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MODULE 5 - Restrictions on Use of Hazardous Substances (ROHS)

Hazardous Substances in E-Waste

1. Introduction
E-waste, or electronic waste, refers to discarded electrical and electronic equipment (EEE) such
as computers, mobile phones, televisions, refrigerators, and other electronic gadgets.
Although e-waste often contains valuable materials like gold, copper, and aluminium, it also
contains a variety of hazardous substances that pose serious environmental and health risks if
not handled properly.

2. Major Hazardous Substances in E-Waste

Category Substance Common Sources Hazards

Neurotoxic; affects
CRT monitors, solder brain development,
Heavy Metals Lead (Pb)
in PCBs, batteries kidneys, and blood
system

Damages brain and

LCD backlights, kidneys;
Mercury (Hg)
switches, thermostats bioaccumulates in food
chains

Rechargeable Ni-Cd
batteries, Carcinogenic; damages
Cadmium (Cd)
semiconductors, kidneys and bones
resistors

Corrosion protection Carcinogenic; causes

Chromium (Cr VI) coatings, metal skin and respiratory
housings problems

Causes lung disease

Motherboards,
Beryllium (Be) (berylliosis) when
connectors
inhaled

Polybrominated Flame Persistent organic

Halogenated Plastic casings, circuit
Retardants (PBDEs, pollutants; endocrine
Compounds boards, cables
PBBs) disruptors

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Category Substance Common Sources Hazards

Capacitors, Toxic; affects immune,

Polychlorinated
transformers (older reproductive, and
Biphenyls (PCBs)
devices) nervous systems

Deplete ozone layer;

Gases and Chlorofluorocarbons Refrigerators, air
contribute to global
Others (CFCs) conditioners
warming

Releases dioxins and

Cable insulation,
Polyvinyl Chloride (PVC) furans when burned;
casings
carcinogenic

Semiconductors, LCD Toxic to liver, skin, and

Arsenic (As)
panels nervous system

3. Sources of Hazardous Substances in E-Waste

1. Printed Circuit Boards (PCBs) – Contain lead solder, brominated flame retardants,
and beryllium.
2. Cathode Ray Tubes (CRTs) – High levels of lead in glass and phosphor coatings.
3. Batteries – Cadmium, lead, mercury, and lithium compounds.
4. Plastics and Casings – Contain PVC and brominated flame retardants.
5. Capacitors and Transformers – May have PCBs (in older equipment).
6. LCD and Plasma Displays – Contain mercury in backlights.
7. Refrigeration Units – Use CFCs and HCFCs as coolants.

4. Environmental Impact of Hazardous Substances

1. Soil Contamination:
Improper disposal (open dumping or landfilling) causes leaching of heavy metals into
soil, reducing fertility and entering food chains.
2. Water Pollution:
Leachate containing lead, cadmium, and mercury can contaminate groundwater and
surface water.
3. Air Pollution:
Open burning of cables and plastics releases toxic fumes (dioxins, furans) and fine
particulate matter.

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4. Global Warming and Ozone Depletion:

Release of CFCs and HCFCs from e-waste refrigeration units contributes to
greenhouse gas effects and ozone layer damage.

5. Health Impacts of Hazardous E-Waste Components

 Lead: Damages central nervous system (CNS); particularly harmful to children.
 Mercury: Affects brain and kidneys; organic mercury compounds are extremely toxic.
 Cadmium: Causes kidney failure and skeletal damage (Itai-Itai disease).
 Chromium VI: Causes DNA damage and lung cancer.
 Beryllium: Inhalation causes chronic beryllium disease.
 PBDEs/PCBs: Endocrine disruption, developmental and reproductive toxicity.
 PVC burning: Produces dioxins – among the most toxic substances known.

6. Management and Mitigation Measures

1. Safe Recycling Practices:
o Use certified e-waste recycling facilities.
o Avoid manual dismantling and open burning.
2. Substitution and Design for Environment (DfE):
o Replace lead-based solders with lead-free alternatives (e.g., tin-silver-copper).
o Use halogen-free flame retardants.
3. Proper Collection and Segregation:
o Source segregation of hazardous components before recycling.
4. Extended Producer Responsibility (EPR):
o Producers should take responsibility for end-of-life management.
5. Regulations:
o Basel Convention (1989): Controls transboundary movement of hazardous
waste.
o E-Waste Management Rules, 2022 (India): Mandates EPR and safe recycling.

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Global RoHS Compliances (RoHS Directive 84)

1. Introduction
RoHS stands for Restriction of Hazardous Substances.
It is one of the most significant environmental directives aimed at controlling hazardous
substances in electrical and electronic equipment (EEE).
The original RoHS Directive 2002/95/EC, often referred to as the RoHS Directive (EU
Directive 84) due to its relation to the European Union environmental framework
(84/500/EEC onwards), came into effect in 2003 and was implemented in 2006 across
the EU.
The main objective of RoHS is to reduce the environmental and health impact of
hazardous substances present in electrical and electronic products, particularly during
their manufacturing, recycling, and disposal phases.

2. Objectives of RoHS Directive

1. To minimize hazardous substances in electrical and electronic equipment (EEE).
2. To promote recycling and recovery of e-waste by preventing toxic contamination.
3. To ensure safer working conditions for manufacturing and recycling workers.
4. To align global standards for product safety and environmental protection.
5. To complement the WEEE Directive (Waste Electrical and Electronic Equipment
Directive) by ensuring that products entering the waste stream are free from dangerous
materials.

