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A facile and cost-effective approach for copper recovery from waste printed circuit boards via a sequential mechanochemical/leaching/recrystallization process Kang Liu, Jiakuan Yang, Huijie Hou, Sha Liang, Ye Chen, Junxiong Wang, Bingchuan Liu, Keke Xiao, Jingping Hu, and Huali Deng Environ. Sci. Technol., Just Accepted Manuscript • DOI: 10.1021/acs.est.8b06081 • Publication Date (Web): 30 Jan 2019 Downloaded from http://pubs.acs.org on February 4, 2019
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A facile and cost-effective approach for copper recovery
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from waste printed circuit boards via a sequential
3
mechanochemical/leaching/recrystallization process
4
Kang Liu†‡, Jiakuan Yang*,†‡§, Huijie Hou*,†‡, Sha Liang†‡, Ye Chen†‡, Junxiong Wang†‡,
5
Bingchuan Liu†‡, Keke Xiao†‡, Jingping Hu†‡, Huali Deng∥
6
†
7
Technology (HUST), 1037 Luoyu Road, Wuhan, Hubei, 430074, China
8
‡
9
Recycling, 1037 Luoyu Road, Wuhan, Hubei, 430074, China
School of Environmental Science and Engineering, Huazhong University of Science and
Hubei Provincial Engineering Laboratory of Solid Waste Treatment, Disposal and
10
§
11
(HUST), 1037 Luoyu Road, Wuhan, Hubei 430074, China
12
∥
13
*Co-Corresponding author
14
* Prof. Jiakuan Yang
15
Tel: +86-27-87792102, Fax: +86-27-87792101.
16
E-mail:
[email protected].
17
* Associate Prof. Huijie Hou
18
Tel.: +86-27-87793948.
19
E-mail:
[email protected] State Key Laboratory of Coal Combustion, Huazhong University of Science and Technology
Dongjiang Environmental Protection Co., Ltd., Shenzhen 518000, China
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■ ABSTRACT
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The recovery of copper (Cu0) from waste printed circuit boards (WPCBs) is a great
23
challenge due to its heterogeneous structural properties, with a mixture of metals,
24
epoxy resin, and fiberglass. In this study, a three-step sequential process—including
25
mechanochemical processing, water leaching, and recrystallization—for Cu0 recovery
26
from WPCB powder is reported. Potassium persulfate (K2S2O8), instead of acid/alkali
27
reagents, was employed as the sole reagent in the cupric sulfate (CuSO4) regeneration
28
process. Complete oxidation of the Cu0 in the WPCBs to copper oxide (CuO) and
29
CuSO4 was first achieved during mechanochemical processing with K2S2O8 as the
30
solid oxidant, and the K2S2O8 was simultaneously converted to sulfate compounds
31
(K3H(SO4)2) via a solid-solid reaction with epoxy resin (CnHmOy) as hydrogen
32
donator under mechanical force. The rapid leaching of Cu species in the forms of CuO
33
and CuSO4 was therefore easily realized with pure water as a non-toxic leaching
34
reagent. The kinetics of the leaching process of Cu species was confirmed to follow
35
the shrinking nucleus model controlled by solid-film diffusion. Finally, CuSO4·5H2O
36
was successfully separated by cooling crystallization of the hot saturated solution of
37
sulfate salt (K2Cu(SO4)2·6H2O). An efficient conversion of Cu0 to CuSO4·5H2O
38
product, for WPCB recycling, was therefore established.
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TOC ART
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■ INTRODUCTION
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According to statistics from the United Nations Environment Programme, in 2016, the
45
global e-waste generation has exceeded 40 million tons, while e-waste still maintains
46
an annual growth rate of 3-5%.1 As the main components of various electronic and
47
electrical equipment, it is estimated that about 2 million tons of printed circuit boards,
48
are discarded annually worldwide assuming the weight proportion of printed circuit
49
boards is 5 wt% of waste electronic and electrical equipment.2 Specifically, the
50
average copper content in waste printed circuit boards (WPCBs) comes to more than
51
20 wt%, much higher than the 0.2-0.7 wt% in copper ore, making it the main
52
economic drive for the recycling of WPCBs.
53
significant quantities of heavy metals (e.g., Pb, Hg, Cd, and Cr) and toxic substances
54
(e.g., organochlorine and organobromine) that pose serious environmental threats if
55
not properly managed (Table S1).9-12 Therefore, the recycling of WPCBs has become
56
an important issue of both global environment and human health. 13, 14
3-8
Furthermore, WPCBs also contain
57
The copper in WPCBs is generally in the form of Cu0. Conventional recycling
58
processes for Cu0 recovery from WPCBs include physical,15, 16 electrochemistry,17, 18
59
pyrometallurgical,19,
60
However, direct leaching and separation of Cu0 from WPCB powder is extremely
61
challenging, even when using a mineral acid as the leaching reagent.27, 28 Further, the
62
direct conversion of the Cu0 in WPCBs into high-value copper compounds is even
63
more daunting.29 Currently, hydrometallurgy is a widely accepted approach in mature
64
industrial recycling system for Cu0 recovery from WPCBs due to its advantages of
65
low recovery cost, high metal recovery rate, and mild operational conditions.22
66
However, the generation of waste acids and liquid wastes pose severe environmental
67
risks, requiring a complex supplementary wastewater treatment process.30,
20
hydrometallurgical,21-23 and biometallurgical24-26 method.
