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Extracting rare materials from electr(on)ic scrap
16th IFAC Conference on Technology, Culture and International Stability 16th IFAC Technology, Culture Stability 16th IFAC Conference Conference on Technology, Culture and and International International September 24-27, 2015.on Sozopol, Bulgaria Available online at www.sciencedirect.com Stability September 24-27, 2015. Sozopol, Bulgaria Stability September September 24-27, 24-27, 2015. 2015. Sozopol, Sozopol, Bulgaria Bulgaria
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48-24 (2015) 157–161 ExtractingIFAC-PapersOnLine rare materials from electr(on)ic scrap Extracting rare materials from electr(on)ic scrap Extracting Extracting rare rare materials materials from from electr(on)ic electr(on)ic scrap scrap
B. Kopacek* and P. Kopacek** B. Kopacek* and P. Kopacek** B. and P. B. Kopacek* Kopacek* and and P. Kopacek** Kopacek** *Austrian Society for Systems Engineering Automation (SAT), Gurkgasse 43/2, *Austrian Society for Systems Engineering and Automation (SAT), Gurkgasse 43/2, 1140 Vienna, Austria e-mail : [email protected] *Austrian Society for Engineering and Automation (SAT), Gurkgasse *Austrian Society forofSystems Systems Engineering and Automation (SAT), Gurkgasse 43/2, 43/2, 1140 Vienna, Austria e-mail : [email protected] **Vienna University Technology, Institute for Mechanics and Mechatronics, IHRT 1140 Vienna, Vienna, Austria Austria e-mail e-mail :: [email protected] [email protected] 1140 **Vienna University of Technology, Institute for Mechanics and Mechatronics, IHRT Favoritenstrasse 9-11/E325 A6, A – 1040 Wien.(e-mail:[email protected]) **Vienna University of Institute for **Vienna University of Technology, Technology, for Mechanics Mechanics and and Mechatronics, Mechatronics, IHRT IHRT Favoritenstrasse 9-11/E325 A6, A –Institute 1040 Wien.(e-mail:[email protected]) Favoritenstrasse 9-11/E325 A6, A – 1040 Wien.(e-mail:[email protected]) Favoritenstrasse 9-11/E325 A6, A – 1040 Wien.(e-mail:[email protected]) Abstract: As the price for natural resources will increase in the future the goal of this paper is that Abstract:resources As the price for materials natural resources will increaseand in not thebe future the In goal of the thisRaw paper is that valuable like rare have to be extracted wasted. 2010 Materials Abstract: As price for natural will increase in the future the goal of this paper is Abstract:resources Asthethe the price forCommission natural resources resources will increaseand in not thebe future the In goal of the this paper is that that valuable like rare materials have to be extracted wasted. 2010 Raw Materials Initiative of European defined 14 critical raw materials, most of rare metals (including valuable resources like rare materials have to be extracted and not be wasted. In 2010 the Raw Materials valuable resources like rare materials have to be extracted and not be wasted. In 2010 the Raw Materials Initiative of the European Commission defined 14 critical raw materials, most of rare metals (including rare earthsofoxide) which are used for electr(on)ic devices belong to this category. The idea is (including to recover Initiative the Commission defined 14 critical raw materials, most rare metals Initiative of the European European Commission defined 14devices critical raw materials, most of of by rarehydrometallurgical metals rare earths oxide) which are used WEEE for electr(on)ic belong to this batteries category. The idea is (including to recover rare and precious metals from including lamps and spent rare earths oxide) which are used for electr(on)ic devices belong to this category. The idea is to earths oxide) which are used for electr(on)ic devices belong to this category. The idea is to recover recover rare and precious metals from WEEE including lamps and spent batteries by hydrometallurgical processes. Furthermore to develop a mobile plant using hydrometallurgical processes to extract metals rare and and precious precious metals from WEEE WEEE including lamps and spent spent batteries batteries by hydrometallurgical hydrometallurgical rare metals from including lamps and by processes. Furthermore to develop a mobile plant using hydrometallurgical processes to extract metals like yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin in a high purity (above processes. Furthermore to develop aa mobile plant using hydrometallurgical processes to metals processes. Furthermore to the develop mobile plant using hydrometallurgical processes to extract extract metals like yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin intransportation a high puritycosts, (above 95%) from scrap. Because amount of scrap in industry is usually and to avoid in like yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin aa high (above like framework yttrium, indium, lithium, cobalt, copper, gold, silver, nickel, lead, tin in intransportation high purity purity (above 95%) from scrap. Because theprojects amountzinc, of scrap in industry is usually and to avoid costs, in the of two EU (HydroWEEE) a mobile and a stationary recycling plant is in 95%) from Because the amount of in is and to transportation costs, in 95%)framework from scrap. scrap. amount ofisscrap scrap in industry industry is usually usually and to avoid avoid transportation costs, the ofBecause twogoal EUthe projects (HydroWEEE) a tomobile and a stationary recycling plant is in development. Another of this paper to contribute reduce the amount of material for the recovery the framework of two EU projects (HydroWEEE) a mobile and a stationary recycling plant is in the framework of twogoal EU (HydroWEEE) a tomobile and a stationary recycling plant is in development. ofprojects this parts paper is printed to contribute reduce(PCB`s) the amount material for the recovery process and toAnother recognize reusable on circuit boards in anof economic way. Therefore development. Another goal of this paper is to contribute to reduce the amount of material for the recovery development. Another goal of this paper is to contribute to reduce the amount of material for the recovery process and to recognize reusable parts on printed circuit boards (PCB`s) in an economic way. Therefore aprocess semi-automated disassembly cellparts will be shortly described. and reusable on printed circuit and to to recognize recognize reusable on shortly printeddescribed. circuit boards boards (PCB`s) (PCB`s) in in an an economic economic way. way. Therefore Therefore aprocess semi-automated disassembly cellparts will be aKeywords: semi-automated disassembly cell will be shortly described. © 2015, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. a semi-automated cell will be materials, shortly described. End of disassembly Life Management, rare semi-automated disassembly. Keywords: End of Life Management, rare materials, semi-automated disassembly. Keywords: Keywords: End End of of Life Life Management, Management, rare rare materials, materials, semi-automated semi-automated disassembly. disassembly. 1. INTRODUCTION This European Directive “Waste from Electric and Electronic 1. INTRODUCTION This European Directive from Electricfor and8,3 Electronic INTRODUCTION – WEEE” “Waste were responsible to 9,1 Rapid changes of 1. consumer demands have affected that Equipment 1. INTRODUCTION This European European Directive Directive “Waste from Electric Electric and and Electronic Electronic This “Waste from Equipment –of waste WEEE” were responsible for 8,3so tocalled 9,1 Rapid changes oftheconsumer demands have affected that million tons within the EU in 2005. This WEEE represents fastest growing waste stream in the EU Equipment – WEEE” were responsible for 8,3 to 9,1 Rapid changes of consumer demands have affected that million Equipment –of waste WEEE” were for 8,3so tocalled 9,1 Rapid changes ofthe consumer demands have affected tons within the responsible EU by in 2005. This WEEE represents fastest growing waste stream in the that EU WEEE Directive was implemented the EC in order to with between 3 and 5 % per year, which means that it doubles million tons of waste within the EU in 2005. This so called WEEE represents the fastest growing waste stream in the EU million tons of waste within the EU in 2005. This so called WEEE represents the fastest growing waste stream in the EU WEEE Directive was implemented by the EC inend-of-life order to with between 3years. and 5 In % per year, which means that it doubles ensure an environmental friendly treatment of every 12-15 average every three years the IT WEEE Directive was by the in order with 3 and % year, which means that it WEEE Directive was implemented implemented by the EC EC order to to with between between 3years. and 55 In % per per year, growing which that it doubles doubles ensure an environmental friendly