3. Key Features of the RoHS Directive

1. Scope:
Applies to most categories of EEE — including large household appliances, IT and
telecom equipment, consumer electronics, lighting equipment, tools, toys, and
automatic dispensers.
2. Prohibition:
Prohibits the use of specific hazardous materials above set threshold levels in EEE sold
in EU markets.
3. Manufacturer Responsibility:
Manufacturers must ensure compliance through material declaration, testing, and
documentation before selling products.
4. Compliance Proof:

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Requires CE marking on products to indicate conformity with RoHS requirements.

4. Restricted Substances under RoHS Directive

Originally, six hazardous substances were restricted under RoHS 1 (2002/95/EC).
Later, RoHS 2 (2011/65/EU) and RoHS 3 (2015/863/EU) added four more.

Maximum
Limit (by
Health/Environmental
No. Substance weight in
Hazards
homogeneous
material)

Neurotoxic,
1 Lead (Pb) 0.1%
developmental disorders

Damages brain and

2 Mercury (Hg) 0.1%
kidneys

Carcinogenic, kidney
3 Cadmium (Cd) 0.01%
damage

Hexavalent
Carcinogenic,
4 Chromium 0.1%
respiratory problems
(Cr⁶⁺)

Polybrominated
Persistent organic
5 Biphenyls 0.1%
pollutants
(PBBs)

Polybrominated
6 Diphenyl Ethers 0.1% Endocrine disruptors
(PBDEs)

Bis(2-
ethylhexyl)
7 0.1% Reproductive toxicant
phthalate
(DEHP)

Benzyl butyl
8 0.1% Hormonal interference
phthalate (BBP)

Dibutyl
9 0.1% Affects fertility
phthalate (DBP)

Diisobutyl
10 phthalate 0.1% Developmental toxicant
(DIBP)

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5. Categories of EEE Covered under RoHS

1. Large and small household appliances
2. IT and telecommunications equipment
3. Consumer electronics (e.g., TVs, radios)
4. Lighting equipment (lamps, bulbs, LEDs)
5. Electrical and electronic tools
6. Toys, leisure, and sports equipment
7. Automatic dispensers
8. Monitoring and control instruments (industrial and medical)

6. Exemptions under RoHS

Certain applications are exempted due to lack of feasible alternatives:
 Lead in high-temperature solders (>85% Pb)
 Mercury in specific medical or calibration devices
 Cadmium in photovoltaic panels
 Hexavalent chromium in certain corrosion-resistant coatings
Exemptions are reviewed periodically as technology advances.

7. Global Implementation of RoHS (RoHS-like Regulations)

The RoHS Directive originated in the European Union, but its influence is now global.
Many countries have adopted similar regulations, often referred to as “RoHS-like”
directives.

Region / Regulation Implementatio

Remarks
Country Name n Year

RoHS 1
(2002/95/EC),
RoHS 2
Europea Basis for global
(2011/65/EU), 2006–2019
n Union standard
RoHS 3
(2015/863/EU
)

China RoHS
China 2006 Similar to EU
(Management
RoHS; focuses on
Methods for

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Region / Regulation Implementatio

Remarks
Country Name n Year

the Control of labeling and

Pollution from disclosure
Electronic
Information
Products)

Emphasizes
J-MOSS product marking
Japan 2006
(Japan RoHS) and consumer
awareness

USA California State-level

(various RoHS, New 2007 onwards adoption; aligns
states) Jersey RoHS with EU limits

E-Waste
RoHS provisions
Management
under Rule 16;
India Rules, 2016 2016
restricts six
(amended
substances
2022)

Integrated under
“Act for Resource
Korea K-RoHS 2008 Recycling of
Electrical/Electroni
c Products”

Environmenta
l Protection
Singapor and Aligns closely with
2016
e Management EU RoHS 2
(RoHS)
Regulations

Turkey, Adopted to ensure

National
UAE, trade compatibility
RoHS 2015–2020
Brazil, and environmental
frameworks
Canada safety

8. RoHS Compliance Process

To ensure that products meet RoHS requirements, manufacturers and importers must:
1. Identify Restricted Substances: Review Bill of Materials (BOM) for compliance.

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2. Testing and Verification: Use X-Ray Fluorescence (XRF) and chemical analysis for
detection.
3. Documentation and Declaration: Prepare a Declaration of Conformity (DoC) and
Technical File for inspection.
4. Product Labelling: Apply CE Marking to products indicating RoHS compliance.
5. Periodic Audits: Conduct regular supplier audits and testing to ensure ongoing
compliance.

9. Relationship between RoHS and WEEE Directives

Aspect RoHS Directive WEEE Directive

Restricts hazardous Manages collection,

Focus substances in new recycling, and recovery
products of e-waste

Prevent pollution at the Manage waste after

Objective
design stage product use

Implementation Before product After product becomes

Stage manufacturing and sale waste

Depends on RoHS to
Reduces hazardous
Connection ensure safer waste
waste in WEEE stream
composition

10. Benefits of RoHS Compliance

 Reduces environmental contamination.
 Protects human health, especially workers in recycling industries.
 Promotes green design and cleaner production.
 Facilitates international trade compliance.
 Supports circular economy principles and sustainable electronics.

11. Challenges in RoHS Implementation

 High cost of material testing and certification.
 Supply chain complexity and lack of transparency.
 Technical limitations for certain components.
 Differences between national RoHS laws (EU vs China vs India).

