MONETIZATION OF ELECTRONIC INDUSTRY WASTE FOR SUITABLE CHEMICAL PRODUCTION

Abstract

This report presents the design, evaluation, and economic analysis of a 50-tonne-per-day e-waste recycling plant aimed at recovering valuable metals from electronic industry waste. The plant is developed under the project title "Monetization of Electronic Industry Waste for Sustainable Chemical Production", with a focus on sustainability, economic feasibility, and technological scalability. The proposed process flow includes multiple stages: mechanical pre-treatment (crushing, shredding, grinding), separation techniques (magnetic, eddy current, hydrocyclone), hydrometallurgical leaching using batch stirred tank reactors (BSTRs), and electro-refining via specialised electrowinning systems for copper, aluminium, nickel, zinc, and precious metals (gold, silver, palladium). Supporting units such as rotary washers, spray dryers, and furnaces enhance product purity and ensure safe handling of intermediate streams. A total of 17 major equipment categories and 300 electrowinning tanks were specified and costed using the Detailed Factorial Method, yielding a total capital expenditure (CAPEX) of approximately RM 63.9 million. Operating expenditure (OPEX), which includes labour, utilities, maintenance, and raw material cost, is estimated at RM 19.43million annually. The plant is projected to generate over RM 5.7 billion in annual revenue, driven by the recovery of high-value metals from the e-waste stream. Key performance indicators, including a theoretical payback period of less than four days, demonstrate an exceptionally high economic potential. A comprehensive plant layout was developed to ensure logical process flow, worker safety, and accessibility, while environmental and safety considerations were integrated into the design philosophy. In conclusion, the proposed recycling facility offers a highly profitable and sustainable solution for managing electronic waste. The results strongly support further development and potential scale-up, subject to pilot-scale validation and market volatility considerations.