusion
10.1 Choice of separations process
10.2 Future development 11 Bibliography
12 Acknowledgements
13 Appendices
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Table of Figures Figure 1: Overall Process ......................................................................................................................... 3
Figure 2: General Separations Process Description ................................................................................ 13
Figure 3: Schematic diagram of a simple pressure Nutsche filter cycle ................................................... 17
Figure 4: Acid Wash Showing Example of Nitric Acid .......................................................................... 29
Figure 5: Quantity of electronic products ready for end-of-life management in the United States............ 32
Figure 6: Quantity of electronic products collected for recycling or disposal by year. ............................. 33
Table of Tables Table 1: Approximate E-Waste Composition ........................................................................................... 4
Table 2: Gantt Chart ................................................................................................................................ 8
Table 3: Uses of Phosphorous ................................................................................................................ 26
Table 4: Lithium Separation .................................................................................................................. 26
Table 5: Results of Electronics Recycling Survey .................................................................................. 31
Table 6: Preliminary Revenues .............................................................................................................. 34
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1 Executive Summary
Our design project involves taking electronic waste and breaking it down to an atomic level where
precious metals can be extracted and resold for a profit. The electronic waste is initially broken down and
fed into an industrial gasification unit. Once broken down, to ensure that there are no waste molecules
left, the stream is fed into a plasma arc reactor. This breaks the e-waste down to an atomic level. Once
broken down, the metal is cooled and ground up into a metallic dust stream. The project focuses
specifically on the separation and purification of a metallic dust stream. After speaking with our client to
determine the goals and objectives of the project, significant research was conducted to determine
separation process. The platinum group metals (PGM) are the focus of the process optimization, because
those metals are expected to provide the most profit. Much research was done to determine the best
process to separate these metals. Technology rejected included electrophoresis, magnetic separation, and
hydrological separation due to their high costs and complexity. The technology selected to isolate the
PGM elements is an acid wash. The dust feed stream is dissolved into an acidic solution, which allows
certain elements to precipitate out as salts and metallic oxides. Those elements will then be filtered out,
purified, and sold.
Our goal for this technique is to optimize for the lowest cost. Our technique will require approximately
$265.5 million in total investment and will cost approximately $115 million a year to operate. The
process will produce approximately $214 million in sales revenue per year, which results in a profit from
this process of approximately $46 million per year once the plant has been paid for. The payback period
will be approximately three years.
Additional considerations have been made regarding the waste that will be generated from the stream. All
toxic elements are separated out and treated according to legal environmental standards which are
discussed in later sections. Other considerations have also been made regarding the economic and
environmental impact of our plant in places where electronic waste pollution is rampant, specifically in
Guiyu, China, the “electronic graveyard” of the world. Not only does this process produce nearly zero
EPA reportable emissions, it can reduce the amount of pollution and waste already present in both
developing and developed countries.
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2 Introduction
2.1 Project Overview
The project focuses on recovering the precious metals out of electronic waste. Electronic waste is defined
as any consumer or business electronic equipment that is near or at the end of its useful life. Equipment
that is considered electronic waste includes computers, refrigerators, lamps, microwaves, etc. Because
new electronic products are being developed and sold at an exponential rate, more and more electronic
waste is generated.
Before our process is explained, it is worth noting that electronic waste (e-waste) must be dealt with
differently than municipal waste. This is due to the materials that make up e-waste. Common elements in
this waste include copper, iron, gold, and silver, all of which are relatively harmless. Electronic waste
becomes a problem because of the toxic and hazardous materials within the waste such as lead, mercury,
and cadmium. In parts of China, villages that recycled this material by hand are now uninhabitable
because of the toxic materials released from this waste. In order to stop this from happening, special
techniques must be utilized to eliminate this waste to prevent adverse health and environmental
conditions. This new process eliminates electronic waste in an environmentally friendly, zero emissions
process, all while turning a profit.
The process begins by taking electronic waste and grinding it into a workable stream that is fed into an
industrial gasification unit. This unit melts the waste to a single molten stream. The gasification unit
burns the waste in the absence of oxygen and nitrogen. The significance of this is that it causes zero EPA
reportable emissions from the process. Once the waste is melted down, it is fed into an arc plasma reactor
which reduces everything to an atomic level. This ensures that each element is purely atomic. No
compounds remain after being fed through the plasma separation unit. From the elements in the plasma
unit, the carbon and hydrogen are removed as a byproduct in the form of a synthetic gas, which can be
recycled and used directly as an energy source elsewhere in the plant to reduce costs. Once the carbon and
hydrogen are stripped from the plasma unit, the remaining material is cast into a sheet and cooled. The
sheet of metal is then crushed into a dust that must be separated into its individual elements, purified to
various levels, and sold. This separation and purification process is where our group has decided to focus
our analysis, and can be seen in
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Gasification UnitSeparation and
PurificationPlasma Arc ReactorMolten
Stream
SellableProduct
E-wasteAtomicStream
Figure 1: Overall Process below.
Gasification UnitSeparation and
PurificationPlasma Arc ReactorMolten
Stream
SellableProduct
E-wasteAtomicStream
Figure 1: Overall Process
The goal of our project is to take the metallic dust and separate it into individual elements or
combinations of elements that can be sold. It is important to note the purity of these elements does not
need to be 100%. If an element can be separated to a high level purity in an economically feasible
process, that would be ideal. However, if it is more economically feasible to sell an alloy of gold and
silver for example, that will be done instead of designing a separations unit for separating the gold from
the silver. The system will be designed with the objective of maximizing profits while being safe and
environmentally friendly. Our goal is to recover as much of the purified metal as possible using the least
expensive processes.
Certain design guidelines govern our project. One of which is cost, which was discussed previously.
Another guideline for our project is the environmental impact of our separation units. Our process is
designed so that it will not produce any harmful byproducts that operators would handle, or that would be
released to the environment. It is also designed to use as few separation units as possible in order to
minimize the footprint that our plant creates. This is related to the cost optimization as well as adding an
element of stewardship to our project.
Because we are designing a segment of the metal recovery process, the feed stream is variable over a
wide range depending on the e-waste being recycled. Our design must have the flexibility to allow for this
while still optimizing for cost efficiency. As a starting point for analysis, the following table shows the
approximate composition of our feed stream.
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Table 1: Approximate E-Waste Composition
Element Percent in Feed Element Percent in Feed
Ferrous Metal* 43% Palladium 0.00003%
Aluminum 14% Indium 0.00%
Copper 12% Brominated Plastics 29%
Lead 1.6% Plastics 19%
Cadmium 0.0014% Lead Glass 0.00%
Mercury 0.0038% Glass 1.7%
Gold 0.000067% Other 10%
Silver 0.00077%
*Ferrous metal is removed from the process immediately after the plasma separator using electrophoresis.
The component labeled “other” contains variable amounts of platinum, rhodium, lead, cadmium, arsenic,
mercury, titanium, gallium, cobalt, neodymium, phosphorus, lithium, and sulfur. The obvious elements
that will prove hazardous are the lead, cadmium, and mercury. Waste treatment for hazardous elements is
an essential part of the process that has been taken into account as part of the optimization of the process.
2.2 Design Norms1
2.2.1 Stewardship
The definition of stewardship as a design norm is to design with careful respect to the earth’s resources,
economic resources, and human resources. This includes taking responsibility for the causes and effects
of the design.
Our project is essentially a recycling system for electronic waste. Because the focus is to recover and
repurpose many metals in the waste, the general focus to continue using the resource of that metal. In
addition, regard for the effects of our process is being considered by having the goal of a “green” system.
A “green” system means that it will have next to no emissions, and it will return materials that enter the
process in a better or purer state than when they entered. This is a key objective. If the cost of being
1 Vanderleest, Steve. “Design Norms.” Senior Design. Science Building Calvin College, Grand Rapids. 8 October.
2012. Lecture.
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“green” means the process is not economical and thus not done, this is a problem. Therefore, a way to
handle the waste appropriately will need to be determined.
2.2.2 Integrity
The definition of integrity as a design norm is with respect to the overall finished project. The final
project should be complete, functional and the form should be uniform, promote human values and
relationships, and be easy or intuitive to use.
Again, the focus is one the recycling of the electronic waste. Recycling promotes human values and
relationships by showing a good intention for a cleaner environment and a better use of the world’s
resources. The evidence of how not utilizing the electronic waste can be seen in Guiyu, China2 where
children suffer from lead poisoning as a result of poor recycling methods already in place. Other health
concerns for the area include a higher-than-average miscarriage rate, and lacerations from poor safety of
working with the metals. The last environmental impact includes how the soil is saturated with lead,
chromium, tin, and other heavy metals poisoning it so that it can no longer be useful for agriculture. By
using our electronic waste recycling system the impacts that affect Guiyu can be avoided. That is why it is
an easy choice to use this system.
Industry benefits from considering these environmental and humane considerations because it creates a
better image for the public. The public will be happier with a “green” or friendly plant compared to the
one in Guiyu. Over time, this design will put other options for recycling e-waste because the public will
be partial to this kind of recycling.