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RoHS Compliance Requirements in India

1. Introduction
RoHS stands for Restriction of Hazardous Substances. It is an environmental regulation
designed to limit or eliminate the use of certain hazardous materials in the manufacture
of Electrical and Electronic Equipment (EEE).
In India, RoHS compliance is an integral part of the E-Waste (Management) Rules,
2016, which were notified under the Environment (Protection) Act, 1986.
These rules are aligned with the European Union’s RoHS Directive (2011/65/EU) to
ensure environmental safety and global trade compatibility.
The main purpose of RoHS in India is to reduce toxic substances in electronic products,
making them safer for human health and the environment during use, recycling, and
disposal.

2. Legislative Background
1. Environment (Protection) Act, 1986 – The parent act empowering the Central
Government to regulate environmental pollution.
2. E-Waste (Management) Rules, 2016 – These rules replaced the 2011 version and
included RoHS provisions in Rule 16.
3. Amendments in 2018 & 2022 – Strengthened compliance mechanisms, expanded
coverage, and clarified producer responsibilities.

3. Objective of RoHS Compliance in India

 To minimize the presence of hazardous substances in electronic products.
 To ensure eco-friendly design and promote “Green Electronics.”
 To reduce pollution during e-waste recycling and disposal.
 To encourage Extended Producer Responsibility (EPR) by making producers
accountable for compliance.
 To align Indian standards with international environmental norms (EU RoHS, China
RoHS, etc.).
4. Scope of Application
The RoHS provisions in India apply to Electrical and Electronic Equipment (EEE)
placed in the Indian market under Schedule I of the E-Waste Management Rules.
It includes 21 categories of products such as:

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1. Large and small household appliances

2. IT and telecommunication equipment
3. Consumer electronics (TVs, audio systems, etc.)
4. Lighting equipment
5. Electrical and electronic tools
6. Toys and sports equipment
7. Monitoring and control instruments
8. Automatic dispensers
9. Medical devices (with some exemptions)

5. RoHS Compliance Requirements for Producers

As per the E-Waste (Management) Rules, 2016 (Rule 16), every producer,
manufacturer, and importer of EEE must:
(a) Limit Use of Hazardous Substances
Ensure that new equipment does not contain restricted substances beyond the specified
limits.
(b) Declaration of Conformity
 Producers must issue a self-declaration confirming compliance with RoHS limits.
 This declaration must be submitted to the Central Pollution Control Board (CPCB).
 Labels on products must mention “Complies with the E-Waste (Management) Rules,
2016 – Restriction of Hazardous Substances”.
(c) Technical Documentation
Maintain documentation including:
 Material composition reports
 Supplier declarations
 Test reports from accredited labs
These documents serve as proof during audits or inspections by pollution control
authorities.
(d) Extended Producer Responsibility (EPR)
Producers are responsible for:
 Establishing collection centres or take-back systems.
 Ensuring environmentally sound recycling of e-waste.

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 Submitting EPR plans and targets to CPCB for approval.

(e) Record Keeping and Audits
Maintain records of products manufactured, imported, or sold.
The CPCB may conduct periodic audits or require sample testing for verification.

6. Testing and Verification of Compliance

 Testing must be done using recognized laboratories accredited by NABL (National
Accreditation Board for Testing and Calibration Laboratories).
 Analytical methods such as X-Ray Fluorescence (XRF) or Inductively Coupled Plasma
(ICP) spectroscopy are used.
 Manufacturers must provide a Material Composition Report (MCR) or Test Certificate
to CPCB.

7. Exemptions under Indian RoHS

Certain applications are temporarily exempted due to technical or economic
infeasibility:

Exemption Example Description

Lead in high-temperature solder

Used in servers, network infrastructure
alloys

Mercury in certain fluorescent lamps Until suitable alternatives are available

Limited exemption for photovoltaic

Cadmium in solar panels
applications

Hexavalent chromium in corrosion

For heavy-duty industrial use
coatings

The MoEFCC (Ministry of Environment, Forest and Climate Change) periodically

reviews and updates these exemptions.

8. Regulatory and Enforcement Agencies

Authority Role

Policy formulation and overall

MoEFCC
coordination

Central Pollution Control Board Monitoring, certification, and

(CPCB) enforcement

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Authority Role

State Pollution Control Boards

Regional implementation and inspections
(SPCBs)

Aligns product standards with RoHS

BIS (Bureau of Indian Standards)
requirements

9. Penalties for Non-Compliance

Failure to comply with RoHS norms may result in:
 Revocation of authorization or EPR registration
 Monetary penalties under the Environment (Protection) Act, 1986
 Product recall or ban on sale
 Legal prosecution for serious violations
These measures ensure accountability among manufacturers and importers.

10. Benefits of RoHS Compliance in India

1. Reduces environmental pollution and toxic e-waste.
2. Protects worker health in recycling and manufacturing sectors.
3. Encourages innovation and sustainable product design.
4. Enhances India’s export competitiveness (especially to EU and US markets).
5. Supports national initiatives like “Make in India” and “Digital India” with a green
focus.

11. Challenges in Implementation

 Lack of awareness among small-scale manufacturers.
 Limited number of accredited testing labs.
 Difficulty in verifying compliance across large supply chains.
 High cost of RoHS-compliant materials.
 Enforcement challenges in the unorganized sector.

12. Recent Developments (2022 Amendment Highlights)

 Strengthened EPR portal system for registration and tracking.

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 Mandatory online filing of Annual Returns for producers.

 Encouragement for authorized recyclers and formal sector recycling.
 Proposal to include additional hazardous substances (e.g., phthalates) in future updates.

E-Waste Recycling: E-Waste Recycling Operations

1. Introduction
E-waste recycling refers to the collection, dismantling, separation, and recovery of valuable
materials from discarded electrical and electronic equipment (EEE).
Since e-waste contains both valuable materials (like gold, copper, aluminum, plastics) and
hazardous substances (like lead, mercury, cadmium, and brominated compounds), recycling
must be done through environmentally sound and safe operations.
The main goal of e-waste recycling is to minimize waste going to landfills, recover useful
resources, and prevent environmental pollution.