treatment of inend-of-life every 12-15 average every means three years theThe IT electrical and electronic equipment. Waste from Electrical equipment is exchanged by rapid turnover rates. ensure an environmental friendly treatment of end-of-life every 12-15 years. In average every three years the IT ensure an environmental friendly treatment of end-of-life every 12-15 years. In average every three years the IT electrical and electronic equipment. Waste from Electrical equipment is exchanged by rapid growing turnover rates. The and Electronic Equipmentequipment. (WEEE) isWaste the fastest growing life cycle isofexchanged Automation and growing IT devices is decreasing and from Electrical equipment by rapid turnover rates. The electrical and electronic electronic equipment. from Electrical equipment by rapid growing turnover rates. The electrical and Electronic Equipment (WEEE) isWaste the fastest growing life cycle isofexchanged Automation and IT devices is and decreasing waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster faster. and Electronic Equipment (WEEE) is the fastest growing life cycle of Automation and IT devices is decreasing and Electronic Equipment (WEEE) is the fastest growing life cycle of Automation and IT devices is decreasing waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster and faster. from 20-50 million cubic meters e-waste. About 5% of the Obsolete equipment ends up as e-waste which leads more and waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster and faster. waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster and faster. from 20-50 million cubic meters e-waste. About 5% of the Obsolete equipment ends up as e-waste which leads more and total waste stream can be derived from End of Life of more to a global problem: With its complex composition of from 20-50 20-50 million million cubic cubic meters meters e-waste. e-waste. About About 5% 5% of of the the Obsolete equipment ends as which leads from Obsolete ends up upand as e-waste e-waste which substances, leads more more and and total waste stream can Automation be derived fromITEnd of Life of more to aequipment global problem: With its complex composition of Electr(on)ics including and devices. In the materials, components hazardous it total stream can be derived from of Life of more to problem: With its complex composition of total waste wasteUnion stream canmore be than derived fromITEnd End of electrical Life of more to aa global global problem: and With hazardous its complex composition of including Automation and devices. In the materials, components substances, it Electr(on)ics European alone 17 million tons of constitutes a considerable threat to the environment. About Electr(on)ics including Automation and IT devices. In the materials, components and hazardous substances, it Electr(on)ics including Automation and IT devices. In the materials, components and hazardous substances, it European Union will alonebecome more than 17 million tons of electrical constitutes considerable threat tois the environment. About electronics obsolete this year. Predictions 70% of the aaheavy metal in landfill directly coming from e- and European Union alone more than 17 tons of electrical constitutes considerable threat environment. About European Union alone more than 17 million million tonswhich of electrical constitutes considerable threat to tois the the environment. About and electronics will become obsolete this2020, year. Predictions 70% of the aheavy metal in landfill directly coming from e- forecast a growth to 12,3 million tons till means waste. and electronics will become obsolete this year. Predictions 70% of the heavy metal in landfill is directly coming from eandexpected electronics will become obsolete this year. Predictions 70% of the heavy metal in landfill is directly coming from e- an forecast a growth to 12,3 million tons till 2020, which means waste. growth rate of around 40-50% forecast aa growth to 12,3 million tons till 2020, which means waste. forecast growth to 12,3 million tons till 2020, which means waste. an expected growth rate of around 40-50% Electr(on)ic products like automation and IT hardware an expected growth rate of around 40-50% an expected growth rate of around 40-50% Electr(on)ic products like automation and IT hardware The final disposal of electrical and electronic devices is an consist of a products high amount of diverse metals. According Electr(on)ic like automation and IT hardware Electr(on)ic like automation anda metal IT According hardware The final disposal of electrical andDisposal electronic is an consist of surveys a products high e.g. amount of phones diversehave metals. anddevices incineration issue of current worldwide concern. to several mobile content The final final disposal of electrical electrical and electronic electronic devices is an an consist of aa high amount of diverse metals. According The disposal of and is consist of high e.g. amount of phones diverse metals. According Disposal anddevices incineration issue of current worldwide concern. to several surveys mobile have a metal content can pose threats to the whole environment, from the of 25% (accumulator and recharger not included), mainly Disposal and incineration issue of current worldwide concern. to several several surveys surveys e.g. e.g. mobile mobile phones phones have have aa metal metal content content Disposal and incineration issue of current worldwide concern. to can pose threats the whole environment, from the of 25% (Cu), (accumulator andnickel recharger included), mainly atmospheric to theto and terrestrial compartments. copper iron (Fe), (Ni), not silver (Ag) and zinc can pose threats toaquatic the whole environment, from the of 25% (accumulator and recharger not included), mainly can posegases threats theduring whole environment, from(e.g., the of 25%Though (accumulator andnickel recharger included), mainly atmospheric to produced thetoaquatic and thermal terrestrial compartments. copper (Cu), iron (Fe), (Ni), not silver (Ag) and zinc Indeed, treatments (Zn). the absolute amounts of each device atmospheric to the aquatic and terrestrial compartments. copper (Cu), iron (Fe), nickel (Ni), silver (Ag) and zinc atmospheric to the aquatic and terrestrial compartments. copper (Cu), iron (Fe), nickel (Ni), silver (Ag) and zinc Indeed, gases produced during thermal treatments (e.g., (Zn). Though thevaluable absolute amounts of (16 eachgCu, device dioxins, furans,produced polybrominated organic treatments pollutants, (e.g., and regarding the most elements are low 0.35 Indeed, gases during (Zn). Though the absolute amounts of each device Indeed, gases produced during thermal thermal treatments (e.g., (Zn). Though thevaluable absolute amounts of g(16 each device dioxins, furans, polybrominated organic pollutants, and the gmost elements are low gCu, 0.35 polycyclic aromatic hydrocarbons) can be released into the gregarding Ag, 0.0034 Au, 0.015 g Pd, and 0.00034 Pt) this adds dioxins, furans, polybrominated organic pollutants, and regarding the most valuable elements are low (16 gCu, 0.35 dioxins, furans, polybrominated organic pollutants, and regarding the most valuable elements are low (16 gCu, 0.35 polycyclic aromatic hydrocarbons) can be released into the g Ag, 0.0034 g Au, 0.015 g Pd, and 0.00034 g Pt) this adds environment if adequate flue gas cleaning systems are not up to e.g. 0.35 of platinum based on estimated 1 billion polycyclic aromatic hydrocarbons) can be released into the g Ag, 0.0034 g Au, 0.015 gg Pd, and 0.00034 gg Pt) this adds polycyclic aromatic hydrocarbons) can be released into the g Ag, 0.0034 g Au, 0.015 Pd, and 0.00034 Pt) this adds environment if adequate flue gas cleaning systems are not up to e.g. 0.35 of platinum based on estimated 1 billion 2Similarly metals can be released from waste implemented. of cell phones in 2010. environment if adequate flue gas cleaning systems are not up to e.g. 0.35 of platinum based on estimated 1 billion environment adequatemetals flue gas systems not up to e.g. 0.35 in of 2010. platinum based on estimated 1 billion 2if Similarly cancleaning be released fromare waste implemented. of cell phones electrical and electronic equipment (WEEE) disposed of in Similarly metals metals can can be be released released from from waste waste implemented.22Similarly of cell phones in implemented. of phonesWEEE in 2010. 