2.2.3 Caring
The definition of caring as a design norm is designing so that the care for people is considered and takes
into account the effect physically, socially, and psychologically on individuals.
The recovery of metals from e-waste by a process which includes maximizing profit, a safety, an
environmentally friendliness, and efficiency demonstrates caring. This is because it cares for people by
considering how it impacts the surrounding environment and how it is concerned with the safety of its
employees. Overall, the recycling makes resources available to people again for their benefits.
2.2.4 Trust
The definition of trust as a design norm is that the design should be trustworthy, dependable, reliable, and
avoids conflicts of interest.
2 "Electronic waste in Guiyu - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p., n.d. Web.
11 Nov. 2012. <http://en.wikipedia.org/wiki/Electronic_waste_in_Guiyu>
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It is an aim of this project that wherever a plant would be, the surrounding community could trust that all
the hazardous materials including the toxic ones are responsibly taken care of.
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3 Project Management
3.1 Team Organization
3.1.1 Team Structure
Team 1 is made up of four chemical engineering students. All four team members took separations and
process design classes relating to the design project. Each of the team members is roughly equal in
technical capability, and each is expected to contribute equally to the project. Team members are held
accountable throughout the project by the amount of effort, time, and quality of work they are able to
contribute. Because members of the team have all their classes together, impromptu collaboration, team
meetings, and when necessary, confrontations are always possible. In addition, the team meets every
Thursday evening to work on the project and collaborate. Weekly meetings with the team advisor happen
every Friday at 10:30am.
Each of the team members has different skills to contribute to the team, which are capitalized on
throughout the project. Some team members are excellent at designing simulations, one team member has
a gift for doing presentations, and others are talented and speedy researchers.
3.1.2 Sam Allison
Sam will graduate in August 2013 with a Chemical Engineering degree. In his time at Calvin College, he
was a four year member of the Men’s Varsity Swimming and Diving Team. He was elected to lead the
team as the captain his senior year. During the summer between his junior and senior years of school,
Sam worked as a process engineering intern at Vertellus Specialty Chemical Company. When he
graduates, Sam plans on moving to Houston to start his career as a Chemical Engineer, Technical Sales
Engineer, or a Petroleum Engineer.
3.1.3 Annelle Eben
Annelle will graduate in May 2013 with a Chemical Engineering degree and international designation.
Annelle has participated in multiple research groups, and was able to discover and isolate the DNA of a
novel virus while at Calvin. She also did research on nonlinearities in high temperature superconductors
and was able to help prove the breaking of time reversal symmetry. This past summer Annelle enjoyed
working as an intern for Michigan Industrial Tools. While at Calvin, Annelle was able to participate in the
summer in Germany program with Calvin, along with the interim in Cambodia trip, and she hopes to
combine this passion for different cultures and travel with engineering by obtaining a chemical
engineering career abroad.
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3.1.4 Allyson Hofman
Allyson is from Ann Arbor, Michigan. She will be graduating from Calvin College in May of 2013 with
degrees in chemical engineering with an international designation and in chemistry. She will be pursuing
a career afterwards in industry, but is uncertain what kind of field it will be. Her hopes are that she will be
working with either energy or agriculture.
3.1.5 Joe Mohan
Joe is from Minneapolis, MN and will be graduating in May 2014 with a Bachelor of Science in
Engineering: Chemical Concentration. He loves experiencing different cultures, speaks 5 languages and
has lived in 3 different countries. After leaving Calvin, Joe plans on earning a Master’s in Business
Administration. In the future, he has designs to work his way up in management in the manufacturing
industry.
3.2 Schedule
Team 1 laid out a detailed Work Breakdown Schedule (WBS) at the beginning of the semester, which can
be found in Appendix 12.1. The schedule helped the team make deadlines, know which team member was
responsible for which deadlines, and estimate time required for different portions of the project. The WBS
was initially created as a rough outline of the bigger deadlines. Details, smaller deadlines, and sub
projects were added or corrected throughout the semester. Table 2: Gantt Chart provides a summary of
the Gantt chart, and the full chart can be found in Appendix 12.2.
Table 2: Gantt Chart
Task Name Duration Start Finish
Project Proposal 2 days Mon 9/10/12 Tue 9/11/12
Project Objectives & Requirements
1 day Sun 9/23/12 Sun 9/23/12
Project Poster 2 days Wed 9/26/12 Thu 9/27/12
Work Breakdown Structure 2 days Wed 10/3/12 Thu 10/4/12
Scheduled WBS 1 day Wed 10/10/12 Wed 10/10/12
Verbal Presentation 1 3 days Thu 10/11/12 Mon 10/15/12
Project Brief for Industrial Consultant
2 days Sat 12/15/12 Mon 12/17/12
PPFS Outline 1 day Sun 10/21/12 Sun 10/21/12
Project Website Posting 4 days Sun 10/21/12 Wed 10/24/12
Preliminary Cost Estimate 2 days Mon 11/5/12 Tue 11/6/12
Updated Project Poster 1 day Wed 11/7/12 Wed 11/7/12
PPFS Draft 4 days Sat 12/8/12 Wed 12/12/12
Final PPFS 5 days Wed 11/28/12 Tue 12/4/12
Verbal Presentation 2 2 days Wed 12/5/12 Thu 12/6/12
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3.3 Method of Approach
3.3.1 Project Definition
Because the project was presented by the client Steve Hester from Houston, Texas, as an open-ended
problem, the team took some time to narrow and define the scope. It was necessary to determine how
many different processes would be considered, and how detailed the optimization would be.
3.3.2 Research
Team 1 took a class on separation processes the Fall semester of 2012. This class was extremely helpful
in designing the separations processes for this project. However, the class covered only the few most
common separations systems. In order to select the optimum separation process, many more processes
were researched. For each new process considered, the extent of current industry use, economic
implications, and effectiveness were all researched in depth.
3.3.3 Process Selection
For each step of the metal separation/purification process, many different separation technologies exist.
These technologies can then be combined in an exponentially large number of ways. In order to determine
which series of separations was the best, the processes used currently in industry were addressed as a
starting point. From there, the processes that worked best for this specific scenario were chosen, and a
quantitative decision was made based on rough cost estimates.
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4 Project Background Information
4.1 What is E-waste?
As previously defined, electronic waste (e-waste) is any old, end-of-life or discarded appliances that used
electricity.3 The composition of this waste is a mixture of various metals, some of which are toxic and
hazardous to the environment. This presents a problem when trying to break the waste down. The process
must be different than normal municipal waste that decomposes in a landfill. Were e-waste left to sit and
decompose in a landfill, toxins like mercury, lead, and cadmium for example would seep into the ground,
polluting the surrounding area. This pollution could make its way into aquifers and other water supplies
which could lead to negative effects on the surrounding inhabitants. Therefore, the Waste Electrical and
Electronic Equipment Directive (WEEE) and the Restriction of Hazardous Substances Directive (RoHS)
were established to make limitations and guidelines for the management of disposal of electronic waste.
This prevents the waste from being deposited in landfills and the eventual pollution of the area.
If not disposed of properly, e-waste pollution could severely impact the area surrounding the landfill in a
catastrophic way. Such is the case for the small city of Guiyu, China4, the largest e-waste site on earth.
The process by which e-waste is broken down in this town is primitive and severely lacks any sort of
regulations that would protect the health and wellbeing of the workers. E-waste there is often broken
down by hand which leads to the heavy metals in the waste being absorbed into the skin of the workers
leading to heavy metal poisoning. Approximately 88% of the children in Guiyu suffer from lead
poisoning. The ash that is formed by melting down the waste gets into the air and eventually settles to the
ground. This is ash is inhaled as well as absorbed through the skin of the inhabitants.
Another major problem in Guiyu is that toxins from the mounds of e-waste around the city seep into the
ground. This contaminates the water table. The ground water is so contaminated that drinking it would be
fatal. The ground is so saturated with these toxins that nothing planted in the ground can grow. Water and
food must be trucked into Guiyu because of the contamination. The toxins also seep into the major river
that flows though the town. The lead levels in the river are twice the European safety levels. Drinking the
river water would be just as fatal as drinking the ground water. Unfortunately, the poor conditions of the
3 "e-Waste Definition | ewasteguide.info."ewasteguide.info | A knowledge base for the sustainable recycling of e-
Waste. N.p., n.d. Web. 11 Nov. 2012. <http://ewasteguide.info/node/201>.
4 "Electronic waste - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p., n.d. Web. 7 Dec.
2012. <http://en.wikipedia.org/wiki/Electronic_waste#Hazardous>
11
town mean that wash must be done in the river which leads to more heavy metals and pollutants coming
in contact with the citizens’ skin.
While the conditions in Guiyu are grim, activist groups and the city government are trying to change the
culture. Bans have been made on many of the furnaces that burn the e-waste. This limits the amount of
pollutants that are released into the air. Fines for violations such as soaking waste in acid or burning the
waste have been instituted to try and deter the manual processing of waste.
