RENOCELL® TECHNOLOGY - HEAVY & PRECIOUS METALS APPLICATIONS 2007
“... RenoCell removes dissolved heavy metals from water, as metal, better than any process in the world. By using electrons directly instead of from chemical reagents, the RenoCell is the least expensive, most efficient and environmentally friendly electrochemical reduction process available today...” RenoCell M500 *REDOX - of or relating to reduction-oxidation. Chemical reactions involving metals in aqueous solutions involve a balance of oxidizing and reducing reactions. Reagents are substances that react with metals by exchanging electrons to cause their oxidation or reduction.
RENOVARE INTERNATIONAL Founded in 1996 Over 180 systems sold and operating in over 15 countries Expanded RenoCell Product Line Diversified industries Printed Circuit Boards Plating & Metal Finishing Semiconductors & Electronics Aerospace/Automotive Precious Metals Recovery & Mining
TECHNOLOGY & PRODUCTS OVERVIEW Electrochemical metal recovery High surface area carbon fiber cathode Large improvement in performance envelope (operating range & costs) Cathode cartridge periodically replaced to recover metal Industrial Metal Recovery Products RenoCell Models 250, 500 & 1000 with divided cell capability RenoCell Modular Systems sized and configured as market and applications dictates Specialty RenoCell Systems Value-added niche systems, e.g., Electroless Nickel Bath treatment Range of capacities to best serve customer needs Modular, expandable system line
TECHNOLOGY OVERVIEW
ELECTROCHEMICAL PROCESSES The term electrochemical reaction applies to those reactions of oxidation or reduction which take place at the surface of conductive electrodes immersed in a chemical medium under the influence of an applied electrical potential or voltage At the negative electrode or cathode, the reactions include reduction of a metal ion to the metal itself Ni+ + + 2 e- —> Ni and, in aqueous media, the reduction of the hydrogen ion to hydrogen gas 2H+ + 2 e- —> H2 gas
ELECTRODEPOSITION OF METALS Historically 2D cells, such as tank or plate-and-frame cells, are suitable for bulk metal removal, but they can not meet stringent recovery or treatment standards Development efforts have been directed towards finding high surface area, stationary electrode materials. Testing shows that low concentrations of metals can only be achieved with reasonable current efficiencies by using porous, 3D electrodes
ELECTRODEPOSITION OF METALS (Continued) RenoCell improvements in electrochemical cell performance focused on: Obtaining high active cathode surface areas which allow compact design and efficient conversions even at low metal concentrations High current efficiency to minimize energy usage High current density to effect rapid metal removal Intimate contact between electrolyte and electrodes to provide high mass transport Ease of product removal Safety and ease of control Lower operating costs
RENOCELL’S PATENTED*TECHNOLOGY Porous, high surface area cathode Replaceable cathode cartridge for easy metal removal Industry standard components and compact, robust design Optional divided cell (reactor) configuration Applicable to all electroplatable metals or electroprecipitable metal hydroxides and oxides *USA No. 5,690,806 and USA No. 6,162,333
RenoCell’s Carbon Fiber Cathode Element, Magnified RENOCELL CATHODE DESIGN RenoCell’s Carbon Fiber Cathode Element, Magnified
RENOCELL POROUS CARBON CATHODE ASSEMBLY M-500 Cathode: Diameter = 10 cm Length = 1/2 m 2-D Area = 0.11 m2 3-D Area = ~55 m2
RENOCELL CATHODE DESIGN M100 Cathode Before Test After Deposit
RENOCELL ELECTROCHEMICAL CELL Enclosed Polypropylene Housing Cylindrical Anode & Cathode Porous 3D Carbon Cathode Replaceable Cathode Several Sizes Small Footprint U.S. Patent No. 6,162,333
PERFORMANCE OVERVIEW
SUCCESSFULLY TREATS 20+ HEAVY METALS Cadmium • Gold Copper • Cobalt Mercury • Nickel Chromium • Silver Tin • Palladium Iron • Lead Platinum • Zinc Indium • Arsenic Osmium • Tungsten Ruthenium • Rhodium Others (metalloids) being or to be tested
99.99 % COPPER RECOVERY FROM DILUTE PLATING BATH
ELECTROLESS COPPER WASTE M100 CATHODE (Multiple Batches)
TYPICAL RENOCELL OPERATING PERFORMANCE
TYPICAL RENOCELL OPERATING PERFORMANCE (Continued)
COST COMPARISON FOR COPPER REMOVAL FROM RINSE WATERS Based on: 40 ppm copper removal to 1 ppm copper Sludge management (including dewatering, transportation and treatment) is $350/ton Ion exchange spent resin is assumed to be treated on site
NICKEL Removal of Ni from the Watt's bath and other chemistries was achieved at a good rate and less than 1 mg/L was achieved Recently an Electroless Nickel bath treatment process was developed that successfully overcomes the strongly complexing nature of the EN solution. This process technology is being patented
