CEReS – Co-processing of Coal Mine & Electronic Wastes: Novel Resources for a Sustainable Future

Most coal mines produce waste which has the potential to generate acid mine drainage (AMD). If not properly managed, this can cause environmental damage through contamination of ground and surface waters and soils for hundreds of years. At the same time, the pace of technological development means that most electrical and electronic equipment becomes obsolete within a matter of years, resulting in the generation of vast quantities of electronic waste (e-waste). Where this cannot be recycled, it must be discarded. The CEReS project developed a co-processing approach for both waste streams to produce metals and other valuable products, and to reduce or eliminate the their environmental impact. This brings together two waste streams from opposite ends of the supply chain; turning each into a novel resource in a single, coherent ‘grave-to-cradle’ process. This industrial ecology approach is key to supporting a circular economy whilst securing the sustainable supply of critical raw materials. The project successfully elaborated a novel co-processing flow-sheet comprising: (i) the accelerated bioweathering of AMD-generating coal production wastes to generate a biolixiviant; (ii) the pyrolysis and catalytic cracking of low-grade PCBs to produce hydrocarbon fuel, a halogen brine and a Cu-rich char; (iii) the leaching of base metals from the char using the biolixiviant; (iv) the reuse of stabilised coal wastes; and (v) the full or partial (as enriched substrates) recovery of valuable metals. These individual process units were demonstrated individually at lab-pilot scale. The data were then used to validate the entire flow-sheet in an integrated process simulator and determine the economic balance. Finally, an LCA approach was used to demonstrate the environmental benefits of the CEReS process over the status quo.