Places like Guiyu would be an ideal location for the plant that we are helping to design. The plant would
dramatically decrease the amount of toxins that the workers would come in contact with. The gasification
and plasma units are all zero pollutant emitters according to the EPA. This would significantly improve
the air quality of the area. No more toxic ash would rain down on the citizens, and the contaminated river
would benefit as well. Because this entire process can distil mass amounts of polluted water, the river
water could be converted from undrinkable water to a viable source of drinkable water. Implementing this
plant in Guiyu would greatly improve the quality of life for the more than 150,000 inhabitants.
4.2 Recycling Mandates
4.2.1 WEEE Directive (2002)5
The WEEE Directive stands for Waste Electrical and Electronic Equipment Directive, which is a legal
standard established in the European Union for the collection, recycling, and recovery of electronic
goods. It sets the amounts of how much pollution of a certain type is allowed.6 This makes manufactures
including recyclers responsible for the material they generate in a way that properly contains hazardous
materials.
Additionally, the WEEE Directive holds a list of persons producing electrical and electronic equipment
for the market. These producers are expected to register for a small fee, report their data, and deliver the
data to the appropriate agency. The WEEE Directive plays a large role in the motivation for the
development of novel recycling technologies.
5 "WEEE registration & WEEE compliance."WEEE registration & WEEE compliance. N.p., n.d. Web. 11 Nov.
2012. <http://www.weeeregistration.com/index.html>
6 "Waste Electrical and Electronic Equipment Directive - Wikipedia, the free encyclopedia." Wikipedia, the free
encyclopedia. N.p., n.d. Web. 11 Nov. 2012.
<http://en.wikipedia.org/wiki/Waste_Electrical_and_Electronic_Equipment_Directive>
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4.2.2 RoHS Directive (2002)7
RoHS Directive stands for Restriction of Hazardous Substances Directive which restricts the use of six
hazardous materials in the manufacture of various types of electrical and electronic equipment. These six
hazardous materials include lead, mercury, cadmium, hexavalent chromium (welding), polybrominated
biphenyls (flame retardant), and polybrominated diphenyl ether (flame retardant). These materials are
only permitted to be found in concentrations of 1000ppm or less.
4.2.3 United States
California passed the Electronic Waste Recycling Act of 2003. This law holds manufactures to the same
standards as the RoHS. These are just two examples of legislation being written to limit the levels of
toxins present in consumer goods and establish mandated limits on pollution of different kinds. Managing
waste, especially electronic waste, is a global issue that is gaining the attention of governments and
legislation.
4.3 Novel Plasma Arc Technology8
Plasma arc technology is a term for new technology generated in the United Kingdom. Because this is
such new technology, it is still considered a trade secret. We do not have very much information about
how the process works and are being held to confidentiality. However, we can divulge the general
workings.
The plasmafication process occurs in an oxygen-deprived vacuum chamber. This prevents combustion or
incineration from happening. Instead, high temperature ionized gas, also known as an electromagnetic
plasma field, causes thermal cracking of the molecules into their elemental states. Liquid or solid
materials enter the chamber and are converted to a gaseous form without burning in less than a fraction of
a second. Because the reactions happen without oxygen and there is no combustion occurring, neither
toxins, including dioxins and furans, or greenhouse gases, like carbon dioxide, are formed.
Within the plasmafication unit, organic molecules are broken into energy rich Syngas. These gases are let
off, scrubbed and cooled to be used to generate electricity. This electricity can be recycled and used to
power the plasma unit. Excess Syngas can provide additional electricity that can be sold to the grid. The
plasmafication process produces large amounts of heat and requires cooling water. This heat can drive a
7 "Restriction of Hazardous Substances Directive - Wikipedia, the free encyclopedia." Wikipedia, the free
encyclopedia. N.p., n.d. Web. 11 Nov. 2012.
<http://en.wikipedia.org/wiki/Restriction_of_Hazardous_Substances_Directive>
8 “Plasma Arc Technology.” Cypress, TX: Engineered Technologies Energy Corporation. <
http://etecenergy.com/Plasma%20%20Arc%20Technology%20Brochure.pdf>
13
steam-powered generator to generate additional electricity. The steam can then undergo a distillation
process and be recycled back as cooling water or sold as purified potable water.
Excess molten materials from the process are cast as scrap steel for sale to steel mills. Excess slag can be
sold as building material aggregate or spun into mineral wool.7 This process is summarized in Figure 2:
General Separations Process Description. The benefits of the plasma arc technology include:
Process All Carbonaceous Waste Materials
Non Burning Process
Not an Incinerator or Boiler
No Emissions from Gasifier
Zero EPA detectable emissions
Reduced Air & Liquid Emissions from Facility compared to Conventional Solutions
Best Available Technology for Destruction of Hazardous Waste Materials
Recoverable Metals and Vitrified Slag Available for Sale
Easily Scalable to Gasify Large or Smaller Amounts of Wastes
GasifierPlasma
Separation Unit
Separations
Metallic Waste
Electronic Waste
Cooling Water
Purified Water
Syn Gas
Recovered Metals
Waste
Figure 2: General Separations Process Description
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5 Design Constraints
5.1 Client Communication and Relationship
Something rather unique about this project is that it is being developed for an actual client. Sam Allison,
one of the members of Team 1, visited Texas for a week to explore the Houston area and network with
different professionals. Sam met Steve Hester over lunch, where Steve explained about a new company
he was starting up. A few weeks later, when projects were being selected, Sam called Steve to see if there
was anything that our group could do to get involved with his new enterprise. Steve responded and asked
if we would develop an optimal process for the separations of the metal stream. Since the project has
begun, several emails and phone calls have occurred to explain the general process, the requirements, the
goals, etc. Sam remains the main contact person with our client to ensure clear and concise
communication between the two parties.
The scope of our project is to design a metals separation process capable of sorting approximately 300
tons per day of a complex metal dust stream into semi-pure components. The goal is to optimize this
process by maximizing profit while being safe and environmentally friendly. Additionally, cost and
efficiency will contribute to the optimum process by using the least amount of separation units as possible
while gaining the maximum amount of separation from each unit. There are few requirements for this
project, as the client has given us free reign. We are free to look at any kind of separation process that
would optimize metal separation. The only requirement is that we develop a process which meets our
goals. These goals include maximizing profit, a safe process, an environmentally friendly process, and an
efficient process. Our client also stated that if we develop an answer to this problem meeting our goals,
his company would use it and the project would be economically successful. He also said that if we
designed a separations process that was economically unfeasible or that did not work, the company would
use that information as well. That would be one less alternative that they would have to consider and the
project would be wildly successful. Either way, this project will benefit the client we are working for.
5.2 Project Scope
The process begins by taking a collection of assorted electronic waste and grinding it into a workable
stream that can be fed into an industrial gasification unit. This unit melts down the waste to a single
molten stream. The gasification unit burns the waste in the absence of oxygen and nitrogen. The
significance of this is that there are zero EPA reportable emissions from the process. Once the waste is
melted down, it is fed into an arc plasma reactor which breaks everything down to an atomic level. This
ensures that each element is purely atomic. No compounds remain after being fed through the plasma
separation unit. From the elements in the plasma unit, the carbon and hydrogen are taken out as a
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byproduct in the form of a synthetic gas which can be used directly as an energy source to cut down on
costs. Once that carbon and hydrogen are stripped from the plasma unit, the remaining material is cast
into a sheet and cooled. The sheet metal is then crushed into a dust that must be separated into its
individual elements, purified, and sold. This is where our group has decided to focus our analysis.
The goal of our project is to take the metallic dust and separate it into individual elements or
combinations of elements that can be sold. It is important to note the purity of these elements does not
need to be 100%. Achieving high purities is a goal of Team 1, but only to an extent that is economically
feasible. If it is more economically feasible to sell the alloy of gold and silver for example, that will be
done instead of designing a separations unit for separating the gold from silver. The system will be
designed with the objective of maximizing profit while being safe and environmentally friendly. Our goal
is to recover the metals at the highest possible purity.
5.3 Requirements
Due to the open-endedness of this project, there are no set requirements. However, certain basic design
guidelines help narrow the focus. Economic feasibility is the driving design guideline, which was
discussed previously. Another guideline for our project is the environmental impact of our separation
units. We want to make sure that we are using processes that do not produce anything harmful to
operators or the environment. We also are looking to use as few separation processes as we can while still
achieving desired separation. This idea ties in with the economic guidelines as well as incorporating an
aspect of stewardship.
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6 Equipment Research
6.1 Filters9
The type of filter is contingent on the flow of the system whether it is batch, semi-batch, or continuous.
Additionally, the filter depends on the size of the particles being separated. The finer the particles, the
more sophisticated separation is required. Difficulty also arises from removing the solids from a liquid in
an efficient manner. To achieve this, the recommended method of separation is batch separation. There
are different options for material to use as the filter collector such as fabrics of woven fibers or pressed
felt or cotton batting. The following are different options for filters.
6.1.1 Nutsche Filters
This filter operates by a gravity, pressure, or vacuum driving force. The slurry is poured into the tank
which has a false, perforated bottom to let the liquid pass through. Figure 3: Schematic diagram of a
simple pressure Nutsche filter cycle. (a) Filtration; (b) displacement washing; (c) gas deliquoring; (d)
cake discharge by plough.shows how the filter works in more detail. In addition to removing the liquid
from the tank, it is also possible to mechanically remove the cake with a plough (part D).