2010. electrical andbyelectronic equipment (WEEE) disposed of in landfill sites leaching processes. Such gaseous and solid Thecell European Directive aims at WEEE recycling, to electrical and electronic equipment (WEEE) disposed of in electrical andhazardous equipment (WEEE) disposed of in landfill sites byelectronic leachingfor processes. Such gaseous and solid The European WEEE Directive aims at WEEE to recycling, to waste are human beings and for the reduce the disposal of waste and “to contribute the efficient landfill sites by leaching processes. Such gaseous and solid The European WEEE Directive aims at WEEE recycling, to landfill sites by leaching processes. Such gaseous and solid The European WEEE Directive aims at WEEE recycling, to waste are hazardous for devices human such beings and for and the reduce the disposal waste and “to contributesecondary to the efficient As man-made as electrical environment. use of resources andof the retrieval of valuable raw waste hazardous for human beings and for the reduce the of waste and “to contribute to the efficient waste are areequipment, hazardous for devices humanandsuch beings and lamps for and the reduce the disposal disposal ofthe waste and “to contribute tothat the have efficient As man-made as electrical environment. use of resources and retrieval of valuable secondary raw electronic accumulators fluorescent are WEEE represents a source of metals, materials”. As man-made devices such as electrical and environment. use of resources and the retrieval of valuable secondary raw As man-made devices such as electrical and environment. use of resources and the retrieval of valuable secondary raw electronic equipment, accumulators and fluorescent lamps are WEEE represents a source of metals, that have materials”. rich in valuable metalsaccumulators (e.g., Au, Ag,and Cu,fluorescent Zn, Co, Y), WEEE been minedWEEE from ore minerals, where they are often present electronic equipment, lamps are represents aa source of that have materials”. electronic equipment, lamps are WEEE represents source of metals, metals, thatpresent have materials”. rich in valuable metalsaccumulators (e.g., Au, Ag,and Cu,fluorescent Zn, Co, Y), WEEE been mined from ore minerals, where they are often at low concentrations (Rocchetti,L et.al., 2013) rich in valuable metals (e.g., Au, Ag, Cu, Zn, Co, Y), WEEE been mined from ore minerals, where they are often present rich in valuable metals (e.g., Au, Ag, Cu, Zn, Co, Y), WEEE been from ore minerals, where they2013) are often present at lowmined concentrations (Rocchetti,L et.al., at at low low concentrations concentrations (Rocchetti,L (Rocchetti,L et.al., et.al., 2013) 2013)
Copyright © IFAC 2015 157 2405-8963 © IFAC (International Federation of Automatic Control) Copyright © 2015, IFAC 2015 157Hosting by Elsevier Ltd. All rights reserved. Copyright IFAC 2015 157 Peer review© of International Federation of Automatic Copyright ©under IFAC responsibility 2015 157Control. 10.1016/j.ifacol.2015.12.075
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recycling for the production of secondary materials needs to be encouraged.
of the processes implemented with this portable plant, by means of life cycle assessment (LCA) and according to selected environmental impact categories. The unit operations that have a high load on the environment were also identified in each of these processes, and primary production processes were considered as reference. (Rocchetti,L et.al., 2013).
These are then included at higher concentrations as the pure metals or metallic alloys in electrical and electronic equipment. For example, the amount of Au in a printed circuit board (PCB) is an order of magnitude higher than in the mineral ore from which it is mined. Considering the increasing demand of technological equipment in the industrialized and developing countries, it is a priority and real necessity to recycle metals, rather than to mine them (Rocchetti,L et.al., 2013).
This innovative approach applied in the field of WEEE residue recycling covers the final step of the recycling processes, which deals with the dangerous fractions (fluorescent powders are classified as hazardous waste by the European Waste Directive) that are rich in metals. In Europe at present, these fractions are mainly either disposed of in landfill sites or treated in large pyrometallurgical plants. It is very important at this stage of the worldwide state of the art in WEEE residue recycling to determine whether the proposed strategy is the correct way to proceed in this extremely critical field of recycling and secondary raw materials production. (Rocchetti,L et.al., 2013) Until now Recycling was the most common method for EoL. Approximately 20 years ago the research in Reuse started with (semi- automatic) disassembly mostly for electr(on)ic devices (Duta,L.et.al; 2011;), automation devices were included 6 – 8 years ago.
2. THE HYDROWEEE PROJECT According to a study as a part of the research project called HydroWEEE (Innovative Hydrometallurgical Process to recover Metals from WEEE including lamps and batteries), which was funded by the European Commission within the FP7 Capacities Work Program. The aim of the project was the recovery of base and precious metals from WEEE residues. Within the HydroWEEE project, different processes for the exploitation of WEEE residues were developed to extract high-purity metals. In the previous research project a mobile pilot plant with a reactor size of 1 m³ has been developed that has been and still can be used for process development and optimization. However in order to really demonstrate the stability, financial credibility and resource-efficiency of our innovative processes an industrial stationary plant as well as a full-scale mobile plant (2-3m³ reactor) have to be built. Finally the previously developed processes of extracting yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin will be improved even more and new processes to recover additional metals which are still in this fractions (e.g. Cerium, Platinum, Palladium, Europium, Lanthanum, Terbium, …) from WEEE or other sectors (e.g. automotive, …) as well as innovative solutions for the integrated treatment of waste water as well as solid wastes will be developed. The objective of the currently running follow-up FP7-Environment project HydroWEEE Demo (2012-2016) is to build 2 industrial scale, real-life demonstration plants (one stationary and one mobile) in order to test the performance and prove the viability of the processes from an integrated point of view (technical, economical, operational, social) including the assessment of its risks (including health) and benefits to the society and the environment as well as remove the barriers for a wide market uptake later on. These used the WEEE residues for the recovery of Y from fluorescent lamps; Y and Zn from CRTs; Li and Co from Liion accumulators; and Cu, Ag, and Au from PCBs. The advantages and novelty of this portable plant include its costeffectiveness and the use of innovative processes that can be applied anywhere where the plant is based. This last arises from the portable nature of this plant, which allows small enterprises without their own recycling plant, along with the many collection facilities that can now be found in most countries, to take advantage of its trans-portability. The aim of the present study was to assess the environmental impact
3 DISASSEMBLY Usually the hydrometallurgical recovery process is very time consuming and therefore the recovery rate currently relatively low. In addition there are reusable parts on PCB`s which have a reasonable high value on the market. For these must be decided selling or recovery. One possibility is the use of robotized, semi-automated, flexible disassembly cells for printed circuit boards (PCB`s) for minimising the amount of scrap for recovering rare materials. The cell is based on modular disassembly cells developed some years ago for removing re-useable electronic components from old as well as new PCB’s. and consists of a transportation system, a vision system and heating-desoldering stations. Feeding and removing of the cell is done manually.( P.Kopacek and B. Kopacek, 2014). Economic disassembly is only possible today by modularity of the disassembly cells. The main innovative features of such cells will be: Ability to disassemble different products with only few software modifications of the system, low investment costs, step-by-step investments because of the modularity, the predominant working conditions (toxic vapours…) could be changed efficiently by the system. Because of the modularity it is easily possible to build up disassembly cells for different product groups. The disassembly process can be divided in several steps which are performed successively. At the beginning the printed circuit boards (PCB’s) are dismantled from collected electrical and electronic equipment manually. Today automation of this process is not very efficient because today and in the next years this is and will be done by social projects with reasonable low costs. But in the future we have
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to think during the design process on automated assembly and disassembly – assembly and disassembly oriented design.