2. Objectives of E-Waste Recycling Operations

 To recover valuable metals (gold, silver, copper, aluminum, etc.) for reuse.
 To reduce environmental contamination from hazardous substances.
 To conserve natural resources by substituting primary (mined) materials with secondary
(recycled) materials.
 To promote circular economy through reuse, refurbishing, and recycling.
 To create green jobs in formal recycling sectors.

3. Overview of E-Waste Recycling Process

The e-waste recycling process generally involves the following major stages:
1. Collection and Transportation
2. Storage and Sorting
3. Dismantling (Manual or Mechanical)
4. Mechanical Processing (Size Reduction & Separation)
5. Material Recovery (Metals, Plastics, Glass)
6. Refining and Smelting

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7. Treatment and Disposal of Residues

Each of these stages is discussed below in detail.

4. Stages of E-Waste Recycling Operations

4.1 Collection and Transportation
 Collection:
o E-waste is collected from households, offices, retailers, repair shops, and bulk
consumers.
o Collection centres are often operated by producers (under EPR) or authorized
recyclers.
o Example: Drop-off points, take-back systems, and e-waste bins.
 Transportation:
o Transported to authorized dismantlers or recyclers using vehicles that comply
with hazardous waste transportation norms (with labelling and manifests).

4.2 Storage and Sorting

 Collected waste is stored and sorted based on:
o Product category (computers, TVs, mobiles, etc.)
o Reusability (working vs non-working)
o Type of material (plastic, metal, PCB, etc.)
 Reusable devices may be refurbished or donated.
 Sorting helps in efficient downstream processing and maximizes material recovery.

4.3 Dismantling (Manual or Semi-Automatic)

 This is a crucial step in recycling operations.
 Workers manually dismantle devices to separate components such as:
o Printed Circuit Boards (PCBs)
o CRTs / Displays
o Cables and wiring
o Batteries
o Plastic and metal housings

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o Hard drives and processors

 Tools used: screwdrivers, cutters, de-soldering stations.
 Dismantling helps to segregate hazardous components for safe treatment.
Safety Note: Workers must use PPE (Personal Protective Equipment) like gloves, masks, and
safety glasses due to toxic dust exposure.

4.4 Mechanical Processing (Size Reduction and Separation)

After dismantling, mechanical operations are carried out to crush, shred, and separate
different materials.
1. Shredding:
o Large e-waste components are broken down into smaller pieces.
o Equipment: shredders, hammer mills, granulators.
2. Magnetic Separation:
o Used to separate ferrous metals (iron, steel) using magnets.
3. Eddy Current Separation:
o Separates non-ferrous metals like aluminium and copper from plastics.
4. Density Separation (Air or Water Table):
o Uses air or water flow to separate materials based on density differences.
5. Optical Sorting:
o Sensors detect and separate materials by colour and type (used for plastics).
These mechanical processes help in obtaining metal-rich fractions and non-metal fractions
for further refining.

4.5 Material Recovery (Metals, Plastics, Glass)

After separation, each material stream is processed to recover pure forms:
(a) Metal Recovery
 Metal-rich fractions from PCBs are sent to pyrometallurgical or hydrometallurgical
refineries.
 Commonly recovered metals: Copper, gold, silver, palladium, aluminium, tin, and
nickel.
(b) Plastic Recovery
 Plastics are cleaned, shredded, and melted for reuse in new products.

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 Non-recyclable plastics containing brominated flame retardants (BFRs) are treated

in specialized incinerators.
(c) Glass Recovery
 CRT glass and display panels are treated separately.
 Leaded glass (from CRTs) is reused in the battery or lead smelting industry.

4.6 Refining and Smelting

Metallurgical operations are used to extract precious metals and refine base metals.

Example Recovered
Method Description
Metals

High-temperature smelting of PCBs and metal

Pyrometallurgy Cu, Au, Ag, Pb
fractions

Leaching metals using chemical solutions (acid

Hydrometallurgy Au, Ag, Cu
or cyanide-based)

Electrolysis-based recovery of metals from

Electrometallurgy Cu, Ni, Zn
leachate

These processes must include pollution control units to handle fumes, dust, and residues.

4.7 Treatment and Disposal of Residuals

 Non-recyclable materials, toxic residues, and sludge are disposed of at authorized
Treatment, Storage, and Disposal Facilities (TSDFs).
 Hazardous fractions (e.g., mercury lamps, batteries) are treated using stabilization,
encapsulation, or secure landfilling methods.

5. Flow Diagram of E-Waste Recycling Process

Collection → Transportation → Sorting → Dismantling →
Mechanical Separation → Metal/Plastic Recovery → Refining → Disposal

6. Advanced and Emerging Recycling Technologies

Technology Description

Use of microorganisms to extract metals from e-waste (eco-

Bioleaching
friendly method).

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Technology Description

Cryogenic Processing Freezing materials for easy cracking and separation.

High-temperature plasma used to recover metals from complex

Plasma Arc Recycling
waste.

Automated Robotic AI/robotic systems to safely dismantle devices (used in Japan,

Dismantling EU).

These emerging technologies aim to increase recovery efficiency and reduce environmental
impact.

