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Copper extraction from electronic scraps by an
oxidative acid leaching process
Fábio dos Santos, Carlos de Souza, Rafael Peixoto and Priscila da Rocha
Centre for Mineral Technology, CETEM, Brazil
ABSTRACT
According to the literature, scrap from electronic and electrical equipment is becoming a
significant component of waste stream. Because of this scenario, these scraps have been taken
into consideration not only by the government environmental legislation agencies but also by the
public opinion due to their hazardous material content. Part of this waste stream is composed of
computer hardware, which is quite significant in terms of both volume and risk to the
environment. Moreover, a wide range of valuable metals are also present in this waste, copper
being the most abundant one. Therefore, recycling electronic scraps is an important initiative, not
only due to environmental issues but also regarding economic aspects. In order to develop an
environmentally friendly technique for extracting copper from these scraps, the present research
aimed at studying the processing of electronic scraps by acid oxidative hydrometallurgical
techniques at room temperature (about 298 K). The experimental work performed in lab‐scale
focused on the influence of different oxidant agents. The experimental results obtained so far
show that the copper in electronic scrap was oxidised to Cu2+. The copper leaching rate was
definitely influenced by the oxidant agent used. The copper‐bearing leachate can be purified and
concentrated by solvent extraction processes and be used either as raw material for producing
quite valuable copper salts, such as copper oxychloride [3Cu(OH)2*CuCl2], or as electrolyte for
electrowinning the copper as pure metal.
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INTRODUCTION
Under the elements in the earth’s crust, copper occupies the twenty‐fifth place. In the past, this
element could be found in the form of copper nuggets, but such source is largely exhausted [1].
According to UNEP’s report [2] the demand of copper to be used for manufacturing electrical and
electronic equipment (EEE) was about 4,500,000 tonnes in 2006. To meet this demand, mining plays
the most important role in supplying metals, but such activity has a significant environmental
impact. Considerable amounts of land are necessary and energy consumption is huge. Besides, due
to the generation of a variety of wastes from various processing steps, its management is becoming
a burden for copper producers [3]. This scenario seems not to have changed in a short while as the
used electronic equipment became one of the fastest growing waste streams in the world.
Over the last decades the electronic industry has revolutionised the world. The amount of
appliances in the market is increasing every year. Many reviews have been published in the last
years [3‐5] and the interest in recovering the metals contained in this material is growing up fast.
According to Cui & Forssberg [6], six million tonnes of Waste Electrical and Electronic Equipment
(WEEE) were generated in west Europe in 1998. This happens due to both technological
innovations and market expansions accelerating the replacement of equipment leading to a
significant increase of such waste. A recent study shows that in the European Union the total
weight of electronic appliances put on the market in 2005 varied up to more than 9.3 million tons
with a sensible growing rate [2]. An essential part of almost all WEEE is Printed Circuit Boards
(PCBs), of which the average rate of world‐wide manufacture increases by 8.7 %. However, this
number can reach higher values in Asian countries [7]. Recycling PCB waste is an important subject
not only from the waste treatment point of view, but also from metals recovery one (see typical
PCBs composition in Table 1), especially in the case of copper, for which concentration in PCB
amounts to approximately 20 % [2, 7].
Table 1 PCBs composition (typical)
Metal Weight (%)
Iron 7
Aluminum 5
Copper 20
Lead 1.5
Nickel 1
Tin 3
*Source: UNEP [2]
In the past, the recycling of the PCBs has been based on recovery via material smelting [4, 8].
However, this is a highly polluting process that can cause several environmental problems such as
formation of toxic brominated compounds derived from the brominated flame retardants contained
in the circuit boards [9], and lead present in the solder.
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In order to avoid such undesirable consequences and to develop an environmentally friendly
technique for extracting copper from those scraps, the present technical contribution aimed at
studying electronic scraps processing by acid oxidative hydrometallurgical techniques at room
temperature (about 298 K). The hydrometallurgical leaching process consists of releasing valuable
components into solution using leaching agents. In this study both sulphuric acid (as leaching
agent) and hydrogen peroxide (as oxidising agent) were used.