159
The kernel of these stations is a temperature controlled heating device with a very high power. The main problem is the limited space, approximately 270 x 200mm, because the heating device has to fit in the work piece carrier. Until now not more than 3kW are available on the market. This yields to relatively long heating time and therefore more than one station is necessary. The control of these stations get the command variables – position, size, de-soldering temperature, temperature limits,… - from the vision system via the host computer. A suction gripper or a parallel gripper picks up the parts during the heating process. The interesting parts are then removed and stored. From the viewpoint of control engineering this thermal system is very complex because it is nonlinear, time-varying with distributed parameters, dead time and direction dependent dynamics (dynamic nonlinearity). Nevertheless, according to our previous works and experiences for the control a quasi-continuous PI (three level step) controller can be used with some tricks. First of all the parts on a PCB are divided in 4 groups: 1. For reuse and material recovery
As pointed out earlier „stiff“ automatized disassembly in single purpose cells – only for one product – cannot be economically operated today. The number of devices or parts to be collected and concentrated on the place of the disassembly cell is usually to low for a two shift working of the cell. For example in the case of computer-keyboards of a distinct type, all keyboards disposed all over Europe per year could be disassembled in three month by this fully automatized cell. Therefore the idea of a “mobile recycler” comes up. .( P.Kopacek and B. Kopacek, 2014). 4 DISASSEMBLY CELL The main parts of such PCB disassembly cells are: Special gripping devices for a broad spectrum of parts with different geometries and dimensions; Disassembly tools; Transport systems – similar as for assembly cells; Fixture systems for parts with different geometries and dimensions; Intelligent control units able to process information from external sensors; Electronic component database including data of reusable and re-manufacturable parts; a “Cost oriented” vision systems for component recognition; Various sensors for force and moment limitations, position, distance; Storage systems for tools and parts. For the development of a modular, flexible disassembly cell some of the modules are available from assembly cells, but not for the following cell components: extremely flexible and modular gripping devices for disassembly; possible implementation of methods of artificial intelligence in the cell control with a minimum of software costs and computing time; interfaces for the integration of a vision system in such cells, adding visual identification and physical measurement methods.
2.
For reuse only
3.
For material recovery only
4.
Neither for reuse nor for material recovery ( remaining parts).
There are two possibilities: a) Removal of the parts without destruction - for material recovery and reuse. b) Removal of the parts with destruction – only for material recovery. Because the value of reusable parts is higher than for material recovery for the parts in group 1. and 2 possibility a) is necessary. For parts of group 3. possibility b) is enough. For possibility a) a constant temperature over the area of the PCB would be necessary. For b) no temperature control is necessary.
Based on former research (Kopacek P. and Kopacek, B.; 2007) a semi-automated, flexible, single purpose disassembly cell for printed circuit boards (PCB`s) for minimising the amount of scrap and mainly for recovering rare materials ( e.g Yttrium, Indium, Lithium, Cobalt, Zinc, Copper, Gold, Silver, Nickel, Lead, Tin ) as well as for removing of reusable components is described. The cell is based on modular disassembly cells developed some years ago for removing re-useable electronic components from old as well as new PCB’s.
According to our experiences with similar disassembly cells in the past this cannot be realised with the currently available heating possibilities. The main reason is the heat transfer from the PCB to the work piece carriers. Figs.1 shows the temperature profiles at the end of heating.
The new, semi – automated, disassembly cell consists of a transportation system, a vision system and heating-desoldering stations. Feeding and removing of the cell is done manually in an additional station.
Therefore we arranged the interesting components for unsoldering in 4 groups (Tab.1). In this table TG is the maximum chip temperature for avoiding destroying and TL is the necessary unsoldering temperature. The last depends from chemical composition of the sold, the age of the PCB,……. The chips in group A represent the best case, for group B and C an accurate temperature control is necessary and group D can only be used for material recovery. .( P.Kopacek and B. Kopacek, 2014).
The interesting parts for rare material recovery and reuse like chips, transistors, condensers, inductors, .....are disassembled in heating-removal stations. These parts require de-soldering temperatures (TL) between 110 and 380centigrades. Unfortunately the destruction temperature (TG) of some of the parts indicated above is between 70 and 380centigrades. 159
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Tab. 1 Groups of components
Tab. 2 Sequence for optimal removing
Group
Temperature
Part Area [°C]
Rank
A
TG >> TL
a
C
105
8
B
TG > TL
b
C
105
7
C
TG ≈ TL
c
H
105
2
D
TG < TL
d
H
105
3
e
C
235
12
f
H
225
9
g
V/H 225
5
h
V/H 105
1
i
H/C 105
4
j
H/C 225
6
k
C
225
10
l
C
225
11
5 SUMMARY AND OUTLOOK Fig.1 Temperature profile after 120 sec.
After an introduction dealing with rare materials and extraction an overview on disassembly and semi-automated disassembly cells based on previous works of the authors, is given. In the main part first ideas for such, single purpose, disassembly cells are discussed. Some of the necessary modules are described in detail. The parts, like chips, transistors, condensers, inductors, ....., are divided in four groups namely: for reuse and material recovery, for reuse only, for material recovery only and neither for reuse nor for material recovery ( remaining parts). Then for removal two possibilities - removal of the parts without destruction - for material recovery and reuse and removal of the parts with destruction – only for material recovery are defined. The second possibility is very easy to realise because the parts can be overheated.
According to the temperature profile in Fig. 1 the PCB is divided in 4 areas (Fig. 2). 1.
Very hot (V/H)
2.
Hot (H)
3.
Hot/Cool (H/C)
4.
Cool (C)
By means of Fuzzy logic a sequence for optimal removing of the parts can be generated. One example is illustrated in Fig. 2 and in Tab.2.
REFERENCES Duta, L., I. Caciula, S. Addouche (2011): On the Profitability of the Disassembly Processes, In: Proceedings of the 18th World Congress of the International Federation of Automatic Control, Milan, Italy, 2011, p. 4845-4850. P. Kopacek and B. Kopacek (2007): “Intelligent Assembly and Disassembly” in Proceedings of the IFAC Workshop on Intelligent Assembly and Disassembly IAD'07 and IFAC Workshop on Intelligent Manufacturing Systems IMS'07, Alicante, Spain; 23.05.2007 - 26.05.2007; (2007), p. 23 - 24. Fig 2. Components on areas 160
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Kopacek, P. and B. Kopacek (2012): End of Life management of Automation Devices, Proceedings of the 14th IFAC Symposium on “Information Control Problems in Manufacturing – INCOM 2012”, Bucharest, Romania, 2012, p. 534-539, Elsevier 2012. DOI 10.3182/20120523-3-RO-2023.00264. Kopacek, P. and B. Kopacek (2014): Automated disassembly of components from Printed Circuit Boards. Proceedings of Going Green – CARE INNOVATION 2014, Vienna, November 17-20. Rocchetti,L., F. Vegliò, B. Kopacek, F. Beolchini (2013): Environmental Impact Assessment of Hydrometallurgical Processes for Metal Recovery from WEEE Residues Using a Portable Prototype Plant. | Environmental Science & Technology 47(2013), p.1581−1588; dx.doi.org/10.1021/es302192t. ACKNOWLEDGEMENT The research leading to these results has received funding from the European Community’s Seventh Framework Program (FP7/2007-2013) under grant agreements 231962 (HydroWEEE) and 308549 (HydroWEEE Demo).