The advantage is that these filters are low cost to make and operate especially on the small scale.
However, they have some large scale disadvantages. The filter requires excessive floor area encumbered
per area of filtration. Additionally, it is difficult to remove the filter and the filter cake (material removed
from the liquid phase of the solution).
9 Perry’s Chemical Engineering Handbook (pp. 18-90)
17
Figure 3: Schematic diagram of a simple pressure Nutsche filter
cycle. (a) Filtration; (b) displacement washing; (c) gas
deliquoring; (d) cake discharge by plough.10
6.1.2 Plate-and-Frame Press
This filter operates by layers of plate covered with a filter medium. The area constructed by frames is
flooded with the solution of solids and liquid. Then the plates are pressed together, and the liquid is
drained out. There are many possible arrangements for the entry of the solution and exit of the filtrate and
the cake.
The advantages to using this type of filter are low capital cost, simplicity, flexibility, ability to operate at
high or low pressures, and the floor-space and headspace are small. The disadvantages include imperfect
washing, short filter life, and high labor requirements.
6.1.3 Centrifugal discharge filter
This filter operates by filling a tank with the solution. However, inside the tank are proliferated plates
attached to an axial rod that spins. Through the plates, the filtrate is able to be removed or drained to the
10 "6.1: Batch Filter Cycle Configurations On GlobalSpec." GlobalSpec - Engineering Search & Industrial Supplier
Catalogs. N.p., n.d. Web. 6 Dec. 2012. <http://www.globalspec.com/reference/26322/203279/6-1-batch-filter-cycle-
configurations>
18
next part of the system. The cake builds up on the plates and is removed once the filtrate is removed by
rotating the axial rod. The cake goes to the outside of the tank, falls to the bottom, and removed to the
next step in the system.
The primary advantage of this filter is that the cake can be removed without opening the filter tank. Other
advantages are its ability to handle hazardous material, low labor demand, and its ability for automatic
control. The disadvantages are the complexity and the cost.
6.1.4 Rotary drum filters
Rotary drum filters can be constructed from metals or plastics, making them a reasonable capital cost
filter. They range in size from four feet to two thousand feet, meaning rotary drum filters are versatile in
their application scale. For the metal separation processes being considered, filters capable of handling
large volumes are needed.11
Rotary drum filters operate by first dumping a slurry of liquid and solids into a coated surface within the
drum. Then vacuum suction pulls the liquid through the filter and to the center of the drum. Finally the
drum begins to rotate and the filtrate gets flung to the edges of the drum, from where it is later scraped
off.12
Rotary drum filters are the most widely used filter type for continuous flow systems, which is an
advantage in itself, as it proves the cost effectiveness and adequate operation efficiency.
6.1.5 Roll discharge filter
Roll discharge filters operate with a roll placed directly outside the point where the filter cake would exit
rotating at a speed equal to the drum, but in the opposite direction. When the filter and drum are operating
at material properties to enable adequate cohesiveness, the filter cake attaches to the roll, separates from
the drum, and is spun right out of the drum. A small blow of air is sometimes employed to help separate
the filter cake. This process is best for thin, sticky filter cakes.13
6.2 Reactors
Selecting the best type of reactor to use for each phase of the process starts with determining if the feed is
a continuous stream or a batch system. Other information required to select the best reactor includes
operating conditions, the feed and product specifications, and possible catalysts.
11 Perry’s Chemical Engineering Handbook (pp. 18-96)
12 "Rotary vacuum-drum filter - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p., n.d.
Web. 7 Dec. 2012. <http://en.wikipedia.org/wiki/Rotary_vacuum-drum_filter>.
13 Perry’s Chemical Engineering Handbook (pp. 18-97)
19
The most common flow reactors are ideal continuous stirred tank reactors, or CSTRs, which provide
complete mixing, or plug flow reactors, or PFRs, which provide no axial mixing. These reactors represent
the two ends of the mixing spectrum, and real reactors can be found somewhere between. To determine
how close a reactor is to the ideal, a residence time distribution (RTD) should be calculated. This value
helps to determine the overall reactor performance. Brief descriptions of the main reactor types, along
with pros and cons for each can be found below.
6.2.1 CSTR
A continuous stirred-tank reactor is a general ideal reactor model compatible with liquids, gases, and
slurries. CSTRs assume perfect mixing, and the conversion or output composition is a function of reaction
rate and residence time.
Advantages of CSTRs include14
:
Continuous operation
Good temperature control
Capable of handling two phases
Simple construction
Low operating costs
Disadvantages of CSTRs include:
Lowest conversion per volume
Channeling is possible when mixing is not ideal
6.2.2 PFR
A plug flow reactor is a long tube reactor mainly used for gas-phase reactions. In PFRs, the
composition/concentrations change as the mixture travels down the length of the reactor. It is generally
assumed that there is no radial variation in the reaction rate in a PFR.
Advantages of PFRs15
:
Continuous operation
Good for fast reactions
Can be used for homogeneous or heterogeneous reactions
Easily used on large scale
14 "Continuous Stirred Tank Reactors."College of Engineering Home | Michigan Engineering. N.p., n.d. Web. 7 Dec.
2012. <http://www.engin.umich.edu/~cre/asyLear
15 "Plug Flow Reactors (PFRs)." College of Engineering Home | Michigan Engineering. N.p., n.d. Web. 7 Dec.
2012. <http://www.engin.umich.edu/~cre/asyLear
20
Operate at high temperatures
High conversion per volume
Low operating cost
Good heat transfer efficiency
Disadvantages of PFRs:
Unwanted thermal gradients may exist
Bad temperature control
Shutdown and maintenance may be expensive
6.2.3 Batch Reactors
Batch reactors are the simplest type of reactor to design. They have an entrance and exit location for
products and reactants, but throughout the reaction nothing is added or removed from the vessel. Batch
reactors can be used for reactions with solid, liquid, or gaseous reactants, and are often used more for
small-scale production.
Advantages of Batch Reactors:
High conversion per volume
Easy to clean
Regular maintenance not a problem
Flexibility (one reactor can be used for different reactions each time)
Disadvantages of Batch Reactors:
Not continuous operation
High operating cost
Product may vary from batch to batch, more than in continuous processes
Increased labor and materials handling costs
Unproductive down time between batches
6.2.4 Semibatch Reactors
Semibatch reactors operate similar to batch reactors in that the reactants are all combined in a single
stirred vessel at one time. However, semibatch processes allow for the addition of reactant or removal of
product over time. This is done to increase the conversion of the process, or avoid the reverse reaction
from occurring by removing the product with a purge stream. Semibatch reactors have each of the
advantages and disadvantages of a batch reactor written above, as well as the following advantages and
disadvantages.
21
Advantages of semibatch reactors16
:
Improved selectivity of the reaction
Better control of exothermic reactions
Better control of reversibility
Disadvantages of semibatch reactors:
Very expensive for large-scale production
6.2.5 Reactors with Catalysts
6.2.5.1 PBR
Packed bed reactors are tubular reactors that are packed with a solid catalyst. PBRs are used mostly for
gas-phase, or gas-solid reactions.
Advantages of PBRs:
Continuous operation
High conversion per catalyst weight
Low operating cost
Disadvantages of PBRs:
Unwanted thermal gradients may exist
Bad temperature control
Channeling is possible
Shutdown and maintenance may be expensive
6.2.5.2 Catalytic Membrane Reactors
Catalytic membrane reactors are catalyst filled chambers that utilize a membrane, which is impervious to
all species involved in the reaction except one or more of the reaction products. This semi-permeability
allows the concentrations within the reactor to shift and drives the reaction forward according to Le
Chatlier’s Principle. This process enables conversions higher than the original equilibrium conversion to
be achieved.
Advantages of Membrane Reactors:
Allows for conversions higher than equilibrium
16 "Semibatch reactor - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p., n.d. Web. 7 Dec.
2012. <http://en.wikipedia.org/wiki/Semibatch_reactor>
22
Good retention of catalyst
Enables selection of reactants
Disadvantages of Membrane Reactors:
High capital cost
6.2.4 Fluid and Solid Catalyst Reactors
For reactions of fluids with granular catalysts, the main concerns for the choice of reactors are heat
transfer, pressure drop, contacting of the phases, and replacement of catalyst. For economic reasons, fixed
catalyst beds are more commonly used than fluidized beds. Fluidized beds can be used for continuous
processesing and kept at a constant temperature, but fixed beds are simpler to operate and more cost
effective. 17
Types of Fluid and Solid Catalyst Reactors include:
1. Single Fixed Beds
2. Multiple Fixed Beds
3. Multitubular Reactors
4. Slurry Reactors
5. Transport Reactors
6. Fluidized Beds
7. Moving Beds
6.2.5 Gas/Liquid Reactors
Reactors designed for reactions between gases and liquids need to consider the mass-transfer between
phases, heat transfer, the magnitude and distribution of residence times of the phases, energy
requirements, etc. For reactions between phases, the reactor selection process is less dependent on theory
and models as other types of reactor design, and more dependent on experience and pilot plant work.
