The amount of waste electrical and electronic equipment (WEEE) in the world has grown rapidly during recent decades, and with the depletion of primary ores, there is urgent need for industries to study new sources for metals. Waste printed circuit boards (WPCB) are a part of WEEE, which have a higher concentration of copper and precious metals when compared to primary ore sources. PCB materials can be processed using pyrometallurgical routes, and some industrial processes, such as copper flash smelting, have utilized this type of waste in limited amounts for years. For the purpose of recycling these materials through smelting processes, this work studied the behavior of WPCB scrap when dropped on top of molten slag. A series of experiments was carried out during this research at a temperature of 1350 °C, in an inert atmosphere with different melting times. The time required for complete melting of the PCB pieces was 2–5 min, after which molten alloy droplets containing Cu, Pb, Sn, Ni, Au, and Ag formed and started descending toward the bottom of the crucible. The ceramic fraction of the PCB material mixed with slag and the polymer fraction was pyrolyzed during the high-temperature experiments. The results give an understanding of PCB melting behavior and their use as a part of the smelting furnace feed mixture. However, more research is needed to fully understand how the different elements affect the process as the amount of PCB in the feed increases. The physical behavior and distribution of PCB materials in fayalite slag during the smelting process are outlined, and the results of this work form a basis for future studies about the chemical reaction behavior and kinetics when PCB materials are introduced into the copper smelting process.

The extraction of cobalt from secondary resources has become crucial, as cobalt has been identified as a strategically important and critical raw material due to the high risks of supply chain disruptions. In this work, selective sulfation roasting was investigated as a potential recycling strategy to extract cobalt and lithium from an industrial lithium cobalt oxide (LCO)-rich black mass. Additionally, the effect of graphite on metal extraction was studied. In the first set of experiments, the sieved black mass fraction containing both cathode and anode materials was directly roasted in a predetermined composition of gas mixtures of SO₂, O₂, and Ar for 1 h at 850 °C. The gas composition was determined from Kellogg’s diagram to allow for the selective sulfation of Co and Li. In another set of experiments, the carbon present in the black mass was first removed by roasting the material in Ar for 2 h and then in an Ar and O₂ gas mixture for five hours at 600 °C. Afterward, selective sulfation roasting was performed in mixtures of SO₂, O₂, and Ar gas similar to the previous set of experiments. For comparison, similar experiments were performed at 800 °C. The sulfation roasted black mass was leached in water to study the efficiency of Co extraction into the solution. Interestingly, the presence of carbon was found to be beneficial for Co extraction. The extraction efficiency for the first case (with carbon present in the raw material) was observed to be more than three times higher than in the second case (with carbon removed) for sulfation at 850 °C. The extraction efficiency and purity of the extracted Co were found to be better for higher temperature sulfation roasting conditions due to faster reaction kinetics. It was also found that almost all of the Li could be recovered while extracting Co. The maximum efficiency of the extraction was 99.51% Li and 61.21% Co for roasting under a gas flow of 10% SO₂-10% O₂-Ar at 850 °C for 60 min. These results suggest that Co and Li can be selectively extracted from the black mass by sulfation roasting pre-treatment followed by leaching in water. In holistic processing, the leach residue can then be further subjected to battery metal processing by state-of-the-art methods.

Improving metal–slag separation in pyrometallurgical processes is increasingly important. Due to the harsh conditions, direct observations of the molten phases behavior in the settler of the Outotec Flash Smelting Furnace (FSF) are not possible and the ways to improve metal settling can only be studied by simulation and modeling. This study focuses on kinetics and mechanisms of the chemical reactions between matte droplets and slag, which were investigated in laboratory-scale heat-quench equipment at a typical smelting temperature of 1300°C as a function of time in both air and argon atmosphere. The reaction mechanism in the FSF settler was formulated and results in argon atmosphere also indicate that the oxidation of cuprous sulfide by ferric ions in the slag contributes strongly to the copper losses in the slag.