Electronic
waste has emerged as one of the fastest growing segments
of the solid waste stream in the last two decades because of the greater
consumption and obsolescence rates of electronic products. Significant
content of metals and polymers present in e-waste may affect the ecosystem
and human health if treated inappropriately using primitive recycling
methods. Several studies have been reported in the literature for
the recovery of metals from e-waste; however, limitations associated
with ongoing methods incited this study to move toward modern approaches
based on green chemistry principles. The present study is a pioneer
effort to employ a novel green technology based on a unique combination
of chelation–dechelation concepts to extract metals from printed
circuit boards and mobile batteries. The applicability of response
surface methodology (RSM) was explored to investigate the mutual interaction
effect of process parameters and to provide an improved quality of
information. Statistical optimization of the extraction process was
performed by coupling of Box–Behnken design and central composite
design matrices with RSM. Nearly 85.3% Cu2+ and 86.2% Co2+ recovery was predicted at the center level of design matrices
using quadratic regression models for the respective metals. Maximum
±4% deviation was observed between experimental and predicted
extraction efficiency. The high values of regression coefficients
(R
2 = 0.994 for Cu2+ recovery
and R
2 = 0.998 for Co2+ recovery)
indicated that >99% of response variability could be explained
by
regression models. Relatively lower p-values (<0.0001)
and coefficient of variation (<2.8%) indicate the adequacy of the
proposed models. The desirability function approach was employed to
localize the optimum process parameters, and ramp functions were drawn
for the set of optimal points. A well-defined optimal region was identified
to maximize the metal extraction with desirability >0.95. Characterization
of raw material and residues corroborated the significant extraction
of metals. Also, recovered chelating agent was successfully employed
in subsequent extraction cycles, which fortifies the concept of a
zero-waste technology. The proposed design correlations may prove
to be a useful tool in designing pilot and commercial plants for extraction
of heavy metals using environmentally friendly chelation technology.