Extraction and Recovery of Critical Metals from Electronic Waste Using ISASMELT™ Technology

Electronic goods are a major consumer of many critical metals, including copper, nickel, tin, zinc, lead, and precious metals. The processing of end-of-life electronic equipment (E-Scrap) is becoming increasingly important to maintain the supply of the critical metals required globally, and to reduce environmental pollution. Currently, the dominant route for E-Scrap processing is pyrometallurgical processing, with the first stage of processing being reductive smelting to produce a black copper and a 'clean' discard slag. The management of the slag in this first step is central to the success of the E-Scrap recycling process. The E-Scrap ISASMELT (TM) furnace has a highly turbulent bath, providing conditions that generate high rates of zinc fuming and allow a wide range of operable slag conditions. This enables efficient E-Scrap smelting to occur, whilst overcoming the challenges associated with alternative technologies. Operable slag compositions and high zinc fuming are heavily influenced by kinetic processes, with piloting critical to understanding the performance of this process. ISASMELT (TM) pilot tests were performed, with a wide range of fluxing targets tested to confirm these benefits. The testing demonstrated that high levels of zinc fuming (>80%) are obtained in the E-Scrap ISASMELT (TM) furnace, decreasing the iron and silica flux additions required to manage the detrimental viscosity effects of zinc in the slag. In addition, it was demonstrated that slags containing high concentrations of alumina (>10 wt%) are operable in an ISASMELT (TM) furnace. The ISASMELT (TM) technology was demonstrated to be the only E-Scrap furnace technology able to produce a 'clean' discard slag with low concentrations of zinc and minimal fluxing requirements.