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Furthermore, the use of acid/base reagents and organic extractants increases the cost
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of corrosion protection of the equipment and the potential risks to the practitioner.9
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Therefore, new technology and methods for direct Cu0 recovery from WPCBs, or
71
faster conversion of Cu0 into high-value products, is urgently required.
72
Currently, a mechanochemical method is widely used for the recovery of valuable
73
metals from e-waste, because of its unique reaction mechanism.32, 33 First of all, the
74
mechanochemical method utilizes mechanical forces, including shearing, friction,
75
impact force, etc., to apply mechanical energy to condensed matter such as a solid or
76
liquid to induce chemical reactions: this is especially effective for highly dispersed
77
valuable metals in complex e-waste.34 In addition, because the driving force of
78
mechanochemical processing is mechanical energy rather than thermal energy, the
79
extraction reaction of valuable metals in electronic wastes can be easily completed
80
without harsh conditions such as high temperature or high pressure, fulfilling the goal
81
of green chemistry for e-waste recycling.35 Because of all these advantages, the
82
mechanochemical method has now become a popular metal recovery technology for
83
e-waste.36-42
84
Li et al.43 proposed detoxifying cathode ray tube funnel glass for lead recovery by
85
mechanochemical activation. Substantial physicochemical changes have been
86
observed after mechanochemical activation, including chemical breakage and the
87
formation of defects in the inner structure of glass. These changes contribute to the
88
easy dissolution of an activated sample in acid solution. Sun et al.44 proposed a
89
mechanochemical activation method to selectively recycle iron (Fe) and lithium (Li)
90
from the cathode scrap of spent lithium iron phosphate (LiFePO4) batteries. The
91
characterization results confirmed that the chemical bonding of LiFePO4 was
92
destroyed during mechanochemical activation, an effect that could be attributed to the 5
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destructive effect of mechanical force. This approach also significantly promotes the
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leaching of metals in the solid materials after mechanochemical activation. However,
95
few reports on Cu0 recovery from WPCBs using the mechanochemical method can be
96
found in existing research literature.
97
Here in this work, a facile process is proposed, including mechanochemical
98
processing, water leaching, and recrystalization, for the regeneration of Cu0 to
99
high-value chemicals from WPCBs. The integrated three-step process could realize
100
direct conversion of Cu0 from WPCBs into CuSO4·5H2O. The mechanochemical
101
processing paths of K2S2O8 and Cu0 in WPCB powder under the induction effect of
102
mechanical force were explored, and conversion paths of Cu0 to CuSO4·5H2O product
103
for WPCB metal recycling were established.
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■ MATERIALS AND METHODS
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■
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DongJiang Co., Ltd (Xiamen, China). The Cu0 content in the WPCB powders
107
(0.1-0.15 mm) was 5.4 wt%. The XRF result of the WPCB powder (0.1-0.15 mm)
108
used in this study was provided in Table S2. The chemical reagents used were all of
109
analytical grade and were purchased from Chemical Reagent Company of Beijing
110
(Beijing, China). De-ionized water was used for preparation and dilution of the
111
chemical solutions.
112
■
113
resistance) were separated, the bare WPCB boards were shredded and crushed by a
114
cutting and grinding machine (Beijing Grinder Instrument Co., Ltd, China) and passed
115
through sieve mesh to obtain the WPCB powder of varying particle sizes. The particle
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size distribution of the WPCB powder when passing through different sieve mesh is
Materials and reagents WPCB samples were obtained from Xiamen
Experimental procedure After the components (e.g., relays, capacitors, and
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shown in Figure S1. The designed steps for Cu0 recovery from WPCB powder were
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divided into three stages.
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Stage I: All mechanochemical experiments were carried out in a planetary ball
120
mill (QM-3SP2J, Nanjing University Instrument Plant, China). Zirconia (ZrO2)
121
ball-milling pots of 100 mL inner volume and zirconia balls of 8 mm diameter were
122
used in the Cu0 recovery experiments. Conditions for mechanochemical processing
123
are listed in Table S3. First, WPCB powder (0.1-0.15 mm) of 0.5 g and K2S2O8 with
124
various mass ratios (K2S2O8/WPCBs mass ratio = 2:1, 1:1, 2:3, 1:2, 1:3, and 1:4),
125
together with grinding balls, were sealed in the ZrO2 pot. The mixture was then
126
co-ground at different rotary speeds (0, 100, 200, 300, 400, and 500 rpm) under
127
ambient conditions for different periods of time (0, 1, 2, 3, 4, 5, and 6 h).