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48-24 (2015) 157–161 ExtractingIFAC-PapersOnLine rare materials from electr(on)ic scrap Extracting rare materials from electr(on)ic scrap Extracting Extracting rare rare materials materials from from electr(on)ic electr(on)ic scrap scrap
B. Kopacek* and P. Kopacek** B. Kopacek* and P. Kopacek** B. and P. B. Kopacek* Kopacek* and and P. Kopacek** Kopacek** *Austrian Society for Systems Engineering Automation (SAT), Gurkgasse 43/2, *Austrian Society for Systems Engineering and Automation (SAT), Gurkgasse 43/2, 1140 Vienna, Austria e-mail : [email protected] *Austrian Society for Engineering and Automation (SAT), Gurkgasse *Austrian Society forofSystems Systems Engineering and Automation (SAT), Gurkgasse 43/2, 43/2, 1140 Vienna, Austria e-mail : [email protected] **Vienna University Technology, Institute for Mechanics and Mechatronics, IHRT 1140 Vienna, Vienna, Austria Austria e-mail e-mail :: [email protected] [email protected] 1140 **Vienna University of Technology, Institute for Mechanics and Mechatronics, IHRT Favoritenstrasse 9-11/E325 A6, A – 1040 Wien.(e-mail:[email protected]) **Vienna University of Institute for **Vienna University of Technology, Technology, for Mechanics Mechanics and and Mechatronics, Mechatronics, IHRT IHRT Favoritenstrasse 9-11/E325 A6, A –Institute 1040 Wien.(e-mail:[email protected]) Favoritenstrasse 9-11/E325 A6, A – 1040 Wien.(e-mail:[email protected]) Favoritenstrasse 9-11/E325 A6, A – 1040 Wien.(e-mail:[email protected]) Abstract: As the price for natural resources will increase in the future the goal of this paper is that Abstract:resources As the price for materials natural resources will increaseand in not thebe future the In goal of the thisRaw paper is that valuable like rare have to be extracted wasted. 2010 Materials Abstract: As price for natural will increase in the future the goal of this paper is Abstract:resources Asthethe the price forCommission natural resources resources will increaseand in not thebe future the In goal of the this paper is that that valuable like rare materials have to be extracted wasted. 2010 Raw Materials Initiative of European defined 14 critical raw materials, most of rare metals (including valuable resources like rare materials have to be extracted and not be wasted. In 2010 the Raw Materials valuable resources like rare materials have to be extracted and not be wasted. In 2010 the Raw Materials Initiative of the European Commission defined 14 critical raw materials, most of rare metals (including rare earthsofoxide) which are used for electr(on)ic devices belong to this category. The idea is (including to recover Initiative the Commission defined 14 critical raw materials, most rare metals Initiative of the European European Commission defined 14devices critical raw materials, most of of by rarehydrometallurgical metals rare earths oxide) which are used WEEE for electr(on)ic belong to this batteries category. The idea is (including to recover rare and precious metals from including lamps and spent rare earths oxide) which are used for electr(on)ic devices belong to this category. The idea is to earths oxide) which are used for electr(on)ic devices belong to this category. The idea is to recover recover rare and precious metals from WEEE including lamps and spent batteries by hydrometallurgical processes. Furthermore to develop a mobile plant using hydrometallurgical processes to extract metals rare and and precious precious metals from WEEE WEEE including lamps and spent spent batteries batteries by hydrometallurgical hydrometallurgical rare metals from including lamps and by processes. Furthermore to develop a mobile plant using hydrometallurgical processes to extract metals like yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin in a high purity (above processes. Furthermore to develop aa mobile plant using hydrometallurgical processes to metals processes. Furthermore to the develop mobile plant using hydrometallurgical processes to extract extract metals like yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin intransportation a high puritycosts, (above 95%) from scrap. Because amount of scrap in industry is usually and to avoid in like yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin aa high (above like framework yttrium, indium, lithium, cobalt, copper, gold, silver, nickel, lead, tin in intransportation high purity purity (above 95%) from scrap. Because theprojects amountzinc, of scrap in industry is usually and to avoid costs, in the of two EU (HydroWEEE) a mobile and a stationary recycling plant is in 95%) from Because the amount of in is and to transportation costs, in 95%)framework from scrap. scrap. amount ofisscrap scrap in industry industry is usually usually and to avoid avoid transportation costs, the ofBecause twogoal EUthe projects (HydroWEEE) a tomobile and a stationary recycling plant is in development. Another of this paper to contribute reduce the amount of material for the recovery the framework of two EU projects (HydroWEEE) a mobile and a stationary recycling plant is in the framework of twogoal EU (HydroWEEE) a tomobile and a stationary recycling plant is in development. ofprojects this parts paper is printed to contribute reduce(PCB`s) the amount material for the recovery process and toAnother recognize reusable on circuit boards in anof economic way. Therefore development. Another goal of this paper is to contribute to reduce the amount of material for the recovery development. Another goal of this paper is to contribute to reduce the amount of material for the recovery process and to recognize reusable parts on printed circuit boards (PCB`s) in an economic way. Therefore aprocess semi-automated disassembly cellparts will be shortly described. and reusable on printed circuit and to to recognize recognize reusable on shortly printeddescribed. circuit boards boards (PCB`s) (PCB`s) in in an an economic economic way. way. Therefore Therefore aprocess semi-automated disassembly cellparts will be aKeywords: semi-automated disassembly cell will be shortly described. © 2015, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. a semi-automated cell will be materials, shortly described. End of disassembly Life Management, rare semi-automated disassembly. Keywords: End of Life Management, rare materials, semi-automated disassembly. Keywords: Keywords: End End of of Life Life Management, Management, rare rare materials, materials, semi-automated semi-automated disassembly. disassembly. 1. INTRODUCTION This European Directive “Waste from Electric and Electronic 1. INTRODUCTION This European Directive from Electricfor and8,3 Electronic INTRODUCTION – WEEE” “Waste were responsible to 9,1 Rapid changes of 1. consumer demands have affected that Equipment 1. INTRODUCTION This European European Directive Directive “Waste from Electric Electric and and Electronic Electronic This “Waste from Equipment –of waste WEEE” were responsible for 8,3so tocalled 9,1 Rapid changes oftheconsumer demands have affected that million tons within the EU in 2005. This WEEE represents fastest growing waste stream in the EU Equipment – WEEE” were responsible for 8,3 to 9,1 Rapid changes of consumer demands have affected that million Equipment –of waste WEEE” were for 8,3so tocalled 9,1 Rapid changes ofthe consumer demands have affected tons within the responsible EU by in 2005. This WEEE represents fastest growing waste stream in the that EU WEEE Directive was implemented the EC in order to with between 3 and 5 % per year, which means that it doubles million tons of waste within the EU in 2005. This so called WEEE represents the fastest growing waste stream in the EU million tons of waste within the EU in 2005. This so called WEEE represents the fastest growing waste stream in the EU WEEE Directive was implemented by the EC inend-of-life order to with between 3years. and 5 In % per year, which means that it doubles ensure an environmental friendly treatment of every 12-15 average every three years the IT WEEE Directive was by the in order with 3 and % year, which means that it WEEE Directive was implemented implemented by the EC EC order to to with between between 3years. and 55 In % per per year, growing which that it doubles doubles ensure an environmental friendly treatment of inend-of-life every 12-15 average every means three years theThe IT electrical and electronic equipment. Waste from Electrical equipment is exchanged by rapid turnover rates. ensure an environmental friendly treatment of end-of-life every 12-15 years. In average every three years the IT ensure an environmental friendly treatment of end-of-life every 12-15 years. In