dr. eckart döring - to get new picture tubes from old ones - sheet 1 to get new picture tubes from...
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Dr. Eckart Döring - To get new picture tubes from old ones - sheet 1
To get new picture tubes To get new picture tubes from old onesfrom old ones
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 2
Tv glass recycling in Europe - Tv glass recycling in Europe - description of the situation and the description of the situation and the possibilities.possibilities.
Presentation by:
Dr. Eckart Döring
Manager Batch SupplyManager Batch SupplySite Services MainzSite Services MainzSchott Glas, Mainz, GermanySchott Glas, Mainz, [email protected]
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 3
The CRT consists of many The CRT consists of many componentscomponents
Metal parts- Deflection unit- Rimband- Mask- Magnetic shield- Anode, getter- 4 Pins in the panel glass
Metal/Ceramic parts- Electron gun
Glass- Cone glass, frit and neck (contain high amounts of lead)- Panel glass
Neck
DeflectionUnit
Magnetic shield
Rimband
Anode
Front platecoating
Front platecoating
Panel glass
Electron beam
Electron gun
Cone glass
Frit
Other substances- Front plate coating- Plastic foil- Ironoxid/graphite coating on cone glass
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Physical Properties of Color CRT GlassPhysical Properties of Color CRT Glass
Parameter Panelglass Funnelglasslinear expansion coeffizient 10 E-6/K 9,8 E-6/K
TK 100 ca. 300 °C ca. 330 °CDensity 2,78 g/cm³ 3,0 g/cm³
Working Point ca. 1000 °C ca. 960 °CTransformation temperature ca. 500 °C ca. 460 °C
X-Ray absorption >28 cm-1 >63 cm-1
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Range of chemical compositions of color CRT glassRange of chemical compositions of color CRT glass
%
Oxide Min Max Variation Min Max VariationContainer
glasSiO2 58,85 65,40 6,55 51,19 63,45 12,26 72
Al2O3 1,20 3,70 2,50 1,10 5,00 3,90 2 Na2O 6,15 9,80 3,65 5,25 8,05 2,80 13 K2O 6,00 8,95 2,95 7,15 10,30 3,15 1 Li2O 0,00 0,50 0,50
F 0,00 0,83 0,83 BaO 1,90 14,20 12,30 0,00 3,00 3,00 SrO 0,00 11,60 11,60 0,15 0,65 0,50 CaO 0,00 4,55 4,55 1,60 4,45 2,85 10 MgO 0,00 1,95 1,95 0,90 3,00 2,10
As2O3 0,00 0,30 0,30 0,00 0,15 0,15 Sb2O3 0,18 0,70 0,52 0,02 0,35 0,33 TiO2 0,00 0,60 0,60 CeO2 0,00 0,55 0,55 PbO 0,00 3,25 3,25 11,60 24,60 13,00 ZrO2 0,00 3,50 3,50 0,20 0,20 0,00 ZnO 0,00 0,65 0,65
Fe2O3 0,03 0,07 0,04
Funnel glassPanel glass
All figures in weight-%
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 6
0,00
2,00
4,00
6,00
8,00
10,00
12,00
1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993
wt
%
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
wt
% P
bO
, S
iO2
Al2O3
Na2O
K2O
BaO
SrO
CaO
MgO
Sb2O3
%SiO2 (balance)
PbO
Changes of funnel glass compositions in EuropeChanges of funnel glass compositions in Europe
Year of Production
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Changes of panel glass compositions in EuropeChanges of panel glass compositions in Europe
0,00
2,00
4,00
6,00
8,00
10,00
12,00
1976 1979 1982 1984 1987 1990 1993 1995
Year of production
wt
%
55,00
57,00
59,00
61,00
63,00
65,00
67,00
69,00
wt
% S
iO2
Al2O3
Na2O
K2O
BaO
SrO
CaO
MgO
Sb2O3
TiO2
CeO2
ZrO2
%SiO2
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 8
UK 22,8%Germany 22,3%
France 18,3%Italy 12,4%
Spain 8,9%The Netherlands 4,1% Sweden 2,1%Belgium 2,0%Portugal 2,0%Austria 1,9%Denmark 1,7%Finland 1,5%
Total: 100,0%
Distribution of EoL-glass amounts Distribution of EoL-glass amounts throughoutthroughoutEurope in 2000Europe in 2000
About 1 Mio tons/year in Europe
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Present Situation of CRT- Recycling in the Present Situation of CRT- Recycling in the countries of the European communitycountries of the European community
Scandinavia and BENELUXScandinavia and BENELUX
•High public awareness•Collection system organized•Financing system clear
•Funnel glass is being recycled in the closed cycle (SCHOTT GLAS)•Panel glass will be upgraded for the reuse in the open and closed cycle in 2002•Whole CRTs are recycled as mixed cullets (BENELUX)
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Present Situation of CRT- Recycling in the Present Situation of CRT- Recycling in the countries of the European communitycountries of the European community
GermanyGermany•Moderate public awareness•Collection system organized•Financing via waste tax•The amounts are not registrated
•Only some amounts of funnel, panel and mixed glass are recycled in the closed loop (SCHOTT GLAS)•High amounts of crts are still being landfilled•Two upgrading plant are running since 1997 and 2000