METHODOLOGY
Particle size, shape and liberation degree play crucial roles in recycling processes. The electronic
scrap used in this experimental work came from damaged or obsolete personal computers. The
samples were comminuted in a cutting mill until reaching a suitable particle size to release the
metals. The pieces of copper are easily observed after the shredding operation. In Figure 1, an
image obtained through a scanning electronic microscope is shown. The fibreglass material and
pieces of copper are easily identified on it.
Figure 1 Photography of the shredded scrap obtained through a scanning electronic microscope
After the fragmentation operation the particle size distribution was evaluated. After accurately
observing each size fraction, it was realised that there were metal particles spread over each one of the
different sizes accordingly. The particle size distribution is shown in Table 2.
It can be observed in Figure 2 that the gold particles are present mostly in the finest fraction of the
ground sample. This behaviour suggests that there is a correlation between the application of the
metal in the PCBs, either as wiring or as a surface coating. This leads to very different values in the
sample copper content. An explanation for that is the presence of metallic particles hindering a correct
sampling, and, thus, the results of copper may vary considerably in different tests, leading to the so‐
called “nugget effect”. The results out of this work show the variation of copper content in the sample
ranging from to 12 to 22 % and are presented in Table 3.
The focus of this work was concentrated on extracting copper from the aforementioned electronic
scraps. Other not less important metals will not be considered in the discussion, although they
have been analysed; due to their economic value some comments about gold and silver will be
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made. However, as the composition of the solution may impact the technology to be used to
upgrade the copper in the leach solution, a detailed sample composition was performed and
presented in Peixoto et al. [10].
As mentioned before in this work, sulphuric acid and hydrogen peroxide were used to extract
copper, which overcame problems related to both toxicity and selectivity, avoiding the production
of substances which can cause damage to health. Secondly, sulphuric acid and hydrogen peroxide
were used to improve the copper extraction given the heterogeneous nature of the sample in terms
of composition, in other words improving the selectivity of the reaction system.
Figure 2 Photography of the shredded samples under 200 Mesh obtained through
a scanning electronic microscope
Table 2 Size distribution of the PCBs after the shredding operation
Size (Mesh) Weight (g) %
6 59.45 6.00
8 123.64 12.47
10 144.40 14.57
14 124.00 12.51
20 81.00 8.17
28 94.70 9.55
35 77.50 7.82
48 53.70 5.42
65 70.00 7.06
100 48.50 4.89
150 23.90 2.41
200 33.30 3.36
270 20.90 2.11
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Determination of the composition of the studied WEEE
Table 3 shows the copper content in the scrap under study. To obtain the composition of the WEEE
studies, aqua‐regia was used to leach 25 g of the shredded sample producing a metals‐bearing leachate.
In each test the samples were leached for five hours in a glass beaker containing 250 cm3 of just
prepared aqua‐regia. The reaction time used was enough for extracting copper. The solution: electronic
scrap ratio of 10:1 was maintained in all leaching tests accomplished in this experimental work,
whether using aqua‐regia or sulphuric acid/oxidising agent solution. In preliminary leaching tests of
the samples, that ratio was found to be the most effective for leaching the scrap sample used in this
experimental work. The scrap sample was mechanically suspended in the leaching solution using a
magnetic stirrer. Other metals, such as nickel, lead, tin and cadmium, in addition to copper, silver and
gold, were also analysed, but will not be discussed as they are not included in the scope of this work.
From the obtained data it is possible to affirm that copper is the main element present in the scrap,
reaching about 18 %, which is in accordance with the value of about 20 % of copper in WEEE found
in the literature, as mentioned before.
Table 3 Size distribution of the electronic scrap after the shredding operation
As mentioned before, the results of leaching have demonstrated that other metals, which are
economically interesting, are also found in the sample. Table 4 shows the results obtained for
gold and silver.
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After determining the copper content in the studied electronic scrap, tests were accomplished using
mainly the following oxidising agents: air, sodium hypochlorite and hydrogen peroxide. A fourth
option was tested following the method proposed by Ping et al., [11] by using copper sulphate,
which was added as a kind of oxidant. According to the authors, the Cu2+ ions work together with
air promoting the oxidation of metallic copper to cuprous ions (Cu+). Those ions are then oxidised
to Cu2+ through the generation of an intermediate complex ion [CuCl2]‐, which in acid solution can
be transformed into copper sulphate. The results obtained with air and sodium hypochlorite
provided copper extraction of less than 1 %. Copper sulphate has demonstrated a better copper
extraction, which did not exceed 10 %.