There are four main industrial processes that require Gas/Liquid Reactors:18
1. Purification of gases
2. Liquid phase processes, including hydrogenation, nitration, oxyidation, etc.
3. Biochemical processes, including fermentation, manufacturing of proteins, etc.
4. Synthesis of pure products
For these processes, there are many types of gas/liquid reactors, of which the most common are:
17 Perry’s Chemical Engineering Handbook (pp.23-36 – 23-38)
18 Perry’s Chemical Engineering Handbook (pp.23-39 – 23-50)
23
1. Bubble Reactors
2. Liquid Dispersion
3. Tubular Reactors
4. Falling Film Reactor
6.2.6 Liquid/Liquid Reactors
Many industrial chemical processes are liquid/liquid reactions. This means that the variations on the
equipment are extensive. The equipment can be very specialized versions of towers or mixer-settlers.
Towers can be packed or empty, still or agitated, or include spray injections.
6.2.7 Gas/Solid/Liquid Reactors
In most cases where all three phases are present for a reaction, the solid is a granular or porous catalyst.
The actual reaction normally occurs at the surface of the catalyst or in the liquid regime. Fixed bed
reactors are a common solution, with catalyst filling roughly 50% of the reactor volume.19
Some of the
main considerations for design of multi-phase reactors are catalyst size and stirring
necessity/effectiveness. There is a broad spectrum of multi-phase reactors. For example, in a trickle bed
reactor, the phases flow down over each other as films, but the gas and liquid phases flow up through a
fixed bed in flooded reactors. A slurry reactor keeps the catalysts suspended with mechanical mixing,
while a fluidized bed reactor maintains a stationary bed of catalyst, which the fluids flow through. Some
of the main types of these reactors include:
1. Trickle Beds
2. Flooded Fixed Bed Reactors
3. Suspended Catalyst Beds
6.2.8 Solid Reactors
Reactions between solids often involve combustion reactions at high temperatures with gaseous
byproducts. The activation energy, operating temperature, thermal and mass-transfer resistances, mixing
effectiveness, and residence time are all important considerations for designing or selecting the
appropriate reactor. Some of the more common type of solid-solid reactors include:20
1. Rotary Kiln Reactors
2. Multiple Hearth Reactors
3. Vertical Kiln Reactors
19 Perry’s Chemical Engineering Handbook (pp. 23-50 – 23-54)
20 Perry’s Chemical Engineering Handbook (pp.23-55 – 23-61)
24
7 Separations Research
7.1 Acid Washes
Upon initial patent research, our team determined a viable option for separating some of the metals using
acid washes. Based on solubility of metals, components of the feed stream can be separated as
precipitates. The major components of the feed can be removed from the acid wash by precipitation and
filtration. The solubility rules21
are as follows:
1. All common compounds of Group I and ammonium ions are soluble
2. All nitrates, acetates and chlorates are soluble.
3. All binary compounds of the halogens (other than fluorine) with metals are soluble, except those
of silver, mercury I, and lead. Lead halides are soluble in hot water.
4. All sulfates are soluble, expect those of barium, strontium, calcium, lead, silver, and mercury I.
the latter three are slightly soluble.
5. Expect for rule one, carbonates, hydroxide, oxides, silicates, and phosphates, are insoluble.
6. Sulfides are insoluble except for calcium, barium, strontium, magnesium, sodium, potassium, and
ammonium.
A conclusion drawn from these rules is that there are numerous ways to dissolve the metal feed dust into a
solution for further separation rather than separating solids. This led to the resulting acid wash premise.
An example involving nitric acid22
as the mother liquor is described in the following paragraphs.
The system begins with a mother liquid consisting of nitric acid combined with the metal dust feed
stream. The gold and platinum are insoluble in nitric acid, and they will precipitate out of solution. Gold
and platinum can then be further separated independently of the remaining metals.
The remaining solution is comprised of metals oxides formed for the interaction of the metals with the
acid solution. The following steps are dependent on the acid used. The first consecutive step is the
addition of iron filings. The iron reacts with some of the metals, namely silver and copper, in a redox
reaction, which allows a mixture of only silver and copper to be precipitated and then be filtered. An
example redox reaction for copper is below:
21 Sibert, Gwen. "Solubility Rules." Roanoke Valley Governor's School. N.p., n.d. Web. 11 Nov. 2012.
<www.files.chem.vt.edu/RVGS/ACT/notes/solubility_rules.html>
22 Akridge, James R. “System for the Sustainable Recovery of Metals from Electronic Waste.” Patent 129271 A1. 22
October 2009.
25
7.2 Separation of metals by pyrometallurgy and hydrometallurgy23
Metals could be recycled by mechanical processing, pyrometallurgy, hydrometallurgy,
biohydrometallurgy or a combination of these techniques. Pyrometallurgy is used to recover precious and
non-ferrous metals from e-waste. It involves different high temperature processes, including incineration,
melting, and others.
Leaching agents are also widely used in the separation and purification of metals, of which the most
efficient leaching agents are acids, due to their ability to leach both base and precious metals. Generally,
base metals are leached in nitric acid. Copper is leached by sulfuric acid or aqua regia. Aqua regia can
also be used for gold and silver, but these metals are more often leached by thiourea or cyanide.
One of the advantages of biohydrometallurgy is a new, cleaner and one of the most promising eco-
friendly metal separation technologies. Biosorption is a process that employs biomass to absorb heavy
metals from aqueous solutions. This is physico-chemical mechanism based on ion-exchange, metal ion
surface complexation adsorption, or both. Copper could be recovered from printed circuit boards by
hydrometallurgical techniques. The proposed process involves leaching, solvent extraction, and
electrowinning. In the first stage, mechanical processing is used, followed by magnetic and electrostatic
separation. After pretreatment, the fraction with concentrated copper, lead, and tin is dissolved with acid
and treated in an electrochemical process. The metals are recovered individually using sulfuric acid and
aqua regia.
Gold from computer chips could also be leached and recovered as nanoparticles. The first stage is
leaching of base metals with nitric acid and then gold is leached with aqua regia due to its flexibility, ease
and low capital requirement. Silver could also be recovered from mobile phones using an identical
process. Non-metallic materials are also recovered this way, mainly plastic and ceramics.
7.3 Separation of metals using gaseous reagents24, 25
Elemental phosphorous is categorized as white phosphorus or red phosphorus. White phosphorus ignites
at 30C and reacts strongly with any halogen and produces a white glow upon contact with oxygen. Red
phosphorus is more stable than white phosphorous and ignites at 300C. The longer phosphorus is in air,
23 Kamberović, Željko, Marija Korać, Dragana Ivšić, Vesna Nikolić, and Milisav
Ranitović. HYDROMETALLURGICAL PROCESS FOR EXTRACTION OF METALS FROM ELECTRONIC
WASTE-PART I: MATERIAL CHARACTERIZATION AND PROCESS OPTION SELECTION. N.p.: n.p., 2009.
Web. 12 Nov. 2012.
24 "Dynamic Periodic Table." Dynamic Periodic Table. N.p., n.d. Web. 11 Nov. 2012. <http://www.ptable.com/>.
25 <http://pubs.ext.vt.edu/424/424-035/424-035_pdf.pdf>
26
the darker and more stable it becomes. Elemental phosphorus can be oxidized to , which is an
essential component of fertilizers:
P4 + 5O2 2P2O5
Table 3: Uses of Phosphorous
Widely used compounds Use
Ca(H2PO4)2·H2O Baking powder and fertilizers
CaHPO4·2H2O Animal food additive, toothpowder
H3PO4 Manufacture of phosphate fertilizers
PCl3 Manufacture of POCl3 and pesticides
POCl3 Manufacturing plasticizer
P4S10 Manufacturing of additives and pesticides
Na5P3O10 Detergents
Metallic lithium is corrosive, a serious irritant, and produces caustic hydroxide when exposed to moisture.
However, it has many important uses including lithium-ion batteries, an ingredient in high temperature
lubricating greases, lithium chloride is a desiccant for gas streams, and metallic lithium is used as a high
energy additive for rocket propellants. Lithium metal reacts strongly with hydrogen gas to form lithium
hydride:
Lithium hydride is used in the production of many different reagents, and therefore can be sold as a
reactant.
Table 4: Lithium Separation
Ceramics and glass 29%
Batteries 27%
Lubricating greases 12%
Continuous Casting 5%
Air treatment 4%
Polymers 3%
Primary Aluminum Production 2%
Pharmaceuticals 2%
Other 16%
The advantages of using hydrogen and oxygen as reagents are that they are both readily available and
inexpensive.
27
7.4 Separation of metals by supported liquid membrane16, 17
A supported liquid membrane is used for the extraction of metal ions and consists of a solution of an
organic solvent containing the carrier. The membrane is interposed between two aqueous solutions: a feed
solution containing the metal ions to be extracted, and a stripping solution for the recovery of extracted
ions. The pH is adjusted between the feed solution and the stripping solution thus providing a driving
force for the metal ions to be extracted from the feed solution and transported through the membrane and
into the stripping solution. This method provides a supported liquid membrane apparatus including a
micro porous polybenzimidazole membrane containing an extractant mixture within the membrane pores
to separate metal ions such as arsenic, platinum, cobalt, cadmium, gallium, indium, mercury, and
neodymium.
