Kopacek 2008a WasteCon Slides 0

Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling

Liquid Crystal DisplayLiquid Crystal Display

ReRe--use and Recycling use and Recycling


Table of ContentTable of Content

Ø Introduction of the ReLCD project

Ø Alternative technologies• Jet Cutting• Laser Cutting• Sawing

Ø Manual DismantlingØ Processing CostsØ Quality assessmentØ Total processing costsØ Conclusion


ProjectProject

Ø Full Title: Liquid Crystal Display Re-use and Recycling

Ø Acronym: ReLCD

Ø Program: Co-operative Research Project, FP6

Ø Start: March 8, 2004

Ø Duration: 24 Months


Consortium Consortium

SME Partner:

Ø Ecotronics (AT) – Coordinator

Ø Active Recycling (UK)

Ø RelektrA (DE)

Research Partner:

Ø SAT (AT)

Ø Gaiker (ES)

Ø BZF (HU)


LCD LCD –– Market Market

Global LCD-Sales Figures (in m)

8,849

19,619

46,247

60,640

76,659

31,368

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

2004 2005 2006 2007 2008 2009

From 2004 until 2009 LCD sales will rise 54% per yearSource: Elektonik Praxis, Feb. 2006


Goals of the Project (1)Goals of the Project (1)

Ø To find a cheap and fast test methodology to verify if the obsolete or excess LCDs are still working

Ø To develop a technology to refurbish the working LCDs and re-integrate them into repair and in exemptions also in production processes

Ø To find a test method to detect hazardous substances in LC-mixtures


Goals of the Project (2)Goals of the Project (2)

Ø To develop an eco-efficient disassembly and recycling technology for the non-working LCDs

Ø To research possible enhancements to the existing LCD design and production in order to come to a more sustainable life-cycle of LCDs (publication of guidelines)

Ø Building up a pilot plant incorporating and testing the developed technologies


Work PlanWork Plan

5 Work Packages:

Ø WP 1: LCD Test & Refurbishment

Ø WP 2: Technology of LCD Disassembly & Recycling

Ø WP 3: Design & Evaluation of Disassembly & Recycling System

Ø WP 4: Guidelines for Sustainable LCD Design, Production & Recycling

Ø WP 5: Project Management


User GroupUser Group

• Coolrec• Electrocycling

• Flextronics• Indumetal Recycling • LG

• Nokia

• Samsung

• Sony

• STENA Technoworld


IntroductionIntroduction

Ø Backlight Lamps contain mercury

• Hazardous

• Separation

Ø Tendency to non-hazardous lamps

• Process for the next 5-8 years

Ø Possible ways to separate the lamps

• Cutting

• Manual dismantling


Water Jet CuttingWater Jet Cutting

Ø Processing Parameter• Pressure 2000 bar

• Cutting speed§ Border area: 50 – 60 mm/min

§ Rest: 550 – 800 mm/min

• Mean Processing Time ~ 2,7min

Ø Disadvantage:• Investment costs (EUR 130.000)

• Maintenance costs

Jet Cutter of Bay-Logi (Miskolc)


Water Jet CuttingWater Jet Cutting

Ø Disadvantage:• Investment costs (EUR130.000)

• Maintenance costs

Ø Cutting surface:


LASER CuttingLASER Cutting

Ø Processing Parameter• Power: 2,5 kW

• Cutting speed: 1,5 m/min

• Cutting gas: 10bar Nitrogen

• Mean Processing Time ~ 1 min


• Emissions

Laser Cutter of BAY-ATI (Budapest)


LASER CuttingLASER Cutting


Ø Cutting surface:


Circular SawCircular Saw

Ø Processing Parameter• Cutting speed 1,2 m/min• Mean Processing Time ~ 0,9 min

Ø Disadvantage:• Durability• Emissions• Vibrations• Sharp chips


Circular SawCircular Saw

Ø Disadvantage:• Vibrations

• Durability of saw blade

• Emission

• Sharp chips

Ø Cutting surface:


Manual dismantlingManual dismantling

Ø Processing Parameter• Mean Processing Time ~

1,5 min

Ø Advantages:• Low investment cost• 40% disassembly friendly


Processing CostsProcessing Costs

Ø Investment costsØ Personnel Costs

Ø Maintenance costs:• Manual disassembly: tools• Jet Cutting: sand and water, nozzle• Laser Cutting: cutting and laser gas• Circular Saw: saw

1st Year

0

1

2

3

4

2500

5000

7500

1000

0

1250

0

1500

0

1750

0

2000

0

2250

0

2500

0

2750

0

3000

0

Items per Year

Eu

ro/# Manual Disassembly

Laser Cutting

Circular Saw

Jet Cutting


Quality assessmentQuality assessment

Ø Hazardous materials (red)Ø Non-hazardous materials (green)Ø Damage ratio of lamps about 1,5% for all

investigated processes


Total cost situationTotal cost situation

Parameter:Ø 5.000 t per yearØ Material revenue:

• Hazardous -720€/t• Non-hazardous -69 €/t

Current SituationØ Material revenue:

• Hazardous -720€/

Ø Total Costs: 3.600.000 €Ø Saving Potentials:

• 12% (1,7min dismantling time)• 16% (1,4min dismantling time)• 8% (Laser cutting)

4.557.3266324.3683.802.460570.620207378.000Circular SawIV

3.338.4655854.4152.614.099476.441165459.089Laser cuttingIII

5.776.3028114.1894.904.940232.2236321119.256Jet cuttingII

3.301.014834.9172.904.169205.0904214177.882Manual disassemblyI

[EUR][t][t][EUR][EUR]Employees[#][#/a]

Resulthazardous Non-hazardousAll Systems1 Systemof systemsCapacity

TOTALMaterialsProcessing CostsNumberParallelMax.

METHOD


Saving potentialsSaving potentials

Parameter:Ø 900 t per yearØ Material revenue:

• Hazardous -720€/t• Non-hazardous -69 €/t

Current SituationØ Material revenue:

• Hazardous -750€/

Ø Total Costs: 675.000 €Ø Saving Potentials:

• 12% (1,7min dismantling time)• 16% (1,4min dismantling time)• 11% (Laser cutting)

11675000600.9241459.089Laser cuttingIII

16675000569.0802216.000Manual disassembly(1,4min)II

12675000594.1833177.882Manual disassembly(1,7min)I

[%][EUR][EUR][#][#/a]

Potentialtreatment costsResultsystemsCapacity

SavingsCurrentTOTALParallelMax.

METHOD


Summary & ConclusionSummary & Conclusion

Ø No alternative method to manual dismantling• Low investment• Mean Processing Time ~ 1,5 min

Ø Nowadays about 40% of the LCDs are disassembly friendly• Investigations of 50 different types / 10 manufacturer

Ø High investment costs for alternative methods result to inefficient processes and high financial risk

• Laser cutting: EUR 340.000• Water Jet Cutting: EUR 130.000

Ø Material compositions of the panels result to difficulties in cutting processes

• Durability of tools• Vibrations• Emissions


Summary & ConclusionSummary & Conclusion

Ø Pre-treatment result to a reduction of the total treatment costs

• 12% at the moment

• 20% can be expected for the future

Ø Material recycling is preferable to incineration because of environmental aspects

Ø Pre-treatment necessary to fulfil requirements of WEEE directive

• Notebook: 40% LCD

• Recycling quota 65% / Recovery quota 75%

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