128
Stage II: Co-ground products of 0.5 g were leached in 50 mL of de-ionized water
129
with constant magnetic stirring (300 rpm). The leaching temperature was set at
130
different temperatures: 25, 35, 45, and 55 oC. The leaching solution and solid residues
131
were rapidly separated by vacuum filtration after the reaction was complete.
132
Stage III: CuSO4·5H2O was separated from the filtrate by a heating concentration
133
and cooling recrystallization process. First, the leaching solution obtained in stage II
134
was converted into a saturated solution of sulfate salt (K2Cu(SO4)2·6H2O) by
135
continuous heating, and then the saturated solution was cooled to room temperature.
136
After filtration, CuSO4·5H2O could be easily separated from K2SO4 solution because
137
of their differences in solubility. The proposed flow chart for Cu0 recovery from
138
WPCB powder is shown in Figure 1.
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WPCBs (Cu0) Crushing and sorting WPCB powders (Cu0) Solid oxidant (K2S2O8)
Stage I
Mechanochemical processing Reaction products (CuSO4 + CuO + K3H (SO4)2) Stage II Water leaching Vacuum filtration
Residues
Leaching products (K2Cu(SO4)2 ·6H2O) Stage III Cooling recrystallization CuSO4·5H2O
139
K2SO4
140
Figure 1 Proposed flow chart for Cu0 recovery from WPCB powder
141
■ Analytical methods The percentage of Cu recovery after the mechanochemical
142
processing and water leaching process was calculated as follows:
143
Cu recovery percentage (%) = W1/W2 × 100%
144
where W1 is the Cu element in the leaching solution (g); and W2 is the original Cu
145
element in the WPCB powders (g).
146
The residual ratio of K2S2O8 after the mechanochemical and water leaching processes
147
was calculated as follows:
148
Residual ratio of K2S2O8 = C/C0 × 100%
149
where C is the measured S2O82− residual amount in the leaching solution (g); and C0 is
150
the initial amount of S2O82− in the starting material of K2S2O8 (g).
(1)
(2)
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Metal contents of the WPCB powder were determined using an inductively
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coupled
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PerkinElmer, USA) after digestion with a HNO3-HCl-HClO4-HF mixture. The
154
concentrations of copper ions in the leaching solution were measured using ICP-OES,
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and the concentrations of S2O82− in the leaching solution were measured using the
156
potassium iodide colorimetric method (Content S1) with a Lambda-14 UV
157
spectrophotometer (PerkinElmer Inc., Waltham, MA). The error bars in all data plots
158
represent the maximum and the minimum values of triplicate runs.
plasma-optical
emission
spectrometer
(ICP-OES,
OPTIMA
8300,
159
XPS analysis was conducted using a PHI Quantera SXM (PHI-5300/ESCA,
160
ULVAC-PHI, Inc, Japan). FT-IR spectra (Thermo Scientific Nicolet iS10 FR-IR
161
Spectrometer, USA) were employed for the identification of relevant characteristic
162
bands of different reaction products. The crystalline phases of samples before and
163
after the mechanochemical processing were characterized with XRD (PW 1700,
164
Philips, USA) using Cu Kα radiation with 30 kV voltage and 30 mA current. The
165
morphological properties of the K2S2O8/WPCBs samples before and after the
166
mechanochemical processing were examined with a scanning electron microscope
167
with energy dispersive X-ray analysis (SEM-EDAX, Hitachi S-3000N, Japan). The
168
carbon and sulfur contents in various solid samples were analyzed using a
169
high-frequency infrared carbon and sulfur analyzer (HCS-140, Shanghai DeKai
170
Instrument Co., Ltd. China).