7. Environmental and Health Safety in Recycling Operations

 Workers must be provided with PPE, ventilation systems, and training.
 Recyclers must have:
o Dust collection units
o Effluent Treatment Plants (ETP)
o Air pollution control systems
 Proper waste handling prevents:
o Air contamination (from burning plastics)
o Water pollution (from acid leaching)
o Health risks (from heavy metal exposure)

8. Role of Authorized Recyclers in India

Under the E-Waste (Management) Rules, 2016, only CPCB-registered and authorized recyclers
can process e waste
They are responsible for:
 Ensuring safe dismantling and material recovery.

 Maintaining records and submitting annual returns to CPCB/SPCB.

 Operating within approved environmental and safety standards.
Examples: Attero Recycling (Noida), TES-AMM (Bangalore), E-Parisaraa (Bangalore).

9. Benefits of E-Waste Recycling Operations

 Reduces environmental pollution.
 Recovers valuable metals and materials.

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 Reduces demand for mining and raw material extraction.

 Generates employment in formal recycling sectors.
 Supports circular economy and sustainable development goals (SDGs).

10. Challenges in E-Waste Recycling

 Dominance of the informal sector (unregulated backyard recycling).
 Lack of public awareness and proper collection systems.
 High cost of advanced recycling technology.
 Weak enforcement of RoHS and EPR provisions.

Dismantling and Segregation in E-Waste Recycling

1. Introduction
E-waste dismantling and segregation are critical stages in the e-waste recycling process.
They form the initial steps of material recovery, where complex electronic products are taken
apart, and their components are separated into different material streams (metals, plastics, glass,
etc.) for further processing.
E-waste dismantling not only helps in recovering valuable materials but also ensures safe
handling of hazardous components, reducing environmental and human health risks.

2. Objectives of Dismantling and Segregation

1. To separate reusable, recyclable, and hazardous components from mixed e-waste.
2. To prepare e-waste for downstream recycling processes (mechanical, thermal, or
chemical recovery).
3. To maximize recovery efficiency by improving material purity.
4. To prevent contamination and enable safe disposal of toxic fractions.
5. To facilitate proper treatment of hazardous materials like lead, mercury, and cadmium.

3. Importance in the E-Waste Recycling Chain

Dismantling and segregation serve as a bridge between collection and mechanical/chemical
recycling.
They ensure that:

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 Reusable parts (like RAM, CPUs, power supplies) are recovered for refurbishing.
 Hazardous fractions (like batteries, CRTs, mercury lamps) are isolated safely.
 Material-specific streams (metals, plastics, glass) are prepared for processing.
Without proper dismantling and segregation, recycling efficiency drops and contamination risk
increases.

4. Types of Dismantling Operations

E-waste dismantling can be manual, semi-mechanical, or fully automated, depending on the
scale and technology used.

Type Description Used For

Common in small and

Manual Dismantling Hand tools used to disassemble parts
medium recyclers

Semi-Mechanical Combination of manual disassembly and

Large-scale recyclers
Dismantling machines (cutters, crushers)

Automated Robotic or AI-based systems for precision Advanced facilities (e.g.,

Dismantling dismantling Japan, EU)

5. Steps Involved in Dismantling and Segregation

Step 1: Receiving and Inspection
 E-waste received from collection centers is inspected for product type and condition.
 Devices that can be reused or refurbished are separated.
Step 2: De-pollution
 Removal of hazardous or pollutant components before mechanical processing.
These include:
o Batteries (Ni-Cd, Li-ion, lead-acid)
o Mercury-containing switches, bulbs
o Ink cartridges, toner
o Capacitors with PCBs
o CRTs (lead glass)
This step ensures safe handling and prevents toxic emissions in later stages.
Step 3: Manual Dismantling

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 Products are opened using simple hand tools like screwdrivers, pliers, and de-
soldering guns.
 Components are sorted and separated into categories such as:
o Printed Circuit Boards (PCBs)
o Plastic casings
o Cables and wiring
o Ferrous and non-ferrous metal parts
o Glass and CRT components
o Hard drives, motors, and fans
Example:
In a desktop computer:
 The metal casing → sent for metal recycling
 PCB → sent for copper and gold recovery
 Plastic → sent for granulation
 CRT monitor → sent for lead glass treatment
Step 4: Segregation of Materials
After dismantling, materials are segregated based on their composition and recyclability:

Category Examples Processing Route

Ferrous Metals Steel, iron parts Magnetic separation → metal recycling

Eddy current separation →

Non-Ferrous Metals Copper, aluminum, brass
smelting/refining

Plastics Casings, insulation Cleaning → granulation → reuse

CRT screens, LCD

Glass Lead recovery or reuse in glass industry
panels

Electronic
PCBs, chips, capacitors Precious metal recovery
Components

Batteries, mercury,
Hazardous Waste Authorized hazardous waste treatment
PCBs

Step 5: Storage and Labeling

 Each segregated material is stored separately in labeled containers.
 Hazardous components are stored in safe, ventilated, and leak-proof areas until sent
to authorized recyclers or disposal facilities.

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6. Equipment Used in Dismantling and Segregation

 Hand Tools: Screwdrivers, cutters, pliers, wrenches
 De-soldering Equipment: Hot air guns, soldering irons
 Mechanical Tools: Shredders, magnetic separators, eddy current separators
 Safety Equipment: Gloves, goggles, masks, ventilation systems

7. Safety and Environmental Considerations

During dismantling, workers are often exposed to dust, fumes, and toxic materials. Hence,
safety is critical.
Safety Measures:
 Use of PPE (gloves, goggles, masks, aprons).
 Proper ventilation and dust extraction systems.
 Avoidance of open burning or acid leaching.
 Training for workers on handling hazardous components.
 Emergency procedures for spills or injuries.
Environmental Measures:
 Maintain separate zones for hazardous and non-hazardous waste.
 Avoid contamination of soil or water through proper containment.
 Dispose of residues at authorized Treatment, Storage, and Disposal Facilities
(TSDFs).