average every three years the IT electrical and electronic equipment. Waste from Electrical equipment is exchanged by rapid growing turnover rates. The and Electronic Equipmentequipment. (WEEE) isWaste the fastest growing life cycle isofexchanged Automation and growing IT devices is decreasing and from Electrical equipment by rapid turnover rates. The electrical and electronic electronic equipment. from Electrical equipment by rapid growing turnover rates. The electrical and Electronic Equipment (WEEE) isWaste the fastest growing life cycle isofexchanged Automation and IT devices is and decreasing waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster faster. and Electronic Equipment (WEEE) is the fastest growing life cycle of Automation and IT devices is decreasing and Electronic Equipment (WEEE) is the fastest growing life cycle of Automation and IT devices is decreasing waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster and faster. from 20-50 million cubic meters e-waste. About 5% of the Obsolete equipment ends up as e-waste which leads more and waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster and faster. waste stream in Europe. Worldwide figures are ranging continuously, products are exchanged faster and faster. from 20-50 million cubic meters e-waste. About 5% of the Obsolete equipment ends up as e-waste which leads more and total waste stream can be derived from End of Life of more to a global problem: With its complex composition of from 20-50 20-50 million million cubic cubic meters meters e-waste. e-waste. About About 5% 5% of of the the Obsolete equipment ends as which leads from Obsolete ends up upand as e-waste e-waste which substances, leads more more and and total waste stream can Automation be derived fromITEnd of Life of more to aequipment global problem: With its complex composition of Electr(on)ics including and devices. In the materials, components hazardous it total stream can be derived from of Life of more to problem: With its complex composition of total waste wasteUnion stream canmore be than derived fromITEnd End of electrical Life of more to aa global global problem: and With hazardous its complex composition of including Automation and devices. In the materials, components substances, it Electr(on)ics European alone 17 million tons of constitutes a considerable threat to the environment. About Electr(on)ics including Automation and IT devices. In the materials, components and hazardous substances, it Electr(on)ics including Automation and IT devices. In the materials, components and hazardous substances, it European Union will alonebecome more than 17 million tons of electrical constitutes considerable threat tois the environment. About electronics obsolete this year. Predictions 70% of the aaheavy metal in landfill directly coming from e- and European Union alone more than 17 tons of electrical constitutes considerable threat environment. About European Union alone more than 17 million million tonswhich of electrical constitutes considerable threat to tois the the environment. About and electronics will become obsolete this2020, year. Predictions 70% of the aheavy metal in landfill directly coming from e- forecast a growth to 12,3 million tons till means waste. and electronics will become obsolete this year. Predictions 70% of the heavy metal in landfill is directly coming from eandexpected electronics will become obsolete this year. Predictions 70% of the heavy metal in landfill is directly coming from e- an forecast a growth to 12,3 million tons till 2020, which means waste. growth rate of around 40-50% forecast aa growth to 12,3 million tons till 2020, which means waste. forecast growth to 12,3 million tons till 2020, which means waste. an expected growth rate of around 40-50% Electr(on)ic products like automation and IT hardware an expected growth rate of around 40-50% an expected growth rate of around 40-50% Electr(on)ic products like automation and IT hardware The final disposal of electrical and electronic devices is an consist of a products high amount of diverse metals. According Electr(on)ic like automation and IT hardware Electr(on)ic like automation anda metal IT According hardware The final disposal of electrical andDisposal electronic is an consist of surveys a products high e.g. amount of phones diversehave metals. anddevices incineration issue of current worldwide concern. to several mobile content The final final disposal of electrical electrical and electronic electronic devices is an an consist of aa high amount of diverse metals. According The disposal of and is consist of high e.g. amount of phones diverse metals. According Disposal anddevices incineration issue of current worldwide concern. to several surveys mobile have a metal content can pose threats to the whole environment, from the of 25% (accumulator and recharger not included), mainly Disposal and incineration issue of current worldwide concern. to several several surveys surveys e.g. e.g. mobile mobile phones phones have have aa metal metal content content Disposal and incineration issue of current worldwide concern. to can pose threats the whole environment, from the of 25% (Cu), (accumulator andnickel recharger included), mainly atmospheric to theto and terrestrial compartments. copper iron (Fe), (Ni), not silver (Ag) and zinc can pose threats toaquatic the whole environment, from the of 25% (accumulator and recharger not included), mainly can posegases threats theduring whole environment, from(e.g., the of 25%Though (accumulator andnickel recharger included), mainly atmospheric to produced thetoaquatic and thermal terrestrial compartments. copper (Cu), iron (Fe), (Ni), not silver (Ag) and zinc Indeed, treatments (Zn). the absolute amounts of each device atmospheric to the aquatic and terrestrial compartments. copper (Cu), iron (Fe), nickel (Ni), silver (Ag) and zinc atmospheric to the aquatic and terrestrial compartments. copper (Cu), iron (Fe), nickel (Ni), silver (Ag) and zinc Indeed, gases produced during thermal treatments (e.g., (Zn). Though thevaluable absolute amounts of (16 eachgCu, device dioxins, furans,produced polybrominated organic treatments pollutants, (e.g., and regarding the most elements are low 0.35 Indeed, gases during (Zn). Though the absolute amounts of each device Indeed, gases produced during thermal thermal treatments (e.g., (Zn). Though thevaluable absolute amounts of g(16 each device dioxins, furans, polybrominated organic pollutants, and the gmost elements are low gCu, 0.35 polycyclic aromatic hydrocarbons) can be released into the gregarding Ag, 0.0034 Au, 0.015 g Pd, and 0.00034 Pt) this adds dioxins, furans, polybrominated organic pollutants, and regarding the most valuable elements are low (16 gCu, 0.35 dioxins, furans, polybrominated organic pollutants, and regarding the most valuable elements are low (16 gCu, 0.35 polycyclic aromatic hydrocarbons) can be released into the g Ag, 0.0034 g Au, 0.015 g Pd, and 0.00034 g Pt) this adds environment if adequate flue gas cleaning systems are not up to e.g. 0.35 of platinum based on estimated 1 billion polycyclic aromatic hydrocarbons) can be released into the g Ag, 0.0034 g Au, 0.015 gg Pd, and 0.00034 gg Pt) this adds polycyclic aromatic hydrocarbons) can be released into the g Ag, 0.0034 g Au, 0.015 Pd, and 0.00034 Pt) this adds environment if adequate flue gas cleaning systems are not up to e.g. 0.35 of platinum based on estimated 1 billion 2Similarly metals can be released from waste implemented. of cell phones in 2010. environment if adequate flue gas cleaning systems are not up to e.g. 0.35 of platinum based on estimated 1 billion environment adequatemetals flue gas systems not up to e.g. 0.35 in of 2010. platinum based on estimated 1 billion 2if Similarly cancleaning be released fromare waste implemented. of cell phones electrical and electronic equipment (WEEE) disposed of in Similarly metals metals can can be be released released from from waste waste implemented.22Similarly of cell phones in implemented. of phonesWEEE in 2010. 