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■ RESULTS AND DISCUSSION
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■
173
before and after mechanochemical processing were first analyzed with XPS. Figure
174
2a shows that the characteristic peaks of Cu 2p and S 2p could be observed from the
The oxidation of Cu0 The conversion of Cu0 in the K2S2O8/WPCBs samples
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K2S2O8/WPCBs samples after mechanochemical processing. Figure 2b is the XPS
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spectra of Cu 2p in the K2S2O8/WPCBs samples before and after mechanochemical
177
processing. A significant shake-up peak can be observed at the side of high binding
178
energy of Cu 2p3/2 in the K2S2O8/WPCBs sample after the mechanochemical
179
processing, and a significant satellite peak is observed at EB = 940-950 eV, implying
180
that Cu2+ occupied the main valent states in the K2S2O8/WPCBs sample after
181
mechanochemical processing.45 Further fitting results of Cu 2p XPS high-resolution
182
spectra in Figure 2c show that the peak of Cu 2p3/2 was split into three components,
183
with binding energies of 932.8, 933.5, and 935.7 eV, which correspond to the binding
184
energies of CuO, CuO, and CuSO4, respectively. In addition, the intensity peak of Cu
185
2p1/2 binding energy in 953.0 eV also corresponds to the binding energy of CuO,
186
indicating that the Cu0 in the WPCB powder was converted into CuO and CuSO4 by
187
mechanochemical processing with K2S2O8. From the fitting result of S 2p XPS spectra
188
of Figure 2d, the characteristic peaks of sulfate occurred at 169.2 and 170.1 eV in the
189
S 2p spectra of the ball-milling sample at 400 rpm at a reaction time of 4 h. Therefore,
190
Cu0 in the WPCB powder was converted into CuO and CuSO4 after mechanochemical
191
processing. Furthermore, the possible decomposition products of K2S2O8 after
192
mechanochemical processing were conjectured to be sulfates, a speculation confirmed
193
by XRD and FT-IR analysis.
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(b)
O1s
S2p
Cu2p
C1s O1s
After reaction
C1s
Cu2p
Cu2p1/2
Cu 2p3/2
Intensity (a.u.)
Intensity (a.u.)
(a)
Shake-up peak After reaction
Before reaction
(c)
200
400 600 800 Binding energy (eV)
1200 930
(d)
Cu2p
Cu2p3/2 CuO (932.8 eV)
Intensity (a.u.)
1000
CuO (953.0 eV)
CuO (933.5 eV) CuSO4
940 950 Binding energy (eV)
Cu2p1/2
(935.7 eV)
960
S2p Sulfate (169.2 eV)
Intensity (a.u.)
0
Before reaction
Sulfate (170.1 eV)
Shake-up peak 930
940 950 Binding energy (eV)
960
166
168 170 172 Binding energy (eV)
174
194 195
Figure 2 XPS spectra of K2S2O8/WPCBs samples before and after mechanochemical
196
processing (Conditions: ball-milling time of 4 h, K2S2O8/WPCBs mass ratio of 3:2,
197
ball-to-powder mass ratio of 60:1, and rotary speed of 400 rpm). (a) full spectra
198
analysis; (b) Cu 2p XPS spectra before and after mechanochemical processing; (c)
199
fitting result of Cu 2p XPS high-resolution spectra of the sample after
200
mechanochemical processing; and (d) fitting result of S 2p XPS high-resolution
201
spectra of the sample after mechanochemical processing.
202
■
203
show that the diffraction peaks of Cu0 in the K2S2O8/WPCB sample before
204
mechanochemical processing were difficult to identify due to a much stronger
205
diffraction peak intensity of K2S2O8, compared to Cu0. After mechanochemical
206
processing at different speeds for 4 h, the diffraction peaks of K2S2O8 gradually
207
weakened. The decrease of diffraction peak intensities can be attributed to the grain
Decomposition of potassium persulfate The XRD patterns in Figure 3a
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refinement and lattice distortion of the mixture under the action of mechanical force.46
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As shown in Figure 3b, the sample after ball-milling at 400 rpm for 4 h was identified
210
as K3H(SO4)2 (a mixture of KHSO4·K2SO4), implying that the organic compounds in
211
the WPCB powder were also involved in the mechanochemical processing. Further
212
FT-IR analysis (Figures S2a and S2b) shows that compared with WPCB powder,
213
K2S2O8 had relatively stronger characteristic peaks, so that the characteristic bands of
214
K2S2O8 mainly occurred in the K2S2O8/WPCBs sample before the mechanochemical
215
processing (Figure S2c). After mechanochemical processing at different speeds, the
216
bending vibrations at m = 592.7 and 703 cm−1 appearing in the K2S2O8/WPCBs
217
sample after 400 rpm can be attributed to the medium characteristic absorption peaks
218
of SO42−. The symmetric stretching vibrations appearing in the K2S2O8/WPCBs
219
sample after 400 rpm at v = 1052 and 1210 cm−1 can be attributed to the strong
220
characteristic absorption peaks of SO42− (Figure S2d-S2g). This result strongly
221
confirms that the decomposition products of K2S2O8 after mechanochemical
222
processing with WPCB powder were mainly sulfates. The SEM images of the
223
K2S2O8/WPCB samples before and after the mechanochemical processing are shown
224
in Figure S3.