An explanation of low copper extraction is the formation of CuCl, of which its solubility is low, in
both experiments with air and NaClO.
Since the tests with other oxidising agents have demonstrated not to be adequate in extracting
copper from the studied sample, tests using sulphuric acid and hydrogen peroxide were carried
out. The objective of these tests was to obtain better values of copper extraction from the electronic
shredded scrap than that obtained with the other oxidising agents tested. The samples were leached
in a glass beaker containing a 50 % (v/v) diluted sulphuric acid solution. Approximately 100 g of
scrap could be treated in such solution at room temperature (about 298 K). The addition of
hydrogen peroxide was done slowly to prevent loss of that reagent. The shredded scrap was
mechanically suspended with a magnetic stirrer.
Being a powerful oxidising agent, oxygen peroxide was able to dissolve all metals present in the
sample. The following reaction shows how copper dissolution takes place:
To obtain a more effective copper extraction, tests were carried out with different amounts of
hydrogen peroxide: 30 cm3, 60 cm3, 90 cm3, and 120 cm3. Considering that the hydrogen peroxide is
very unstable, its addition was done in fractions of a volume with a 30 minutes interval between
them. The influence of volume used on each volume fraction of hydrogen peroxide was also
studied. To this end, some tests were performed with fractions ranging from 10 cm3, 15 cm3 and 20
cm3 of hydrogen peroxide on each addition. A summary of the accomplished tests and their
conditions are presented in Table 5.
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Table 5 Summary of the performed copper recovery tests
Test No 1 2 3 4
Addition of 3 additions 3 additions 6 additions 6 additions
H2O2 of 10 cm3 of 20 cm3 of 15 cm3 of 20 cm3
Time 5 hours 5 hours 5 hours 5 hours
Cu (recovery) 49.66 % 85.77 % 90.29 % 99.32 %
It was observed that the increasing amount of hydrogen peroxide makes copper extraction
increase. 30 cm3 of the oxidising agent provides about 50% of copper extraction, 60 cm3 of
hydrogen peroxide increases copper extraction to about 85%, 90 cm3 to about 90%, and finally,
120 cm3 provides more than 99% of copper extraction. Thus, copper extraction is proportional to
the amount of hydrogen peroxide added.
In addition to tests carried out for extracting copper, special attention was driven to the kinetic
aspects of copper extraction from the electronic scrap under the conditions used in this work.
The kinetics of the copper extraction was evaluated and it is shown in Figure 3. It is observed
that about four hours after starting the test the copper concentration in acid solution with
hydrogen peroxide reaches a maximum value, which goes further down probably due to
competing reactions that make insoluble copper compound to precipitate. It is important to
take into account that the reaction system is very heterogeneous and the different elements
present can promote undesirable reactions.
Figure 3 Variation of copper concentration in the leachate
CONCLUSIONS
The still growing copper demand is especially due to technological improvement in the
manufacture of EEE. After their useful service life, copper‐bearing products are discarded. The non‐
renewable sources of copper, and the worldwide increasing generation of WEEE, are pushing the
scientific community to search for new technological processes to enhance copper extraction from
such waste. The results presented in this work have shown that copper extraction from electronic
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scraps by an oxidising acid leaching process, using a mixture of sulphuric acid and hydrogen
peroxide, can be an environmentally friendly alternative to extracting copper from secondary
sources, offering useful chemicals for industrial use such as copper oxy‐chloride [3Cu(OH)2*CuCl2],
or as copper sulphate electrolyte, from which copper can be electrowon as pure metal. This
methodology is being developed by the authors and will be presented in a further publication. In
addition, as another conclusion, one can say that hydrogen peroxide is a useful oxidising agent to
promote copper oxidation, reaching a copper extraction of 99 % from the electronic scraps under
study. The copper extraction kinetics indicate that after running three hour of leaching, in the
aforementioned experimental conditions, a maximum copper concentration is obtained in solution.
After this reaction time, side reactions provoke other copper salts to precipitate.
Furthermore, the results have shown the presence of valuable metals such as silver and gold in the
studied sample.
NOMENCLATURE
EEE = Electrical Electronic Equipment
WEEE = Waste Electrical and Electronic Equipment
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