2010. electrical andbyelectronic equipment (WEEE) disposed of in landfill sites leaching processes. Such gaseous and solid Thecell European Directive aims at WEEE recycling, to electrical and electronic equipment (WEEE) disposed of in electrical andhazardous equipment (WEEE) disposed of in landfill sites byelectronic leachingfor processes. Such gaseous and solid The European WEEE Directive aims at WEEE to recycling, to waste are human beings and for the reduce the disposal of waste and “to contribute the efficient landfill sites by leaching processes. Such gaseous and solid The European WEEE Directive aims at WEEE recycling, to landfill sites by leaching processes. Such gaseous and solid The European WEEE Directive aims at WEEE recycling, to waste are hazardous for devices human such beings and for and the reduce the disposal waste and “to contributesecondary to the efficient As man-made as electrical environment. use of resources andof the retrieval of valuable raw waste hazardous for human beings and for the reduce the of waste and “to contribute to the efficient waste are areequipment, hazardous for devices humanandsuch beings and lamps for and the reduce the disposal disposal ofthe waste and “to contribute tothat the have efficient As man-made as electrical environment. use of resources and retrieval of valuable secondary raw electronic accumulators fluorescent are WEEE represents a source of metals, materials”. As man-made devices such as electrical and environment. use of resources and the retrieval of valuable secondary raw As man-made devices such as electrical and environment. use of resources and the retrieval of valuable secondary raw electronic equipment, accumulators and fluorescent lamps are WEEE represents a source of metals, that have materials”. rich in valuable metalsaccumulators (e.g., Au, Ag,and Cu,fluorescent Zn, Co, Y), WEEE been minedWEEE from ore minerals, where they are often present electronic equipment, lamps are represents aa source of that have materials”. electronic equipment, lamps are WEEE represents source of metals, metals, thatpresent have materials”. rich in valuable metalsaccumulators (e.g., Au, Ag,and Cu,fluorescent Zn, Co, Y), WEEE been mined from ore minerals, where they are often at low concentrations (Rocchetti,L et.al., 2013) rich in valuable metals (e.g., Au, Ag, Cu, Zn, Co, Y), WEEE been mined from ore minerals, where they are often present rich in valuable metals (e.g., Au, Ag, Cu, Zn, Co, Y), WEEE been from ore minerals, where they2013) are often present at lowmined concentrations (Rocchetti,L et.al., at at low low concentrations concentrations (Rocchetti,L (Rocchetti,L et.al., et.al., 2013) 2013)
Copyright © IFAC 2015 157 2405-8963 © IFAC (International Federation of Automatic Control) Copyright © 2015, IFAC 2015 157Hosting by Elsevier Ltd. All rights reserved. Copyright IFAC 2015 157 Peer review© of International Federation of Automatic Copyright ©under IFAC responsibility 2015 157Control. 10.1016/j.ifacol.2015.12.075
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recycling for the production of secondary materials needs to be encouraged.
of the processes implemented with this portable plant, by means of life cycle assessment (LCA) and according to selected environmental impact categories. The unit operations that have a high load on the environment were also identified in each of these processes, and primary production processes were considered as reference. (Rocchetti,L et.al., 2013).
These are then included at higher concentrations as the pure metals or metallic alloys in electrical and electronic equipment. For example, the amount of Au in a printed circuit board (PCB) is an order of magnitude higher than in the mineral ore from which it is mined. Considering the increasing demand of technological equipment in the industrialized and developing countries, it is a priority and real necessity to recycle metals, rather than to mine them (Rocchetti,L et.al., 2013).
This innovative approach applied in the field of WEEE residue recycling covers the final step of the recycling processes, which deals with the dangerous fractions (fluorescent powders are classified as hazardous waste by the European Waste Directive) that are rich in metals. In Europe at present, these fractions are mainly either disposed of in landfill sites or treated in large pyrometallurgical plants. It is very important at this stage of the worldwide state of the art in WEEE residue recycling to determine whether the proposed strategy is the correct way to proceed in this extremely critical field of recycling and secondary raw materials production. (Rocchetti,L et.al., 2013) Until now Recycling was the most common method for EoL. Approximately 20 years ago the research in Reuse started with (semi- automatic) disassembly mostly for electr(on)ic devices (Duta,L.et.al; 2011;), automation devices were included 6 – 8 years ago.
2. THE HYDROWEEE PROJECT According to a study as a part of the research project called HydroWEEE (Innovative Hydrometallurgical Process to recover Metals from WEEE including lamps and batteries), which was funded by the European Commission within the FP7 Capacities Work Program. The aim of the project was the recovery of base and precious metals from WEEE residues. Within the HydroWEEE project, different processes for the exploitation of WEEE residues were developed to extract high-purity metals. In the previous research project a mobile pilot plant with a reactor size of 1 m³ has been developed that has been and still can be used for process development and optimization. However in order to really demonstrate the stability, financial credibility and resource-efficiency of our innovative processes an industrial stationary plant as well as a full-scale mobile plant (2-3m³ reactor) have to be built. Finally the previously developed processes of extracting yttrium, indium, lithium, cobalt, zinc, copper, gold, silver, nickel, lead, tin will be improved even more and new processes to recover additional metals which are still in this fractions (e.g. Cerium, Platinum, Palladium, Europium, Lanthanum, Terbium, …) from WEEE or other sectors (e.g. automotive, …) as well as innovative solutions for the integrated treatment of waste water as well as solid wastes will be developed. The objective of the currently running follow-up FP7-Environment project HydroWEEE Demo (2012-2016) is to build 2 industrial scale, real-life demonstration plants (one stationary and one mobile) in order to test the performance and prove the viability of the processes from an integrated point of view (technical, economical, operational, social) including the assessment of its risks (including health) and benefits to the society and the environment as well as remove the barriers for a wide market uptake later on. These used the WEEE residues for the recovery of Y from fluorescent lamps; Y and Zn from CRTs; Li and Co from Liion accumulators; and Cu, Ag, and Au from PCBs. The advantages and novelty of this portable plant include its costeffectiveness and the use of innovative processes that can be applied anywhere where the plant is based. This last arises from the portable nature of this plant, which allows small enterprises without their own recycling plant, along with the many collection facilities that can now be found in most countries, to take advantage of its trans-portability. The aim of the present study was to assess the environmental impact
3 DISASSEMBLY Usually the hydrometallurgical recovery process is very time consuming and therefore the recovery rate currently relatively low. In addition there are reusable parts on PCB`s which have a reasonable high value on the market. For these must be decided selling or recovery. One possibility is the use of robotized, semi-automated, flexible disassembly cells for printed circuit boards (PCB`s) for minimising the amount of scrap for recovering rare materials. The cell is based on modular disassembly cells developed some years ago for removing re-useable electronic components from old as well as new PCB’s. and consists of a transportation system, a vision system and heating-desoldering stations. Feeding and removing of the cell is done manually.( P.Kopacek and B. Kopacek, 2014). Economic disassembly is only possible today by modularity of the disassembly cells. The main innovative features of such cells will be: Ability to disassemble different products with only few software modifications of the system, low investment costs, step-by-step investments because of the modularity, the predominant working conditions (toxic vapours…) could be changed efficiently by the system. Because of the modularity it is easily possible to build up disassembly cells for different product groups. The disassembly process can be divided in several steps which are performed successively. At the beginning the printed circuit boards (PCB’s) are dismantled from collected electrical and electronic equipment manually. Today automation of this process is not very efficient because today and in the next years this is and will be done by social projects with reasonable low costs. But in the future we have
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to think during the design process on automated assembly and disassembly – assembly and disassembly oriented design.