225
It is well known that K2S2O8 can be converted to KHSO4 and O2 in water at
226
temperatures above 60 oC (2K2S2O8 + 2H2O → 4KHSO4 + O2↑), and the local
227
chemical temperature of the mechanochemical processing could reach 1000 oC or
228
even higher.32,
229
elementary C, H, and O, the production of KHSO4 may be a result of the solid-solid
230
reaction of K2S2O8 with the epoxy resin. Epoxy resin containing the C, H, and O
231
elements in WPCB powder, therefore, played the role of hydrogen donor: 47-49
232
2K2S2O8 + 2H2O (CnHmOy) → 4KHSO4 + O2 (g)
34
Since the composition of the epoxy resin (CnHmOy) is mainly
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The verification experiments in Figure S4 showed that the presence of pure epoxy
234
resin alone or with WPCB powder could significantly increase the production of
235
sulfate, confirming that the hydrogen in CnHmOy could be used as a hydrogen donor
236
for promoting the conversion of K2S2O8 to KHSO4.
Intensity (a.u.)
400 rpm 300 rpm 200 rpm
20
237
30 40 50 2 Theta (degree)
K3H(SO4)2
JCPDS No: 01-087-1987
400 rpm
K 2S 2O 8
10
100 rpm
(b)
Intensity (a.u.)
(a)
0 rpm 70 10
60
20
30 40 50 2 Theta (degree)
60
238
Figure 3 (a) XRD patterns of the K2S2O8/WPCB sample before and after
239
mechanochemical processing at different speeds (Conditions: ball-milling time of 4 h,
240
K2S2O8/WPCB mass ratio of 3:2, and ball-to-powder mass ratio of 60:1); (b) XRD
241
pattern of the K2S2O8/WPCB sample after mechanochemical processing at 400 rpm
242
(enlarged view).
243
■
244
during the water leaching process can be attributed to the effect of H+ in the leaching
245
solution, as shown in Eq. (R2):
246
CuO + 2KHSO4 = CuSO4 + K2SO4 + H2O
247
Figure 4a indicates that Cu leaching from the K2S2O8/WPCB mechanochemical
248
processing product is a very fast process. When the temperature reaches 25 oC, only
249
9.0 min are required to reach a Cu leaching efficiency of 99.8 wt%. During the
250
ball-milling process, mechanical energy is transmitted to the materials in the pot by
Leaching kinetics of copper species The rapid dissolution of Cu species
(R2)
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the grinding balls. Meanwhile, collisions at varying strengths and frequencies could
252
initiate physical and chemical reactions. Due to the distortion of the lattice in the
253
internal structure of the materials caused by the mechanical force activation, a part of
254
the mechanical energy is stored in the mineral crystal structure, promoting Cu
255
leaching. Besides, raising the leaching temperature can obviously promote Cu
256
leaching from the mechanochemical processing products. This result can be attributed
257
to the accelerated reaction process and the mass transfer process in the solution.
258
The kinetics of the Cu leaching process can be described by a shrinking nucleus
259
model. This model can be divided into diffusion control, chemical reaction control,
260
and mixed reaction control, according to the different control steps. Figure 4b and
261
Table S4 indicate that the kinetic equation (1-2/3α-(1-α)1/3=kt; α is the leaching
262
percentage of Cu; k is the diffusion rate constant; and t is the reaction time) of
263
diffusion control at different leaching temperatures presented a sound linear
264
regression relation with time, indicating that the leaching of Cu from the
265
mechanochemical processing products follows the shrinking nucleus model of
266
diffusion control.
267
Based on the diffusion rate constant (k, min-1) of Cu leaching at different leaching
268
temperatures, a linear fitting relation between lnk and 1,000/T was plotted. Figure 4c
269
indicates that the slope between lnk and 1/T was -1847.0. According to the Arrhenius
270
equation, the apparent activation energy was Ea = 15.4 kJ/mo1. This value shows that
271
the Cu leaching from mechanochemical processing products belonged to solid-film
272
diffusion control. Figure S5 indicates that with the disappearance of diffraction peaks
273
of the metallic copper phase, Cu0 had been successfully leached from the WPCB
274
powder after the mechanochemical processing and water leaching processes.