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Present Situation of CRT- Recycling in the Present Situation of CRT- Recycling in the countries of the European communitycountries of the European community
United KingdomUnited Kingdom•Very low public awareness•Now collection system for crts until now•Financing not clear
•Nearly all of the crt glass is being landfilled without any treatment•There are some very promising local initiatives in contact with SCHOTT•Although there are high amounts of glass, no upgrading plant is established
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 12
Present Situation of CRT- Recycling in the Present Situation of CRT- Recycling in the countries of the European communitycountries of the European community
France, Spain, Portugal, ItalyFrance, Spain, Portugal, Italy•Increasing public awareness•Only local collection for crts•Financing not clear•The government is looking for solutions
•Nearly all of the crt glass is being landfilled• There are some local initiatives in contact with SCHOTT•Small amounts of glass are recycled via SCHOTT(France)•Transportation is a big cost factor for these countries
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 13
Present Situation of CRT- Recycling in the Present Situation of CRT- Recycling in the countries of the European communitycountries of the European community
Austria, Austria, Switzerland (not EU)Switzerland (not EU)
•High public awareness•Collection organized•Financing system working
•The closed loop recycling is favorized by the austrian environmental ministry•Crts are integrated into the network by cooperating companies•The mixing of lead containing crt glass into ceramic raw materials is still agreed in switzerland
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How does the disposal of used CRT-How does the disposal of used CRT-glassglasscurrently look like ?currently look like ?
??
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The usual disposal of used CRT-glass The usual disposal of used CRT-glass todaytoday• Disposal of the whole TV-SetsDisposal of the whole TV-Sets
• Reuse in eastern Europe and beyondReuse in eastern Europe and beyond
• Disposal of the glass with or without active layersDisposal of the glass with or without active layers
• Road constructionRoad construction
• Slag former in lead and non-iron productionSlag former in lead and non-iron production
• Use of lead containing mixed glass in the ceramic industry Use of lead containing mixed glass in the ceramic industry
• ......
• ......
• Closed loop recycling in TV-glass productionClosed loop recycling in TV-glass production
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What are the consequences of What are the consequences of today'stoday'spractice ?practice ?
• Glass containing high amounts of lead pollutes the Glass containing high amounts of lead pollutes the environmentenvironment
• The exhaust of container glass melts gets contaminated The exhaust of container glass melts gets contaminated with lead and the filters cannot handle thiswith lead and the filters cannot handle this
• The container glass gets contaminated with leadThe container glass gets contaminated with lead• Price pressure for higher sophisticated recyclingPrice pressure for higher sophisticated recycling• Smaller amounts of glass for closed loop recyclingSmaller amounts of glass for closed loop recycling• ......................
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 17
Large amounts of CRT-glass get disposed by electric waste Large amounts of CRT-glass get disposed by electric waste
recyclers and the glass is not available as raw material for recyclers and the glass is not available as raw material for SchottSchott
Consumer
CRT-Manufacturer
Other Disposale.g. landfill
eastern Europe
TV/PC-MonitorManufacturer
(OEM)
StoresElectronic
goodsdealerships
CRT-Glass-Manufacturer
CRTDismantler
Glass-Recycler
Place of collection
municipal/private
Electronic Waste
Recycler
Quelle: Teamrecherche, -einschätzung
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 18
Schott reduces the bottle necks in the product life Schott reduces the bottle necks in the product life cycle by active acquisition to enable economical cycle by active acquisition to enable economical closed and open loop recycling.closed and open loop recycling.
ConsumerPlace of collection
municipal/private
Electronic WasteRecycler
CRTDismantler
GlassRecycler
CRT-GlassManufacturer
CRT-Manufacturer
TV/ PC-MonitorManufacturer
(OEM)
StoresElectronic
goodsdealerships
OtherDisposal
Acquisition Schott
Quelle: Teameinschätzung
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 19
CRTs do not consist of glass only...CRTs do not consist of glass only...
