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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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 4

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 5

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 7

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 9

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)

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 10

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 11

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 14

How does the disposal of used CRT-How does the disposal of used CRT-glassglasscurrently look like ?currently look like ?

??

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 15

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 16

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.

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 20

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 22

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 24

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 25

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

Dr. Eckart Döring - To get new picture tubes from old ones - sheet 29

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]