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Therefore, after filtration and separation from the residue, the final products recovered
276
from the leaching solution should be CuSO4 and K2SO4. (a)
0.6
(b)
25 oC Adj.R2= 0.9946 35 oC Adj.R2= 0.9974 45 oC Adj.R2= 0.9980 55 oC Adj.R2= 0.9983
1/3
80
1-2/3α-(1-α)
Cu leaching percentage (wt%)
100
60
25oC 35oC 45oC 55oC
40 20 0
0.4
0.2
0.0
0
1
2
3 4 5 6 7 Leaching time (min) -2.0
8
9
0
1 2 3 4 Leaching time (min)
5
(c)
InK
-2.2
-2.4 Slope = -1847.0 Ea = 15.4 kJ/mol
-2.6
R2-Square = 0.9173 3.0
3.1
3.2 1,000/T
277
3.3
3.4
278
Figure 4 (a) Leaching percentage of Cu species from the K2S2O8/WPCB
279
mechanochemical processing product under different temperatures; (b) kinetic curves
280
for different leaching temperatures; (c) Arrhenius curves plot of the leaching reaction
281
(Conditions: ball-milling time 4 h, K2S2O8/WPCB mass ratio 3:2, ball-to-powder
282
mass ratio 60:1, and rotary speed 400 rpm)
283
■
284
solution after vacuum filtration in Figure 5a shows that the crystallization product of
285
the separated leaching solution was mainly a composite sulfate salt (cyanochroite,
286
K2Cu(SO4)2·6H2O; JCPDS No:96-901-2781). This result is consistent with the above
287
characterization analysis. CuSO4 could be effectively separated from the K2SO4
Separation of cupric sulphate The crystallization of the separated leaching
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solution by cooling recrystallization, because of the difference in the solubility of
289
these two sulfate compounds (Figure S6). The XRD pattern in Figure 5b shows that
290
the CuSO4·5H2O products separated by cooling recrystallization agreed well with the
291
XRD diffraction peaks in the standard cards (CuSO4·5H2O, JCPDS No: 01-072-2355).
292
The SEM image shows that the CuSO4·5H2O product presented an irregular sheet
293
stacking structure (Figure 5c). EDAX analysis (Figure 5d) shows that the atomic
294
percentages of Cu, S, and O in the CuSO4·5H2O product were 17.89, 15.17, and 66.94
295
wt%, respectively—close to a pure CuSO4·5H2O product. Therefore, after a three-step
296
sequential process, including mechanochemical processing, water leaching, and
297
recrystallization, Cu0 in the WPCB powders was successfully recovered in the form of
298
CuSO4·5H2O product.
(a)
(b)
Copper sulfate hydrate [CuSO4·5H2O]
Intensity (a.u.)
Intensity (a.u.)
Cyanochroite [K2Cu(SO4)2·6H2O]
JCPDS No: 96-901-2781 10
20
30 40 50 2Theta (degree)
60
JCPDS No:01-072-2355 70
10
20
30 40 50 2Theta (degree)
(d)
(c)
60
70
Area I
Area I
(b)
Element
Atomic percentage
Cu
17.89 wt%
S
15.17 wt%
O
66.94 wt%
10 μm
299 300
Figure 5 (a) XRD pattern of the crystallization of the separated leaching solution
301
(obtained from WPCB particle size = 0.6-0.8 mm), (b) XRD pattern, (c) SEM image,
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and (d) EDAX analysis of the obtained CuSO4·5H2O product (Conditions: reaction
303
time of 4 h, K2S2O8/Cu0 mass ratio of 30:1, and rotary speed of 400 rpm).
304
■
305
metals, organic materials, and inorganic materials in WPCB powder will increase
306
during the mechanochemical processing, resulting in an increase of solid reactivity.
307
The mechanochemical processing can not only reduce the activation energy of
308
chemical reaction, but can also induce a variety of solid chemical reactions.
309
According to the state of the raw materials (K2S2O8/WPCB powder), the possible
310
reactions in the ZrO2 pot during the mechanochemical processing can be divided into
311
a solid-solid reaction and a solid-gas reaction.46 The entire possible reaction paths of
312
Cu0 are shown in Figure 6.
Exploration of the possible reaction paths of Cu0 The inner energies of
313 314
Figure 6 Schematic diagram of the proposed Cu0 recovery paths
315
(Note: R1-R6 in Figure 6 represent reactions of Eq.(R1)–(R6)) 17
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316
In the mechanochemical processing stage (Figure 6a-I), many possible reaction
317
paths for the K2S2O8 and Cu0 were induced under the mechanical force. Based on the
318
identified K2S2O8/WPCB reaction products, a schematic diagram of the proposed Cu0
319
reaction paths is shown in Figure 6b. The possible reaction paths for Cu0 conversion
320
can be summarized as follows:
321
(1) Cu0 could react with K2S2O8 to produce CuSO4 directly due to the redox activities
322
of K2S2O8 as an oxidant and Cu0 as a reducing agent.
323
Cu + K2S2O8 → CuSO4 + K2SO4
324
(2) Cu0 could react with K2S2O8 to form CuO and SO3. However, in a closed reaction
325
system, the new-generated CuO may be corroded by SO3, and CuSO4 will ultimately
326
be generated.
327
Cu + K2S2O8 → CuO + SO3 (g) + K2SO4
328
The results of the carbon and sulfur analyzer in Figure S7 show that the carbon and
329
sulfur percentages of the K2S2O8/WPCBs samples after treatment at different rotary
330
speeds decreased continuously, indicating that the carbon and sulfur species in the
331
K2S2O8/WPCBs sample were partially involved in the mechanochemical processing
332
and were converted to gaseous compounds. The sulfur element conservation of the
333
K2S2O8/WPCBs sample after treatment at different rotary speeds also indicates that
334
some sulfur species was converted into gaseous sulfur compounds (Figure S4b).