COST COMPARISON FOR NICKEL REMOVAL FROM RINSE WATERS Based on: 80 mg/L Ni removal to 1 mg/L Ni Sludge management (including dewatering, transportation and treatment) is $350/ton Ion exchange spent resin is assumed to be treated on-site O&M Cost Estimates: DTC Precipitation: $50/kg Ni Ion Exchange: $25/kg Ni RenoCell: $11/kg Ni
ELECTROLESS NICKEL TREATMENT EN Bath Processing OMG Spent Chemistry pH 5.0 ORP +150 mV Conductivity >90,000 µS/cm Ni ~6,000 mg/L RenoCell Testing ~30 tests runs pH, ORP, T, conductivity, pretreatment undivided/divided
ELECTROLESS NICKEL TREATMENT SUMMARY RenoCell Process Results Divided RenoCell Require Reduce ORP to ~-250 mV No pH adjustment T >50C Other Process Adjustments Operating Cost Comparison Ven Met + $45 - $55/kg Ni RenoCell $9/kg Ni
GOLD & OTHER PRECIOUS METALS An Au drag-out tank on a PCB plating machine was treated. The 265 L tank produced 112.5g of Au during a 20 hour RenoCell M100 test, and is typical of many precious metal applications
RENOCELL—CHEAPER & CLEANER Redox Reagent $/kg Equivalent Ratio ‘Electrolytic’ electron 12.80 1.0 Iron powder 43.20 3.4 Zinc dust 46.40 3.6 Dimethyl-dithiocarbamate (DTC) 89.81 7.0 Sodium borohydride (VenMet) 101.39 7.9 Potassium permanganate 163.26 12.8 - Clean, “Green” Reactions - Electrons are the cheapest, purest, most versatile redox reagent
PRODUCTS OVERVIEW
RENOCELL PRODUCTS AND SYSTEMS OEM COMPONENTS • SYSTEMS M1000 – XM0100D Bench System M1000/D – XM0250 Pilot System M500 – Modular Systems M500/D – Specialty Systems M250 M250/D
RENOCELL® COMPONENT PRODUCTS M250 & M250D M500 & M500D M1000 & M1000D
RENOCELL XM100 BENCH SYSTEM
RENOCELL MODULAR SYSTEMS
RENOCELL MODULAR SYSTEM
RENOCELL MODULAR SYSTEMS DESIGN Redundant, modular design, expandable and reconfigurable Redundant pumps if required Modular design allows for additional modules to be added In multiple cell systems each set of cells is isolatable for service - cathode change-out Small foot print Proven low cost design
APPLICATIONS OVERVIEW
EFFECTIVE OPERATING RANGES FOR METAL REMOVAL TECHNOLOGIES 100k 0.1 1 10 100 1k 10k Copper Remaining (mg/l) Conventional EW RenoCell Chemical Precipitation Ion Exchange
MARKET DRIVERS FOR RENOCELL Process Water Treatment “In-process” for water and or metal recovery, recycle, and or reuse “End-of-Pipe” for waste treatment Performance, quality and cost improvements Recovery of Precious Metals Market Conditions Relentless pressure to reduce operating cost Water compliance restrictions are increasing for discharge and water reuse Waste minimization recognized as essential to economically compete and meet regulatory standards
RENOCELL USES Spent Plating Bath IX Regen Rinse Water Membrane Concentrate Effluent Polishing Scrubber Solutions Precious Metal Scrap Processing Catalyst Solution Photosilver Precious Metal Dragout and Rinses Precious Metal Mining Leach Cleaning Baths Product Purification Contaminant Removal Dragout Solutions Bath Purification Stripping Bath Pickling Baths Redox Reagents Etchant Regeneration
EXPERIENCE OVERVIEW
RENOCELL INSTALLATIONS 20+ Applications in Industrial Sectors Printed Circuit Boards Copper from electroless bath Copper from dragout Gold from dragout Silver from rinse water Impurities from copper plating bath Metal Finishing Cadmium from rinse water Copper from cleaning bath
RENOCELL INSTALLATIONS (continued) 20+ Applications in Industrial Sectors Aerospace/Automotive Cadmium from rinse water Cadmium from IX regeneration Copper and lead removal from cleaning bath Metal Fab Cleaning bath maintenance (Pb,Cu) Precious Metals Platinum, palladium and gold recovery Gold from dragout
TYPICAL RENOCELL INSTALLATIONS Packard Hughes Interconnect Acid Copper, Gold Sanmina Copper, Tin, Nickel, Gold Cesna Aircraft Copper Applied Power Copper, electroless and acid Copper Moen Copper, Lead DDI Thomas Walters Copper etch and microetch INCO Precious metals
SUMMARY OF TYPICAL ECONOMIC BENEFITS Virtual removal of all metal to allow rinse water reuse, saving more than 40% in overall treatment cost Total operational cost savings up to 70% over conventional treatment methods Lower capital cost payback (less than 2 years) Reduced metal and waste water loading on existing waste treatment facilities Conformance with national and local effluent discharge standards
“RenoCell® technology simply works substantially better” IN SUMMARY RenoCell is the next generation technology for process and waste water metal ion removal and value metal reclamation RenoCell products deliver advanced, patented 3-D electrowinning technology incorporated in compact, robust cell and modular system designs The principles of electrowinning are the same for all electrochemical cells. However, . . . . . “RenoCell® technology simply works substantially better”