Process simulator and environmental assessment of the innovative WEEE treatment process

• A novel method of characterization of components contained in WEEE has been developed.
• This technique was applied on several samples generated from different recycling plants.
• Handheld NIR and XRF were used to determine types of plastics and flame retardants.
• WEEE processing flow-sheet was suggested.

The Waste Electrical and Electronic Equipment (WEEE) is one of the fastest growing residual materials as a result of huge production of the Electrical and Electronic Equipment (EEE), its market expansion and technological progress in its conception. The complex compositions of WEEE (precious, strategic and rare elements, ferrous and non-ferrous metals, plastics, hazardous substances…) and its often miniature design lead to the technical and environmental difficulties to propose an efficient and viable flow-sheet for WEEE treatment and for the recovery process.In this context, this study deals with delivering a predictive simulation tool (simulator) for the WEEE physical treatment (size reduction and sorting) useful for coherent matter balance calculation. Calculated material flows are then available for further environmental assessment.The simulator approach is based on combining the flow-sheets, the phase model, the mathematical models and a set of algorithms to get a representation of a given situation in terms of material flows circulating between processes. Data optimization and assessment of the simulator output led to the establishment of an enhanced and innovative process for the WEEE processing.Further, this study provides a methodology to assess the impact of the implementation of a WEEE recycling technology that takes into account economic, social and environmental consequences. Results linked to the chosen examples for aluminum and ABS plastic recycling from WEEE by the established process and their use instead of virgin products showed an important profit for these recycled materials from economic and environmental points of view. In this paper, a developed REWARD process was simulated by using a tool based on the USIMPAC™ software architecture.