335
Nevertheless, the release of gaseous sulfur compounds can be effectively controlled
336
by absorption with the Ca(OH)2 solution.
337
(3) Epoxy resin has a high content of reducible carbon materials. CuSO4 therefore
338
reacted with carbon materials to produce CuO, CO, and SO2.
339
C + CuSO4 → CuO + CO (g) + SO2 (g)
(R3)
(R4)
(R5)
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340
During the water leaching stage (Figure 6a-II), the produced CuSO4 can be
341
dissolved directly in pure water. H+, generated from the hydrolysis of KHSO4, was
342
responsible for the rapid leaching of CuO in solution. CuO was therefore converted to
343
CuSO4 by reacting with KHSO4.
344
In the recrystallization stage (Figure 6a-III), with the difference in solubility
345
between K2SO4 and CuSO4, the separation of CuSO4 can be successfully realized by
346
evaporation recrystallization. Finally, after three steps of transformation, Cu0 was
347
converted to a high-value CuSO4·5H2O product.
348
■
349
The effects of different mechanochemical processing parameters, including time,
350
K2S2O8/WPCBs mass ratio, ball-to-powder mass ratio, and ball-milling speed, on Cu
351
recovery and K2S2O8 decomposition percentage, were studied. The left vertical axes
352
in Figure 7 show the Cu recovery percentages for different mechanochemical
353
processing parameters. In the beginning of the mechanochemical processing, the
354
reactant concentrations of both the Cu in the WPCB powder and the K2S2O8 were
355
high, which would contribute to more effective contacts and hence faster reaction
356
rates (Figure 7a). At the end of 4 h, the Cu recovery percentage reached 90.1 wt%.
357
Obviously, mechanochemical processing significantly promoted the leaching of Cu
358
species from WPCB powder. Beyond that time, the solid materials in the ball mill pot,
359
firmly adhered to each other by the continuous impact of mechanical force, were not
360
easily dispersed during the process of water leaching and thus the Cu recovery
361
percentage decreased gradually.
Influence of different mechanochemical parameters on Cu0 recovery
362
Figure 7b shows that the Cu recovery percentage reached the maximum of 99.6
363
wt% when the mass ratio of K2S2O8 to the WPCBs was 3:2. With a longer
364
ball-milling time and a higher K2S2O8/WPCBs mass ratio, the solid materials in the 19
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365
ball mill pot were also prone to cohere, thus affecting the subsequent water leaching
366
process, which was not favorable for Cu species leaching.
367
Figure 7c shows that the Cu recovery percentage increased with the
368
ball-to-powder mass ratio when the ratio ranged from 20:1 to 60:1, because more balls
369
led to more collisions per unit of time, resulting in the transmission of more energy to
370
the materials. When the ball-to-powder mass ratio exceeded 60:1, less effective
371
collisions occurred since more reactor space was occupied by the larger number of
372
grinding balls, which had negative influences on the interaction between Cu and
373
K2S2O8. Thus, the optimal ball-to-powder mass ratio was proposed to be 60:1.
374
It is generally believed that a higher rotary speed will lead to higher specific
375
collision energy on a substance. The specific collision energy can be expressed in the
376
equation below: 50 n
1 mV j2 j 1 2W
377
Ew
378
(3)
379
where Ew is the specific collision energy (KJ); Vj is the relative speed between balls or
380
between the balls and the wall (m/s); m is the ball mass (g); n is the collision
381
frequency per second; and W is the sample mass in the ball-milling pot (g). The
382
specific collision energy, Ew, would increase with increase in the ball mass (m) and
383
the relative speed (Vj). Figure 7d shows that the Cu recovery percentage was
384
proportional to the specific collision energy. However, too high a rotary speed would
385
lead to more coherence of the K2S2O8/WPCBs materials, causing an adverse effect on
386
the Cu recovery. An optimal rotary speed for Cu recovery was thus chosen to be 400
387
rpm.
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In summary, the optimal mechanochemical processing parameters for Cu recovery
389
were a ball-milling time of 4 h, a K2S2O8/WPCBs mass ratio of 3:2, a ball-to-powder
390
mass ratio of 60:1, and a rotary speed of 400 rpm. Under the optimal conditions, the
391
Cu recovery percentage could be as high as 99.8 wt%. The valence change and
392
leaching behaviors of the impurity metals are shown in Figure S8 and Figure S9,
393
respectively. The XPS results in Figure S8 show that Sn0 and Pb0 in the raw material
394
WPCB powders were oxidized to oxides under the effect of mechanical force and
395
K2S2O8. The leaching results in Figure S9 show that the leaching percentages of Ca,
396
Sn and Pb were lower than 2.8, 0.01, and 0.77 wt%. Thus, the proposed
397
mechanochemical process for Cu0 recycling from WPCBs exhibited excellent
398
selectivity.