...and have in addition to be transported and stored in a save, environmental friendly and economical manner.
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The first look at some End-of-Life CRT deliveries showsThe first look at some End-of-Life CRT deliveries showsmainly metal.mainly metal.
This happens due tocompacting the CRTinside the container.
This needs to be avoided. The recyclerhas than the problemof large amountsof fine refraction's ofglass in the sludge.This cannot be separated and there-fore leads to higherdisposal cost of thesludge.
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 21
First layer of the upgrading processFirst layer of the upgrading process
CompleteTV-sets and
monitors
Remove back side ofcase, ventilate CRT, removal of cables,
speakers, circuit boards,dismantle deflection
unit, remove electron gun
Loosen CRT,remove CRTand removalof attachedsilicon and
rubber
Clean separation of
panel andfunnel
CRT with rimband,
insidecoatings
and metal parts
CRT-mix glasswith metals
Panel glass without funnel glass, frit, pins
and inside coatings
Funnel glass with ironoxide/graphite coating
anode, parts of panel-glass and frit
Plastics
circuit boards,
electroniccomponents
Cable, wire,metal
Electron gun
wood,plastic
Metal
Rubber,Silicon
Rimband,mask,anode,getter
insidecoatings
Processing unit for CRT-mix glassand funnel glass
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Iron, steel
Iron, steel
whole,ventilated
CRT
whole,ventilated
CRT
separation,remove metals
separation,remove metals
CRT culletuncleaned
CRT culletuncleaned
Funnel glassuncleaned
Funnel glassuncleaned
Funnel or mix-glasscleaned
Funnel or mix-glasscleaned
Cle
an
ing
e.g
. w
ith
clo
sed
w
ate
r cycle
Iron
, ste
el
sep
ara
tion
2n
d c
lean
ing
w
ith
clo
sed
w
ate
r cycle
G
rad
ing
Sor t
i ng
Cru
sh
i ng
An
aly
sis
Iron
, ste
el
sep
ara
tion
Raw material,funnel ormix glass
Raw material,funnel ormix glass
SludgeSludge Foreign matterForeign matter
Process to generate raw Process to generate raw material (cullet) from End-of-material (cullet) from End-of-
Life CRT (second layer)Life CRT (second layer)
Homo-genize
Homo-genize
Landfill, reuse, stowing
Smelting
Grafik by UFT-4/Obl: Verfahrensfließbild_d.ppt; 2001/08/17
Processpanel glass
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 23
Ways of ecological use of End-of-Life CRT glassWays of ecological use of End-of-Life CRT glass
Closed loop recycling
Open loop recycling
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Quality aspects for the use of End-of-Life Quality aspects for the use of End-of-Life CRT glass in the closed loopCRT glass in the closed loop
• Clear grades of glass (funnel-, panel-, mix-glass)Clear grades of glass (funnel-, panel-, mix-glass)• HomogenityHomogenity• Grainsize Grainsize • NoNo foreign matter, metals, plastic, wood foreign matter, metals, plastic, wood • Coatings removedCoatings removed
To hold the specifications complex processing is To hold the specifications complex processing is necessarynecessary
Closed loop recyclingClosed loop recycling
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Ready for use: secondary raw material !
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 26
• Usable glasses: Usable glasses: – funnel glass– mix from funnel and panel glass– neck glass– panel glass
Closed loop recyclingClosed loop recycling
• The use of The use of End-of-Life panel glassEnd-of-Life panel glass in the in the panel glass melt is turning from tests to panel glass melt is turning from tests to continous operationcontinous operation
• The use of The use of End-of-Life funnel and mix glassEnd-of-Life funnel and mix glass in the funnel glass melt is standard in the funnel glass melt is standard procedureprocedure
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 27
New products, partly made from old CRTs
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 28
Closed-Loop-Recycling in the glass melt at Closed-Loop-Recycling in the glass melt at SCHOTT GLAS, Mainz and STVG, Valasské SCHOTT GLAS, Mainz and STVG, Valasské Mezírící (CZ)Mezírící (CZ)
• SCHOTT GLAS, MainzSCHOTT GLAS, MainzMix glassMix glass max. 12.000 max. 12.000
tons/yeartons/year Funnel glass Funnel glass max. max. 30.000 tons/year30.000 tons/year Panel glassPanel glass min. min. 15000 tons/year15000 tons/year
• STVG, Valasské Mezírící (CZ)STVG, Valasské Mezírící (CZ)Mix glass Mix glass max.max. 6.000 6.000
tons/yeartons/year Funnel glassFunnel glass max.max.20.000 tons/year20.000 tons/year
How much can be utilized ?How much can be utilized ?