8. Dismantling and Segregation Flow Chart

Collection → Inspection → De-pollution → Manual Dismantling →
Segregation (Metals, Plastics, Glass, Hazardous) → Storage → Recycling/Disposal

9. Role of Authorized Dismantlers in India

Under the E-Waste (Management) Rules, 2016, dismantling can only be performed by
authorized facilities approved by the CPCB (Central Pollution Control Board) or SPCB
(State Pollution Control Board).
Authorized dismantlers are responsible for:
 Safe removal of components.

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 Maintaining proper records and manifests.

 Sending recovered materials to registered recyclers only.
 Ensuring compliance with environmental standards.
Examples of Authorized Dismantlers in India:
 E-Parisaraa Pvt. Ltd. (Bangalore)
 Attero Recycling (Noida)
 TES-AMM India (Bangalore)

10. Challenges in Dismantling and Segregation

1. Informal Sector Dominance:
o Many dismantlers operate illegally without safety measures.
2. Lack of Advanced Equipment:
o Manual dismantling leads to inefficiencies.
3. Worker Health Risks:
o Exposure to lead dust, solder fumes, and broken glass.
4. Poor Segregation Practices:
o Leads to cross-contamination and lower material recovery rates.
5. Regulatory Gaps and Limited Awareness:
o Need for stricter enforcement and better training programs.

11. Advantages of Proper Dismantling and Segregation

 Increases recovery efficiency and resource value.
 Reduces pollution from improper disposal.
 Prevents health hazards to workers and environment.
 Facilitates recycling and circular economy.
 Enhances traceability and compliance under EPR (Extended Producer
Responsibility).

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E-Waste Recycling and Recovery

1. Introduction
E-waste recycling and recovery are crucial stages in the management of electronic waste, aimed
at retrieving valuable materials (like metals, plastics, and glass) and safely disposing of
hazardous substances.
E-waste is a complex mixture of valuable resources (gold, silver, copper, aluminum, and rare
earth elements) and toxic materials (lead, mercury, cadmium, and brominated flame retardants).
Through scientific recycling and recovery operations, these materials are extracted in an
environmentally safe and economically beneficial way.

2. Objectives of Recycling and Recovery

1. To recover valuable materials (metals, plastics, glass) from e-waste.
2. To minimize environmental pollution caused by improper disposal.
3. To reduce demand for virgin raw materials (mining and refining).
4. To promote circular economy by reusing recovered materials.
5. To reduce landfill burden and prevent leaching of toxic elements.

3. Difference Between Recycling and Recovery

Aspect Recycling Recovery

Process of converting waste Extraction of valuable substances (mainly

Definition materials into reusable products metals) from e-waste through physical or
or raw materials. chemical methods.

Material reprocessing (plastic,

Focus Metal recovery (copper, gold, silver, etc.).
glass, metal).

Mechanical separation, melting, Pyrometallurgical, hydrometallurgical, or

Techniques
reprocessing. biometallurgical extraction.

Reusable raw materials (plastic

Refined metals, alloys, and reusable
Output pellets, glass cullets, metal
resources.
ingots).

4. Stages of Recycling and Recovery Operations

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E-waste recycling and recovery usually follow a stepwise process after dismantling and
segregation.
Stage 1: Collection and Sorting
 E-waste is collected and sorted according to product category (computers, mobiles,
TVs, etc.) and material type.
 Segregation helps direct specific components to appropriate recovery methods.

Stage 2: Dismantling
 Devices are manually or mechanically dismantled to remove hazardous and reusable
parts:
o Batteries, CRTs, PCBs, cables, plastic casings, etc.
 Prepares waste for further mechanical or metallurgical treatment.

Stage 3: Mechanical Recycling

Involves physical size reduction and material separation.
Key Processes:
1. Shredding:
o Breaks e-waste into small pieces to expose materials.
2. Magnetic Separation:
o Extracts ferrous metals (iron, steel) using magnets.
3. Eddy Current Separation:
o Separates non-ferrous metals (aluminum, copper).
4. Density or Air Classification:
o Separates light (plastic) and heavy (metal/glass) materials.
5. Optical Sorting:
o Identifies and separates plastics by color or resin type.
Outputs:
 Metal-rich fraction → sent for metal recovery.
 Plastic fraction → sent for reprocessing.
 Glass → sent to glass recycling units.

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Stage 4: Material-Specific Recycling

(a) Plastic Recycling
 Plastics from casings, keyboards, and cables are:
o Cleaned and shredded.
o Melted and extruded into pellets.
 Non-recyclable plastics containing brominated flame retardants (BFRs) are treated
via co-processing in cement kilns or incineration with flue gas treatment.
(b) Glass Recycling
 Glass from CRTs and screens is separated:
o Panel glass (low lead) → reused in new screens or glass products.
o Funnel glass (high lead) → sent for lead recovery or safe disposal.
(c) Metal Recycling
 Basic metals (iron, copper, aluminium) are melted in furnaces and purified for reuse in
manufacturing industries.

Stage 5: Metal Recovery from Printed Circuit Boards (PCBs)

PCBs are rich in valuable and precious metals like copper, gold, silver, platinum, and
palladium.
Recovery from PCBs is the most technically intensive step in e-waste recycling.

Stage 6: Refining
 Metals recovered are refined to improve purity (e.g., electrorefining for copper and
gold).
 Recovered metals can then be used in electronics, jewelry, or industrial
manufacturing.