In this process, a feed solution containing the metal ions is placed in contact with one side of the liquid
supported membrane. The feed solution passes through channels adjacent to the polymer surface. The
other side of the supported liquid membrane is contacted with a stripping solution which also passes
through the channels adjacent to the polymer surface and parallel to the channels through which the feed
solution passed. The driving force for transport is maintained by continuous adjustment of chemical
concentration to achieve a high concentration of the extracted ions in the stripping solution.
One of the advantages of supported liquid membrane over classical ion exchange and solvent extraction
technologies is that small volumes of extractant solutions and the possibility to conduct continuous
process make it more attractive. Due to high diffusion coefficients in supported liquid membrane, it is
possible to have ion extraction, transport, and re-extraction in one continuous step. Hydrophobic hollow
fiber membrane contactors could be used as a porous support and to obtain high membrane surface per
unit of volume with good membrane stability. The high surface area of these systems ensures that the
separation rates viable for industrial purposes. This technology is easily scalable and the payback time is
decreased as plant size increases.
28
7.5 Separation of metals by Eddy Current Separator26, 27
A magnetic field is induced into non-ferrous metals on the belt surface by a high speed, high intensity
magnetic rotor inside the head drum of the Eddy Current Separator conveyor16
. These magnetically
induced metals react with the magnetic field of the rotor causing them to be propelled forward further
than the other material on the belt.
One of the main advantages of the eccentric rotor is that the ferrous metal is significantly less damaging
than it would be to a concentric rotor. Ferrous metal heats up very rapidly on an ECS and needs to
discharge quickly before causing damage. The arrangement of eccentric rotor allows ferrous to discharge
easily from the rotor while on a concentric rotor it discharges less easily and causes significant wear and
damage.
One of the more recent and exciting innovations in material separation is the non-ferrous Eddy Current
Separator which has been playing a key part to reduce waste and damage to the environment by
recovering valuable non-ferrous metals from municipal and industrial refuse17
.
Magnetized systems have been used to sort and separate ferrous metals for many years, but recovering
non-ferrous metals, has been labor intensive, expensive and a time consuming exercise. Hence, metal
mixtures, such as brass, copper, aluminum and steel were relatively worthless as a mixture and were often
land filled.
However, the advantages of the Eddy Current Separator include the ability to separate and recover
aluminum and other non-ferrous metals from household, industrial and incinerated waste, including inert
plastics and other materials, the capacity to separate metals from scrap, and remove metallic particles and
contaminants from glass and other substances, while offering a cost effective method of recovering up to
95% of valuable material from waste, grading precious metal concentrates for further processing and also
improving the purity of non-ferrous auto scrap up to 85-95%, thereby maximizing the speed and
efficiency of recovery and increasing profits. The Eddy Current Separator systems use the latest and most
effective magnetic circuits to produce strong eddy current forces, thus maximizing efficient separation.
16 Takigawa, Doreen. “Separation of metal by supported liquid membrane.” Patent 5114579, 19 May 1992.
17 Kocherginsky, N M., Qian Yang, and Lalitha Seelam. Recent advances in supported liquid membrane
technology. N.p.: n.p., n.d. 171-77. Web. 7 Dec. 2012.
<http://clxy.tjpu.edu.cn/mo/zsyd/js/Recent%20advances%20in%20supported%20liquid%20membrane%20technolo
gy.pdf>.
26 "Eddy Current Separator Operation." Magnetic Processing Technology. MagnaPower, n.d. Web. 7 Dec. 2012.
<http://www.magnapower.co.uk/Eddy-Current-Separator-Operation.asp >.
27 "Eddy Current Separator." Jaykrishna. Jaykrishna Magnetics, n.d. Web. 3 Dec. 2012.
<http://www.magneticequipments.com/eddycurrentseparator.html>.
29
Their design features include quick and easy machine adjustments, single source dependability, and
energy efficiency. The eddy current effect appears if nonferrous conductors of electricity are exposed to a
magnetic alternating field. The eddy currents in turn generate magnetic fields whose flux are opposed to
the fields generating them, thus causing repulsive forces which discharge nonferrous metals out of the
material flow.
Fe + CuNO3 → FeNO3 + Cu
The solution continues to the next step where potassium hydroxide is added to create a pH shift. The shift
in pH causes the iron oxide, Fe2O3, to precipitate and be removed by filtration. What remains in solution
are the hazardous metals, such as mercury and lead, along with other materials (slag). To remove the
mercury and lead, ammonium sulfide, (NH4)2S, is reacted to create mercury sulfide, HgS, and lead
sulfide, PbS and Pb2S. These are separated from the slag. This process can be seen in Figure 4: Acid
Wash Showing Example of Nitric Acid.
pH shift ~3RemainingHg, Pb, slag
Mother liquidHNO3
Metal mixtureFe filings
Au & Pt Ag &Cu Fe2O3 slag
(NH4)2S
KOH or NH3 HgS & PbS/PbS2
Figure 4: Acid Wash Showing Example of Nitric Acid
30
8 Business Plan
8.1 Vision and Mission Statement
Metallic Joules Recycling, Inc. is a firm built on the assumption that there is an intrinsic value, personal
reward and financial reward in producing tangible products and services that offer customers more value
than they expect to receive. We succeed because our customers succeed. We are part of a much larger
community to which we are compelled to act responsibly. We act responsibly when we help protect our
environment, provide economic opportunity fairly, work safely, and consider the person in all of our
business affairs. Our central focus is the recycling of precious metals from electronic waste. Our services
include flexible lead times, custom design by application, design for low cost manufacturing, custom
delivery schedules, and administrative support. We maintain a solid core of business in proprietary
products marketed and sold directly to the end user. In short, we are a robust company that adapts to the
ups and downs in individual industries so our customers can depend on us to be there when they need us
in good times and bad.
8.1 Company Goals and Objectives
The main goal of our company is become a major player in the electronic waste management industry.
We seek to provide an efficient and environmentally way to dispose of electronic waste while turning a
significant profit. Sub-goals have been established to ensure that we meet this overall goal.
The first sub-goal we have has to do with plant operations. We aim to recycle approximately 300 tons of
material a day at each plant. Operating at this capacity allows for the greatest productivity while
maximizing the safety of the employees operating the plant equipment. In order to meet this 300 ton
capacity, equipment must run smoothly and have minimum downtime. While we cannot predict when or
how often equipment problems will arise, we do plan on having an educated and expert maintenance team
that will get the process up and running again as soon as possible.
In addition to a skilled maintenance team, we aim to employ a skilled group of operators. Not only will
these employees know how to do their specific job, they will have a general idea of how other
departments within the plant work. This will allow them to better relate to other employees, producing a
homogeneous work force. There will also be as much transparency regarding the company’s goals and
overall operations as possible in order to give operators a sense of belonging to something bigger than just
the certain process step they are responsible. Operator moral is very important to us as we believe that this
will be a main contribution to the efficiency of the process.
The last operation goal we have has to do with the safety and wellbeing of our employees. Above all,
safety is the main concern for our employees. We plan on shaping the process to allow for approximately
31
one event in roughly 10,000 years. Obviously, the safer the process is, the more controls there are. While
these controls have a significant cost, nothing is more valuable then the lives our employees. Our
employees will see how much the company stresses safety and will feel comfortable operating their
equipment. This will add to the overall moral of the employees and will improve production.
The second sub-goal we have has to do with the company’s finances. Obviously, we aim to gain as much
revenue from this plant as possible. This will allow for future expansion of our company which is critical
as we attempt to establish ourselves as a main player in this market. We aim to be better than industry
standards in all of the financial ratios. To achieve this, we aim to minimize our liabilities while
maximizing our sales.
We are also focusing on proper management of inventories and assets. Once the process becomes
streamlined, we aim to have systems in place that will automatically order the correct amount of materials
that will allow us to run our process. The maximum amount of inventory of process materials will be
enough for two weeks of production. This will minimize the cost of storing raw materials while allowing
for sufficient lead time to obtain more raw materials. As for the products, we aim to have permanent
buyers for the metals that we separate from this electronic waste. This will reduce the costs of storing our
product on our facilities. We aim for products to be stored at our plant for no longer than two weeks. This
allows us to sell products frequently enough to cut down on storage time while providing our customers
with an appealing amount of material.
8.2 Significant Industry Trends
The U.S Environmental Protection Agency Office of Resource Conservation and Recovery requested
annual data on the quantity of electronic products processed by each company in both tonnage and
number of products, for all the electronic products that could fit into the scope of their report collected in
the autumn of 2009.
Table 5: Results of Electronics Recycling Survey
Total tons of consumer
electronic products collected
for recycling by recyclers included in survey
2007
77779
2008
82561
2009
85387
Average Percent:
Reused or refurbished 30% 32% 33%
Recycled 69% 68% 68%
Disposal <1% <1% <1%
32
Figure 5: Quantity of electronic products ready for end-of-life management in the United States.