399
It is also desirable to minimize the residual ratio of K2S2O8. The right vertical axes
400
in Figure 7 show this residual ratio in the presence of WPCB powder under different
401
mechanochemical processing parameters. Under the optimal mechanochemical
402
processing conditions for maximum Cu recovery, the residual ratio of K2S2O8 in the
403
presence of WPCB powder was only 0.10.
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0.4
60
0.2 40
0
1
2
3
4
5
0.0
6
0.8 0.6 80
0.4 0.2
60
0.0 0
1
(c)
1.0 0.8 0.6
80
0.4 0.2
60
0.0 20
40 60 80 Ball-to-powder mass ratio
100
Recovery percentage of Cu (wt%)
Time (h) 100
1.0
2 3 4 K2S2O8/WPCBs mass ratio
(d)
100
1.0 0.8
80
0.6 0.4
60 0.2 40
0.0 100
200 300 400 500 Ball-milling speed (rpm)
404 405
Figure 7 Effect of (a) time (Conditions: K2S2O8/WPCBs mass ratio of 4:1,
406
ball-to-powder mass ratio of 60:1 and rotary speed of 400 rpm), (b) K2S2O8/WPCBs
407
mass ratio (Conditions: reaction time of 4 h, ball-to-powder mass ratio of 60:1 and
408
rotary speed of 400 rpm), (c) ball-to-powder mass ratio (Conditions: reaction time of
409
4 h, K2S2O8/WPCBs mass ratio of 3:2 and rotary speed of 400 rpm), and (d)
410
ball-milling speed (Conditions: reaction time of 4 h, K2S2O8/WPCBs mass ratio of 3:2
411
and ball-to-powder mass ratio of 60:1), on Cu recovery percentage and K2S2O8
412
decomposition percentage.
413
■ Environmental implications
414
The direct conversion of Cu0 into high value-added products may be a more
415
promising approach for WPCBs recycling. This study therefore designed a three-step
416
sequential process for converting Cu0 into a CuSO4·5H2O product. The engineering
417
application results in Figure S10 show that the Cu recovery percentage generally 22
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Residual ratio of K2S2O8 (C/C0)
0.6
(b)
100
Residual ratio of K2S2O8 (C/C0)
0.8 80
Residual ratio of K2S2O8 (C/C0)
1.0
K 2S 2O 8 Recovery percentage of Cu (wt%)
(a)
Residual ratio of K2S2O8 (C/C0)
Recovery percentage of Cu (wt%)
Recovery percentage of Cu (wt%)
Cu 100
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418
exceeded 98 wt%, and the residual ratio of K2S2O8 was negligible, showing that the
419
proposed mechanochemical processing and water leaching process is a promising
420
strategy for Cu recovery from WPCB powder of varying particle sizes. A
421
comprehensive process comparison in Table S5 present that the highlight of the
422
proposed mechanochemical/leaching/recrystallization process for Cu0 recovery from
423
WPCBs is the production of high-value CuSO4·5H2O product at room temperature
424
and high-value CuSO4·5H2O products. Furthermore, economic evaluation in Table S6
425
shows that the proposed strategy could benefit from the high-value products of
426
CuSO4·5H2O and K2SO4 as well as the low energy consumption of mechanochemical
427
process, the proposed three-step process for Cu0 recovery from WPCBs presents
428
considerable economic profits at the current laboratory stage, and could be considered
429
economically favorable and feasible for practical applications.
430
In summary, Cu0 in the WPCB powder was successfully recovered in the form of
431
CuSO4·5H2O after a three-step process: mechanochemical processing, water leaching,
432
and cooling recrystallization. The proposed strategy provides a feasible solution for
433
large-scale conversion of Cu0 in WPCB powder into CuSO4·5H2O products.
434
■ SUPPORTING INFORMATION
435
Supporting Information is available free of charge via Internet at
436
http://pubs.acs.org.
437
■ AUTHOR INFORMATION
438
Co-Corresponding authors*
439
* Prof. Jiakuan Yang
440
Tel: 86+27+87792102.
441
E-mail:
[email protected] (Prof. Jiakuan Yang).
442
* Associate Prof. Huijie Hou 23
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443
Tel.: +86-27-87793948
444
E-mail:
[email protected] (Associate Prof. Huijie Hou).
445
Notes
446
The authors declare no competing financial interest.
447
■ ACKNOWLEDGMENTS
448
The research is supported by the China Postdoctoral Science Foundation
449
(2016M602306), the Foundation of State Key Laboratory of Coal Combustion
450
(FSKLCCA1604), and National Key Research and Development Program of China
451
(2018YFC1900105). Additionally, we would also like to thank the Analytical and
452
Testing Center of Huazhong University of Science and Technology for providing
453
experimental measurements.
454
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