Closed loop recyclingClosed loop recycling
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5%
20%
20%
55%
primäre Rohstoffe
Eigenscherben
diverse Stäube
Recyclat incl. Rejects
Why is the amount of End-of-Life Why is the amount of End-of-Life funnel glassfunnel glass limited to limited to approx. 55 % of the total melting capacity of the funnel approx. 55 % of the total melting capacity of the funnel tank?tank?
To compensate missing components in the secondary raw material a certain amount of "fresh" raw materials is necessary
Cullets and dust from production have to be put into the melt also.
Closed loop recyclingClosed loop recycling
Primary raw materials
Cullets from production
Exhaust dust
Secondary raw materials(EoL CRT glass)
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 30
We know now that 10% of the melting capacity can be replaced by EoL panel glass
And we know, that this is not the end !
Where is the limit for the reuse of Where is the limit for the reuse of panel glasspanel glass in the in the closed cycle (panel glass production) and why?closed cycle (panel glass production) and why?
Closed loop recyclingClosed loop recycling
5%
20%
20%
55%
primary Rawmaterials
Cullets from production
Exhaust Dust
secondary Rawmaterial(EoL-CRT-glass)
To compensate missing components in the secondary raw material a certain amount of "fresh" raw materials is necessary Cullets from production have to be put into the melt also. The optical parameters have to be kept in tolerance !
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 31
The amounts of reused EoL-CRT glass show a strong increase
97/98
3240 t
9245 t
98/99 99/00 00/01 01/02
160 t290 t
Year
Reused EoL cullets
(SCHOTT GLAS)
3240 t
>10000 t
160 t290 t
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 32
Major impediments to the grows of closed loop Major impediments to the grows of closed loop recycling of End-of-Life CRT glassrecycling of End-of-Life CRT glass
• There are cheaper ways of downcycling, landfilling and so on, There are cheaper ways of downcycling, landfilling and so on, despite all factual concerns these are still legal and underlie no despite all factual concerns these are still legal and underlie no limits.limits.
• The definition of the legal ways of disposal and downcycling The definition of the legal ways of disposal and downcycling still does not consider today's technical possibilities of closed still does not consider today's technical possibilities of closed loop recycling.loop recycling.
• Logistical system to register the offered amount and missing Logistical system to register the offered amount and missing knowledge about the possibilities.knowledge about the possibilities.
• Poor technologies to separate End-of-Life CRT.Poor technologies to separate End-of-Life CRT.• Some recyclers use the closed loop recycling only for a small Some recyclers use the closed loop recycling only for a small
portion (alibi) of the collected End-of-Life CRT and dispose the portion (alibi) of the collected End-of-Life CRT and dispose the major part the cheap way.major part the cheap way.
Closed loop recyclingClosed loop recycling
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 33
Open loop recyclingOpen loop recycling
• Panel glass, which amounts to 2/3 of the glass Panel glass, which amounts to 2/3 of the glass in ain aCRT has to be utilized in a ecological and CRT has to be utilized in a ecological and economicaleconomicalwayway
• Following uses are being tested and show Following uses are being tested and show potential:potential:
– Insulation fiberInsulation fiber– Substitute for primary raw material in the Substitute for primary raw material in the
ceramics industryceramics industry– Enamel, glazesEnamel, glazes– Decorative wall tilesDecorative wall tiles
Lead-free End-of-Life panel glass is an excellent choice Lead-free End-of-Life panel glass is an excellent choice to use for open loop recyclingto use for open loop recycling
Only lead-free cullets can be used for open loop recycling !Only lead-free cullets can be used for open loop recycling !
Dr. Eckart Döring - To get new picture tubes from old ones - sheet 34
Many thanks for your attention!Many thanks for your attention!
For further questions you can contact :For further questions you can contact :
Dr. Eckart DöringDr. Eckart Döring Phone +49 6131/66-21 87, Fax +49 6131/66-20 73, Phone +49 6131/66-21 87, Fax +49 6131/66-20 73,
Mobile +49 171/2 20 94 17Mobile +49 171/2 20 94 17
e-mail: [email protected]: [email protected]
Thomas Oberle Thomas Oberle Phone +49 6131/66-38 34, Fax +49 6131/66-19 65, Phone +49 6131/66-38 34, Fax +49 6131/66-19 65,
Mobile +49 171/8 64 39 80Mobile +49 171/8 64 39 80
e-mail: [email protected]: [email protected]