Figure 5: Quantity of electronic products ready for end-of-life management in the United States. shows
the quantity of electronic products ready for end-of-life management in each year between 1990 and
2010. The U.S Environmental Protection Agency Office of Resource Conservation and Recovery
estimates that 2.37 million short tons of electronic products were ready for end-of-life management in
2009 which represents a 122% increase in the quantity of discarded electronics from 1999.
33
Figure 6: Quantity of electronic products collected for recycling or disposal by year.
Figure 6: Quantity of electronic products collected for recycling or disposal by year., presents the
quantities that are collected for recycling and the quantities sent for disposal to landfills or waste-to-
energy incinerators. The Office estimates that the percentage of electronic waste collected for recycling
has increased from 22% in 2006 to 25% in 2009, with a 27% rate projected for 2010.
8.3 Key Success Factors in the Industry
Low transport costs are an important success factor for a recycling business, and these costs are reduced
by a location that for the operator is ideal for access to the downstream market. More specifically, it is
having the freedom to choose the least costly means of transport that gives one recycling business a
definite competitive advantage over its competitors. Preferential or exclusive access at reduced cost to
multi-modal hubs of transportation networks is an essential factor for the activities under study. In this
respect, the recycler's degree of economic contestability is influenced by (i) the burden of investment
required to equip an area for moving goods as inexpensively as possible (by navigable waterway), (ii) the
cost of this means of transport and (iii) whether or not other existing or potential operators can use the
same network within the reference area for collection. These economic conditions together increase the
competitiveness of the historic operator compared with other existing recyclers.
34
Research into the assets necessary to carry on the business leads to the conclusion that for the downstream
market, the recycler's degree of external economic contestability is low. This analysis is strengthened if
the double view of "upstream market - downstream market" is taken into account. Whether the recycler
has exclusive access to the assets (for instance, a site in a port area equipped for processing materials and
used for loading and transporting them) or whether he does not (for instance, a site in the centre of a
geographic collection area with high potential), location reduces his economic contestability compared
with new operators (external contestability) or with upstream operators who want to compete with the
historic operator.
However, the nature of the assets used to gain a competitive position and sustain transactions when the
quality of the good is uncertain increases exposure to external contestation from environmental and health
organizations. There are two reasons for this. The first is that it is economically impossible to avoid social
contestation by relocating; the second is that, given the geographical position of the principal customer
and what defines an ideal location, the business is bound to be near an urban area sensitive to any
nuisance it causes. A site like this causes the residents to adopt a "challenging vigilance". However,
vigilance does not inevitably result in a real social contestation for the recycling business.
A study of the methods of strategic mechanisms organizing the exchanges of recycled materials in the
downstream market adds to the analysis of the recycler's level of external economic contestability.
External economic contestability is significantly reduced by the nature of the market demand (the quality
produced is specific, because of the production equipment); by the near-impossibility of having several
competing downstream customers (reduced access to national and international markets); and by solutions
to the uncertainty over the quality of the batches of material delivered to the downstream market.
However, the recycler remains exposed to an intermediate level of internal economic contestability,
because vertical integration by the steel manufacturer poses a real entry threat, quite apart from its impact
on activities in upstream part of the branch. The steel manufacturer has location assets that allow him to
develop a similar activity, and if he integrates vertically the activities of the recycling firm, he could
resolve the problems of uncertainty over the quality of the supply.
However, among the assets that the upstream market needs to function properly is the complex incentive
mechanism the recycler uses to prevent the collectors form reverting to defection in spite of information
and expertise asymmetries. This is an intangible asset that reduces the level of internal economic
contestability i.e. the exposure to the threat generates by a downstream operator integrating vertically.
The conditions defined in the Contestable Management model are thus fulfilled: the recycler is presumed
to be significantly exposed to the threat of external social contestation on health and environmental issues.
35
By their nature, the activities in question invite a challenging vigilance from residents and public
authorities.
However, taking anticipatory measures to lower the threat may also result, not from the direct exposure of
the recycler, but of his customer, the steel manufacturer. Given the economic relationship between the
established recycler and his principal steel-making customer, the steel manufacturer may become an
active intermediary of the threat of environmentally-based social protest. The steel manufacturer is
himself exposed to challenging vigilance, or even a more generalized protest, because of his activities.
Because the recycler is captive, the steel manufacturer has a means of encouraging his supplier to respect
particular compliance requirements regarding site management, as distinct from the technical
specifications concerning the quality of the material to be delivered. The compliance required may be
based on legislation or on certification standards.
8.4 Potential Competitors
Municipalities, governments, and corporate America are all looking to polish their green and
sustainability images. Like global warming a few years ago, the drum beat to address e-waste properly is
growing louder everyday on a local, national and international basis. There is no denying or ignoring the
electronic waste crisis anymore. Faced with costly clean-ups, looming health concerns, and growing
climate-change-induced public awareness of the planet’s fragility, more states are mandating e-recycling.
Eventually all states should have an electronic waste ban. The trend creates new opportunities for
nationally positioned electronic recyclers as well as those companies that are involved in the recovery and
refining of base metals.
Global demand for scrap will continue to grow as numerous countries are still undergoing their industrial
and technological evolutions which have created an almost unquenchable demand for all commodities
that are derived from the US. Also, increasing electronic arc furnace production capacity on a worldwide
basis along with relatively high cost of scrap substitutes make scrap metal more economically attractive.
Rising standards of living particularly in developing economies result in a greater demand for steel and all
metal commodities has also contributed due to the growing global demand for scrap metal.
36
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37
8.1 Preliminary Cost Estimates
A very preliminary estimate of the total capital investment for this plant has come to approximately
$265.5 million dollars. This was calculated using the Order-of-Magnitude Estimate method. The amount
of major equipment was estimated based on the process flow diagram of our acid wash system. In
addition to this initial investment, a yearly operating cost of $115 million was also estimated. Fortunately,
the total sales revenue was estimated at approximately $214 million a year which will mean that it will
take approximately three years to receive a return on our investment. That return will be approximately
$46 million a year after the initial three years. Detailed financial forecasts for the business model
supporting the hypothetical business of Metallic Joules Recycling Inc. can be found in Appendix 12.3.
38
9 Conclusion
After extensive research and analysis, team one has concluded that an acid wash will be a feasible process
when separating broken down electronic waste. Economic analysis and design matrices have concluded
that the acid wash is the ideal choice. The major strength of the acid wash is the low cost which is a major
design criterion for team one. This separations addition to the entire electronic waste recycling plant will
allow our clients to net approximately $46 million dollars a year, after three years. In the future, team one
plans to move away from the macro scale and focusing more on the process specifics on a micro scale.
The major focus will be on the individual streams and their compositions in order to ensure the process is
operating as planned. Another major goal will be to accurately identify the purities from the process.
Once these details have been covered, the project will go into the final design stage and should be
completed accurately and on schedule.
39
10 Bibliography
Akridge, James R. “System for the Sustainable Recovery of Metals from Electronic Waste.” Patent 129271 A1. 22 October 2009.
Kamberović, Željko, Marija Korać, Dragana Ivšić, Vesna Nikolić, and Milisav
Ranitović. HYDROMETALLURGICAL PROCESS FOR EXTRACTION OF METALS FROM ELECTRONIC WASTE-PART I: MATERIAL CHARACTERIZATION AND PROCESS OPTION
SELECTION. N.p.: n.p., 2009. Web. 12 Nov. 2012.
Kocherginsky, N M., Qian Yang, and Lalitha Seelam. Recent advances in supported liquid membrane
technology. N.p.: n.p., n.d. 171-77. Web. 7 Dec. 2012. <http://clxy.tjpu.edu.cn/mo/zsyd/js/Recent%20advances%20in%20supported%20liquid%20membrane%2
0technology.pdf>.
Perry, Robert H., and Don W. Green. Perry's Chemical Engineer's Handbook. 7th ed. N.p.: n.p., 1997. N. pag. Print.
Sibert, Gwen. "Solubility Rules." Roanoke Valley Governor's School. N.p., n.d. Web. 11 Nov. 2012.
<www.files.chem.vt.edu/RVGS/ACT/notes/solubility_rules.html>
Takigawa, Doreen. “Separation of metal by supported liquid membrane.” Patent 5114579, 19 May 1992.
Vanderleest, Steve. “Design Norms.” Senior Design. Science Building Calvin College, Grand Rapids. 8
October. 2012. Lecture.
"6.1: Batch Filter Cycle Configurations On GlobalSpec." GlobalSpec - Engineering Search & Industrial Supplier Catalogs. N.p., n.d. Web. 6 Dec. 2012. <http://www.globalspec.com/reference/26322/203279/6-
1-batch-filter-cycle-configurations>
"Continuous Stirred Tank Reactors."College of Engineering Home | Michigan Engineering. N.p., n.d. Web. 7 Dec. 2012. <http://www.engin.umich.edu/~cre/asyLear>
"Dynamic Periodic Table." Dynamic Periodic Table. N.p., n.d. Web. 11 Nov. 2012.
<http://www.ptable.com/>.
