Materials and Energy Balance of E-Waste Smelting—An Industrial Case Study in China

The application of Nerin Recycling Technologies (NRT) in electronic waste (E-waste) smelting was introduced in this study, and the material and energy balance was calculated based on the practical data with the METSIM software (METSIM International, USA). The main results are as follows: (1) the optimized processing parameters in the NRT smelting practice were the E-waste feeding rate of 5.95 t/h, oxidation smelting duration of 3.5 h, reduction smelting duration of 0.5 h, oxygen enrichment of 21–40 vol.%, oxygen consumption of 68.06 Nm3/ton raw material, slag temperature of 1280 °C, slag composition: Fe/SiO2 mass ratio of 0.8–1.4, CaO, 15–20 wt.%, Cu in crude copper ≥ 95 wt.%, Cu in slag, 0.5 wt.%, recovery of Cu, Au, and Ag ≥ 98%
(2) 98.49% Au, 98.04% Ag, 94.11% Ni, and 79.13% Sn entered the crude copper phase in the smelting process, 76.73% Pb and 67.22% Zn volatilized to the dust phase, and all halogen elements terminated in the dust and off-gas
(3) total heat input of the process was 79,480 MJ/h, the energy released by chemical reactions accounted for 69.94% of the total, and heat from fuels burning accounted for 33.04%. The energy brought away by the off-gas was 38,440 MJ/h, which was the largest part in heat output. The heat loss with the smelting slag accounted for 28.47% of the total.