159
The kernel of these stations is a temperature controlled heating device with a very high power. The main problem is the limited space, approximately 270 x 200mm, because the heating device has to fit in the work piece carrier. Until now not more than 3kW are available on the market. This yields to relatively long heating time and therefore more than one station is necessary. The control of these stations get the command variables – position, size, de-soldering temperature, temperature limits,… - from the vision system via the host computer. A suction gripper or a parallel gripper picks up the parts during the heating process. The interesting parts are then removed and stored. From the viewpoint of control engineering this thermal system is very complex because it is nonlinear, time-varying with distributed parameters, dead time and direction dependent dynamics (dynamic nonlinearity). Nevertheless, according to our previous works and experiences for the control a quasi-continuous PI (three level step) controller can be used with some tricks. First of all the parts on a PCB are divided in 4 groups: 1. For reuse and material recovery
As pointed out earlier „stiff“ automatized disassembly in single purpose cells – only for one product – cannot be economically operated today. The number of devices or parts to be collected and concentrated on the place of the disassembly cell is usually to low for a two shift working of the cell. For example in the case of computer-keyboards of a distinct type, all keyboards disposed all over Europe per year could be disassembled in three month by this fully automatized cell. Therefore the idea of a “mobile recycler” comes up. .( P.Kopacek and B. Kopacek, 2014). 4 DISASSEMBLY CELL The main parts of such PCB disassembly cells are: Special gripping devices for a broad spectrum of parts with different geometries and dimensions; Disassembly tools; Transport systems – similar as for assembly cells; Fixture systems for parts with different geometries and dimensions; Intelligent control units able to process information from external sensors; Electronic component database including data of reusable and re-manufacturable parts; a “Cost oriented” vision systems for component recognition; Various sensors for force and moment limitations, position, distance; Storage systems for tools and parts. For the development of a modular, flexible disassembly cell some of the modules are available from assembly cells, but not for the following cell components: extremely flexible and modular gripping devices for disassembly; possible implementation of methods of artificial intelligence in the cell control with a minimum of software costs and computing time; interfaces for the integration of a vision system in such cells, adding visual identification and physical measurement methods.
2.
For reuse only
3.
For material recovery only
4.
Neither for reuse nor for material recovery ( remaining parts).
There are two possibilities: a) Removal of the parts without destruction - for material recovery and reuse. b) Removal of the parts with destruction – only for material recovery. Because the value of reusable parts is higher than for material recovery for the parts in group 1. and 2 possibility a) is necessary. For parts of group 3. possibility b) is enough. For possibility a) a constant temperature over the area of the PCB would be necessary. For b) no temperature control is necessary.
Based on former research (Kopacek P. and Kopacek, B.; 2007) a semi-automated, flexible, single purpose disassembly cell for printed circuit boards (PCB`s) for minimising the amount of scrap and mainly for recovering rare materials ( e.g Yttrium, Indium, Lithium, Cobalt, Zinc, Copper, Gold, Silver, Nickel, Lead, Tin ) as well as for removing of reusable components is described. The cell is based on modular disassembly cells developed some years ago for removing re-useable electronic components from old as well as new PCB’s.
According to our experiences with similar disassembly cells in the past this cannot be realised with the currently available heating possibilities. The main reason is the heat transfer from the PCB to the work piece carriers. Figs.1 shows the temperature profiles at the end of heating.
The new, semi – automated, disassembly cell consists of a transportation system, a vision system and heating-desoldering stations. Feeding and removing of the cell is done manually in an additional station.
Therefore we arranged the interesting components for unsoldering in 4 groups (Tab.1). In this table TG is the maximum chip temperature for avoiding destroying and TL is the necessary unsoldering temperature. The last depends from chemical composition of the sold, the age of the PCB,……. The chips in group A represent the best case, for group B and C an accurate temperature control is necessary and group D can only be used for material recovery. .( P.Kopacek and B. Kopacek, 2014).
The interesting parts for rare material recovery and reuse like chips, transistors, condensers, inductors, .....are disassembled in heating-removal stations. These parts require de-soldering temperatures (TL) between 110 and 380centigrades. Unfortunately the destruction temperature (TG) of some of the parts indicated above is between 70 and 380centigrades. 159
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Tab. 1 Groups of components
Tab. 2 Sequence for optimal removing
Group
Temperature
Part Area [°C]
Rank
A
TG >> TL
a
C
105
8
B
TG > TL
b
C
105
7
C
TG ≈ TL
c
H
105
2
D
TG < TL
d
H
105
3
e
C
235
12
f
H
225
9
g
V/H 225
5
h
V/H 105
1
i
H/C 105
4
j
H/C 225
6
k
C
225
10
l
C
225
11
5 SUMMARY AND OUTLOOK Fig.1 Temperature profile after 120 sec.
After an introduction dealing with rare materials and extraction an overview on disassembly and semi-automated disassembly cells based on previous works of the authors, is given. In the main part first ideas for such, single purpose, disassembly cells are discussed. Some of the necessary modules are described in detail. The parts, like chips, transistors, condensers, inductors, ....., are divided in four groups namely: for reuse and material recovery, for reuse only, for material recovery only and neither for reuse nor for material recovery ( remaining parts). Then for removal two possibilities - removal of the parts without destruction - for material recovery and reuse and removal of the parts with destruction – only for material recovery are defined. The second possibility is very easy to realise because the parts can be overheated.
According to the temperature profile in Fig. 1 the PCB is divided in 4 areas (Fig. 2). 1.
Very hot (V/H)
2.
Hot (H)
3.
Hot/Cool (H/C)
4.
Cool (C)
By means of Fuzzy logic a sequence for optimal removing of the parts can be generated. One example is illustrated in Fig. 2 and in Tab.2.
REFERENCES Duta, L., I. Caciula, S. Addouche (2011): On the Profitability of the Disassembly Processes, In: Proceedings of the 18th World Congress of the International Federation of Automatic Control, Milan, Italy, 2011, p. 4845-4850. P. Kopacek and B. Kopacek (2007): “Intelligent Assembly and Disassembly” in Proceedings of the IFAC Workshop on Intelligent Assembly and Disassembly IAD'07 and IFAC Workshop on Intelligent Manufacturing Systems IMS'07, Alicante, Spain; 23.05.2007 - 26.05.2007; (2007), p. 23 - 24. Fig 2. Components on areas 160
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Kopacek, P. and B. Kopacek (2012): End of Life management of Automation Devices, Proceedings of the 14th IFAC Symposium on “Information Control Problems in Manufacturing – INCOM 2012”, Bucharest, Romania, 2012, p. 534-539, Elsevier 2012. DOI 10.3182/20120523-3-RO-2023.00264. Kopacek, P. and B. Kopacek (2014): Automated disassembly of components from Printed Circuit Boards. Proceedings of Going Green – CARE INNOVATION 2014, Vienna, November 17-20. Rocchetti,L., F. Vegliò, B. Kopacek, F. Beolchini (2013): Environmental Impact Assessment of Hydrometallurgical Processes for Metal Recovery from WEEE Residues Using a Portable Prototype Plant. | Environmental Science & Technology 47(2013), p.1581−1588; dx.doi.org/10.1021/es302192t. ACKNOWLEDGEMENT The research leading to these results has received funding from the European Community’s Seventh Framework Program (FP7/2007-2013) under grant agreements 231962 (HydroWEEE) and 308549 (HydroWEEE Demo).
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