| dc.description.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. | en_US |