"e-Waste Definition | ewasteguide.info."ewasteguide.info | A knowledge base for the sustainable
recycling of e-Waste. N.p., n.d. Web. 11 Nov. 2012. <http://ewasteguide.info/node/201>.
"Electronic waste - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p., n.d. Web. 7 Dec.
2012. http://en.wikipedia.org/wiki/Electronic_waste#Hazardous
"Eddy Current Separator." Jaykrishna. Jaykrishna Magnetics, n.d. Web. 3 Dec. 2012. <http://www.magneticequipments.com/eddycurrentseparator.html>.
"Eddy Current Separator Operation." Magnetic Processing Technology. MagnaPower, n.d. Web. 7 Dec.
2012. <http://www.magnapower.co.uk/Eddy-Current-Separator-Operation.asp >.
“Plasma Arc Technology.” Cypress, TX: Engineered Technologies Energy Corporation. < http://etecenergy.com/Plasma%20%20Arc%20Technology%20Brochure.pdf>
"Plug Flow Reactors (PFRs)." College of Engineering Home | Michigan Engineering. N.p., n.d. Web. 7
Dec. 2012. <http://www.engin.umich.edu/~cre/asyLear>
"Restriction of Hazardous Substances Directive - Wikipedia, the free encyclopedia." Wikipedia, the free
encyclopedia. N.p., n.d. Web. 11 Nov. 2012.
<http://en.wikipedia.org/wiki/Restriction_of_Hazardous_Substances_Directive>
"Rotary vacuum-drum filter - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p.,
n.d. Web. 7 Dec. 2012. <http://en.wikipedia.org/wiki/Rotary_vacuum-drum_filter>.
40
"Semibatch reactor - Wikipedia, the free encyclopedia." Wikipedia, the free encyclopedia. N.p., n.d. Web.
7 Dec. 2012. http://en.wikipedia.org/wiki/Semibatch_reactor
"Waste Electrical and Electronic Equipment Directive - Wikipedia, the free encyclopedia." Wikipedia, the
free encyclopedia. N.p., n.d. Web. 11 Nov. 2012.
http://en.wikipedia.org/wiki/Waste_Electrical_and_Electronic_Equipment_Directive
"WEEE registration & WEEE compliance."WEEE registration & WEEE compliance. N.p., n.d. Web. 11 Nov. 2012. <http://www.weeeregistration.com/index.html>
41
11 Acknowledgements
Team 1 would like to thank those that supported us, encouraged us, and provided feedback, including:
Randy Elenbaas, our industrial consultant
Calvin College Engineering Department
Professor Wentzheimer, our team advisor
Our friends and families
42
12 Appendices
12.1 Work Breakdown Structure
Task Deadline Time Required Who?
Project Proposal
PPFS Outline – Mainly preparing a table of
contents
PPFS Draft – Finding out the expectations of the
client, the feasibility of meeting those
expectations as a design team, and laying out in
stone what solution the team hopes to achieve 1. Design options detailed with research
2. Specification of which option is more
beneficial utilizing a gnat chart
(preliminary) 3. Description of process and indication of
needed designs
PPFS PDF on webpage – Possible revision of
the PPFS draft submitted earlier and uploading it on the webpage for public viewing
10/22/2012
11/12/2012
12/07/2012
5 hours
15 hours
5 hours/option 2 hours
4 hours
5 hours
entire team
entire team
entire team
Project Brief
Preparing a Project Brief for Industrial
Consultant taking into account the non-
disclosure agreement which is on the table from the client and therefore explaining the process in
general terms that would not give away any
classified information.
10/17/2012 2 hours entire team
Project Website
Designing the website using Dreamweaver
Providing information about the project
1. Problem definition and client information
2. Design options and decision matrix
3. Description of process and design variables
Providing a bio for each member of the team
(written individually but team revised)
10/24/2012 5 hours Team
webmaster
Preliminary Cost Estimate
Preparing an Equivalent Annual Operating Cost
of the project 1. Research of material costs
2. Research of available markets and receiving
quotes
3. Decision matrix as to how to sell the products
4. Qualification and written description of
choice
11/09/2012
10 hours
2 hours
3 hours
3 hours
2 hours
entire team
Project Poster
Project Poster PDF on Moodle
Updated Project Poster at station
09/28/2012
11/14/2012
2 hours
4 hours
entire team
43
Team pictures 10/18/2012 1 hour
Devotion Preparation 10/10/2012 ½ hour entire team
Research
What materials are involved in the project
MSDS, Safety, Toxicity of materials involved in
the project
Current prices and market trends of materials
involved in the project
Separation Processes /Techniques that could be
used in the project
1. Design options created 2. Comparison of design options
Costs of the possible separation techniques that
could be used in the project – requires some
preliminary design first
Understanding the technology recommended by
the client and using it to optimize the design while indulging in further research to find the
best solution
Understanding the Process and Possibilities flow
diagram provided by the client to optimize the design while indulging in further research to
find the best solution
Possible environmental impact of the techniques
used for separation
Reading a lot of patents including
1. Finding available separation techniques
2. Determining value
3. Determining our ability to use a given patent
12/07/2012 50 hours
2 hours 3 hours
3-4 hours
3+ hours
3 hours
2 hours
5 hours
5 hours
10+ hours
5 hours 2 hours
3 hours
entire team
Presentation
Verbal Presentation 1 – Creating a PowerPoint
and practicing the presentation
1. Power point slides created including…
Client introduction
Problem definition
Design option 1 and design option 2
Preliminary PFD
2. Team revisions
3. Practice presenting
Verbal Presentation 2 – Revising the
PowerPoint created earlier and adding additional
details including elements from PPFS, and
practicing 1. Additional slides created and revisions made
2. Determining who will present what and
practicing
10/19/2012
11/30/2012
5 hours
3 hours
1 hour
1 hour
6 hours
3 hours 3 hours
entire team
Sam
entire team
Creating the design
PFD – Involves a lot of research and liaison
with the client
04/30/2012
30 hours
entire team
44
1. Differing PFD for each preliminary design
option simple ones 2. Differing PFD for each preliminary design
option complex ones
3. After system is determined, first PFD
4. Revisions (dependent on number of drafts) 5. Final PFD
BFD – Involves a lot of research and liaison
with the client
1. Preliminary design options 2. Determined design
3. Revisions
4. Final BFD
UNISIM Design (Possibly) – Initially setting up
the process and then troubleshooting 1. Preliminary design options
2. Determined design process
3. Revisions and multiple drafts 4. Comparison of drafts as a comparison of
design variables
5. Initial final design 6. Revision and completion of final design
04/30/2012
04/30/2012
3 hours ea.
4 hours ea.
3 hours
3+ hours 2 hours
10 hours
1 hour ea.
2 hours
1 hour
1 hour 60 hours
3 hours ea. 3+ hours
3+ hours ea.
3+ hours
4 hours
4 hours
entire team
entire team
Final Report
Submitting a final report of abstract,
introduction, calculations, analysis, conclusions
and suggesting the best solution to the client. 1. Writing the results of the research
Materials and costs
Patent literature
Quotes and available customers for
purchasing of products
2. Writing the results of design options 3. Writing the decision matrix and results
4. Description of design
5. Cost analysis of design
6. Conclusions
04/30/2012 50 hours
10 hours
3 hours 4 hours
5+ hours
5+ hours 2 hours
entire team
45
12.2 Gantt Chart
46
12.3 Financial Forecasts
Metallic Joules Recycling Inc.
Pro-Forma Statement of Income
Year 1
Year 2
Year 3
Sales revenue
214,000,000
222,560,000
231,462,400
Variable Cost of Goods Sold
64,200,000
66,768,000
69,438,720
Fixed Cost of Goods Sold
500,000
500,000
500,000
Depreciation
7,145,000
15,103,000
14,357,500
Gross Margin
142,155,000
140,189,000
147,166,180
Variable Operating Costs
42,800,000
44,512,000
46,292,480
Fixed Operating Costs
20,000,000
20,000,000
20,000,000
Operating Income
79,355,000
75,677,000
80,873,700
Interest Expense
1,440,000
2,304,000
963,000
Income Before Tax
77,915,000
73,373,000
79,910,700
Income tax (40%)
31,166,000
29,349,200
31,964,280
Net Income After Tax
46,749,000
44,023,800
47,946,420
Metallic Joules Recycling Inc.
Pro-Forma Statement of Cash Flows
Year 1
Year 2
Year 3
Beginning Cash Balance
-
45,894,000
72,220,800
Net Income After Tax
46,749,000
44,023,800
47,946,420
Depreciation expense
7,145,000
15,103,000
14,357,500
Invested Capital (Equity)
47
10,000,000 - -
Increase (decrease) in borrowed funds
32,000,000
(12,800,000)
(17,000,000)
Equipment Purchases
(50,000,000)
(20,000,000)
(5,000,000)
Ending Cash Balance
45,894,000
72,220,800
112,524,720
* Assume no change in Accounts Receivable, Inventory or other current assets other than cash; Accounts Payable or other current
Liabilities other than Notes Payable; Fixed Assets other than equipment; or Equity Accounts other than Retained Earnings
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