Stage 7: Disposal of Residual Waste

 Non-recyclable residues, sludges, and contaminated fractions are disposed of at
authorized Treatment, Storage, and Disposal Facilities (TSDFs).
 Ensures no leaching of heavy metals into soil or water.

5. Recycling and Recovery Flow Diagram

Collection → Dismantling → Mechanical Recycling →

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Material Separation → Metal Recovery → Refining → Safe Disposal

6. Technologies Used in E-Waste Recycling and Recovery

Category Examples of Technology Application

Shredders, magnetic separators, eddy current Size reduction and material

Mechanical
separators sorting

Chemical Acid leaching, cyanide process Precious metal recovery

Metal extraction and plastic

Thermal Pyrolysis, plasma arc melting
treatment

Metal extraction in eco-friendly

Biological Bioleaching using bacteria
way

7. Safety and Environmental Considerations

Recycling and recovery must be carried out in authorized, pollution-controlled facilities with
proper safety measures:
 Personal Protective Equipment (PPE) for workers.
 Effluent Treatment Plants (ETPs) for liquid waste.
 Air Pollution Control Devices (APCDs) for fumes.
 Proper ventilation and dust control systems.
 No open burning or acid leaching in the informal sector.

8. Role of Authorized Recyclers in India

Under the E-Waste (Management) Rules, 2016, recycling and recovery can be performed
only by registered recyclers authorized by the Central Pollution Control Board (CPCB).
Authorized recyclers:
 Follow environmentally sound recycling methods.
 Maintain records of input/output and submit annual returns.
 Handle hazardous residues safely.
 Work under Extended Producer Responsibility (EPR) framework.
Examples in India:
 Attero Recycling (Noida) – precious metal recovery.

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 E-Parisaraa Pvt. Ltd. (Bangalore) – mechanical recycling.

 TES-AMM India (Bangalore) – global-grade electronic recovery.

9. Benefits of Recycling and Recovery

1. Environmental Protection: Prevents soil and water contamination.
2. Resource Conservation: Recovers valuable metals and materials.
3. Energy Saving: Recycling uses less energy than mining raw materials.
4. Economic Gains: Generates income from recovered metals and plastics.
5. Employment Opportunities: Creates green jobs in the formal recycling sector.
6. Supports Circular Economy: Promotes sustainable production and consumption.

10. Challenges in Recycling and Recovery

 Dominance of the informal sector (unsafe recycling practices).
 Lack of advanced technologies and infrastructure.
 Complex material composition of modern electronics.
 High cost of chemical and metallurgical recovery.
 Regulatory enforcement gaps in developing countries.

11. Future Trends in E-Waste Recycling and Recovery

 Urban Mining: Extracting metals from discarded electronics as a secondary source.
 AI and Robotics: Automated dismantling and sorting.
 Green Chemistry: Non-toxic leaching agents for metal recovery.
 Circular Product Design: Design-for-recycling approaches by manufacturers.
 Integration of Informal Sector: Formal training and licensing programs.

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Recycling Technologies in E-Waste Management

1. Introduction
Electronic waste (e-waste) consists of discarded electrical and electronic equipment such as
computers, mobile phones, televisions, and household appliances. These items contain a wide
variety of materials, including metals, plastics, glass, and ceramics, as well as hazardous
substances like lead, mercury, and cadmium.
Recycling technologies are the methods and systems used to recover valuable materials from
e-waste while minimizing environmental pollution. These technologies can be mechanical,
chemical, thermal, or biological, depending on the nature of the material and the recovery
process.
The main goal of recycling technologies is to extract reusable materials, reduce hazardous
impacts, and promote circular economy by reintegrating recovered materials into production
chains.

2. Objectives of E-Waste Recycling Technologies

1. To recover valuable metals (Cu, Al, Fe, Au, Ag, Pd, etc.) from discarded electronics.
2. To minimize environmental pollution from hazardous components.
3. To reduce the extraction of virgin raw materials and conserve natural resources.
4. To generate employment in environmentally sound recycling sectors.
5. To support Extended Producer Responsibility (EPR) and sustainable waste
management.

3. Classification of E-Waste Recycling Technologies

E-waste recycling involves a series of technologies applied at different stages.
The main categories are:

Type of
Main Principle Examples / Applications
Technology

Mechanical / Separation of materials based on Shredding, magnetic separation,

Physical physical properties eddy current separation

Use of heat to recover metals or Pyrometallurgy, pyrolysis,

Thermal
degrade plastics incineration

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Type of
Main Principle Examples / Applications
Technology

Dissolution and recovery of metals Hydrometallurgy, electrolysis,

Chemical
through chemical reactions solvent extraction

Use of microorganisms to extract

Biological Bioleaching, biosorption
metals

4. Mechanical (Physical) Recycling Technologies

4.1. Overview
Mechanical processes involve size reduction, separation, and classification of e-waste
materials based on physical characteristics like density, magnetism, or conductivity.
These are usually pre-treatment steps before metallurgical recovery.
4.2. Steps Involved
1. Shredding
o E-waste is broken into small fragments (2–10 mm).
o Exposes metals, plastics, and ceramics for easier separation.
2. Magnetic Separation
o Uses magnets to extract ferrous metals (iron, steel).
3. Eddy Current Separation
o Separates non-ferrous metals (copper, aluminum, brass) using electromagnetic
induction.
4. Density / Air Classification
o Separates light materials (plastics) from heavier ones (metals, glass).
5. Optical / Electrostatic Separation
o Advanced methods for sorting plastics and metals based on conductivity or
color recognition.
4.3. Advantages
 Environmentally clean process (no chemicals used).
 Simple and cost-effective.
 Suitable for large-scale preliminary recycling.
4.4. Limitations
 Limited recovery efficiency for fine or composite materials.

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 Requires further metallurgical processing to extract metals.

5. Thermal Recycling Technologies

5.1. Overview
Thermal technologies use high-temperature treatments to separate or recover valuable
materials and destroy organic contaminants such as plastics and resins.
5.2. Major Thermal Techniques
(a) Pyrometallurgy
 Metals are recovered through smelting or roasting at high temperatures (up to 1200°C).
 Involves oxidation or reduction reactions to separate metals.
Example: Recovery of copper, gold, and silver from Printed Circuit Boards (PCBs).
Advantages:
 High recovery efficiency.
 Suitable for large volumes of mixed waste.
Disadvantages:
 High energy consumption.
 Emission of toxic gases (requires air pollution control).

(b) Pyrolysis
 Thermal decomposition of organic materials (plastics, resins) in absence of oxygen.
 Produces gases, oils, and solid residues containing metals.
 Helps recover metals embedded in plastic-based PCBs.
Example: Conversion of plastic waste into fuel oils.
Advantages:
 Reduces volume of waste.
 Recovers both metals and energy-rich oils.
Disadvantages:
 Requires temperature control and emission treatment.

(c) Incineration with Energy Recovery

 Controlled burning of e-waste to generate heat or electricity.

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 Residual ash contains recoverable metals.

Advantages:
 Volume reduction up to 90%.
 Can generate electricity from waste heat.
Disadvantages:
 Not suitable for all e-waste types.
 Requires flue gas cleaning systems.

6. Chemical Recycling Technologies

6.1. Overview
Chemical methods involve leaching valuable metals from e-waste using acids, bases, or
other chemical reagents, followed by precipitation, solvent extraction, or electrolysis to
recover pure metals.
6.2. Major Chemical Techniques
(a) Hydrometallurgy
 Metals are dissolved from shredded e-waste using aqueous solutions (HCl, H₂SO₄,
cyanide, thiourea, etc.).
 Followed by selective precipitation or solvent extraction.
Example:
Gold recovery using cyanide or thiourea leaching.
Advantages:
 High purity of recovered metals.
 Lower energy requirement compared to pyrometallurgy.
Disadvantages:
 Generates chemical effluents that require treatment.
 Slower and more complex than mechanical methods.

(b) Electrometallurgy (Electrolysis)

 Metal ions from leach solutions are recovered through electro-deposition on cathodes.
 Commonly used for copper, nickel, and silver recovery.
Advantages:
 Produces high-purity metals.

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 Energy efficient when used with hydrometallurgy.

Disadvantages:
 Requires purified leach solutions.
 Limited to specific metals.

(c) Solvent Extraction

 Selective extraction of metals from mixed leach solutions using organic solvents.
 Used for separation of rare earth elements (REEs).
Example: Extraction of neodymium from magnet waste.

7. Biological Recycling Technologies

7.1. Overview
Bio-recycling uses microorganisms (bacteria or fungi) to recover metals from e-waste
through bioleaching or biosorption.
7.2. Techniques
(a) Bioleaching
 Microbes like Acidithiobacillus ferrooxidans and Leptospirillum ferrooxidans oxidize
sulfide minerals and release metal ions into solution.
Metals Recovered: Copper, zinc, nickel, and gold.
Advantages:
 Eco-friendly and low energy consumption.
 No toxic chemicals required.
Disadvantages:
 Slow process (takes weeks to months).
 Requires controlled temperature and pH.

(b) Biosorption
 Microbial biomass or plant material adsorbs metal ions from waste streams.
 Suitable for trace metal recovery.

8. Emerging and Advanced Recycling Technologies

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Technology Principle / Description Application

Uses extremely high temperatures

Treatment of complex
Plasma Arc Recycling (~5000°C) to melt and vaporize e-waste,
waste streams.
leaving clean metal slag.

Supercritical Fluid Uses supercritical CO₂ or water for metal Environmentally

Extraction (SCFE) and plastic recovery. friendly extraction.

Freezing e-waste to make materials brittle Recycling of flexible

Cryogenic Separation
for easier separation. circuit boards.

AI and Robotics in Automated sorting and dismantling using Efficient and precise
Dismantling AI and sensors. material recovery.

9. Comparison of Different Recycling Technologies

Aspect Mechanical Thermal Chemical Biological

Energy Use Low High Moderate Very Low

Moderate
Pollution Risk Low High (fumes) Minimal
(effluents)

Recovery
Moderate High Very High Moderate
Efficiency

Cost Low High High Low

Initial Large-scale metal Precious Low-grade ores and eco-

Best For
processing recovery metals friendly processes

10. Environmental and Safety Considerations

 Use of air pollution control systems (APCDs) in thermal recycling.
 Effluent treatment plants (ETPs) for chemical residues.
 Personal protective equipment (PPE) for workers.
 Waste minimization and residue disposal at authorized TSDFs.
 Strict compliance with E-Waste (Management) Rules, 2016 and Amendments, 2022.

11. Challenges in Implementing Recycling Technologies

1. High investment and operational costs.

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2. Lack of advanced technology infrastructure in developing countries.

3. Presence of informal recycling sector using unsafe methods.
4. Complex composition of modern electronics.
5. Need for skilled workforce and technology transfer.

12. Future Prospects

 Development of green leaching agents (biodegradable and non-toxic).
 Integration of AI-based sorting systems.
 Growth of urban mining for precious metals.
 Increasing focus on modular and design-for-recycling electronics.
 Promotion of Public-Private Partnerships (PPP) for formal recycling units.

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