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Fluorescent Lighting in Ontario

Lifespan Model and Research

Report

to

Waste Diversion Ontario

August, 2007

Fluorescent Lighting In Ontario

Table of Contents

Section Title and Contents Page # Executive Summary ES-1 1 Introduction 1 2 Residential and Small IC&I Fluorescent Light Lifespan Model 2

3 Profile Of CFLs and Fluorescent Tubes in Ontario Households and Small IC&I Establishments 3

3.1 Approach to Developing CFL and Fluorescent Tube Sales Profile 3 3.2 Residential Lighting Sockets in Ontario 3 3.3 Available Fluorescent Lighting Sales Data for Ontario 4 3.4 Lamp Types in Residential Sockets 4 3.5 CFLs and Fluorescent Tubes in Small IC&I Locations 6 3.6 New Lighting Designs Which Might Impact on Analysis 6

4 Lifespan and Storage Data 9

4.1 Reported Lifespan of Different Lighting Types 9 4.2 Storage Assumptions 12 4.3 Reuse Assumptions 12 4.4 Use of Lifespan, Storage and Reuse Assumptions to Construct the Lifespan Model 12

5 Annual Sales Estimates 13

5.1 Annual Residential Light Bulb Sales Estimates By Type, 2003 to 2015 13 5.2 Sales of Fluorescent Lamps to Small IC&I Establishments 13

6 Fluorescent Lamp Discards Over Time 15

6.1 Fluorescent Lamp Discards 15 6.2 Processing Capacity Requirements 17

7 Weight and Composition of Fluorescent Bulbs and Tubes 18

7.1 Weight Of Fluorescent Tubes 18 7.2 Mercury Content of Fluorescent Lamps 18

7.2.1 Mercury Content of CFLs 19 7.2.2 Mercury and PCB Content of Fluorescent Tubes 19 7.2.3 Ballasts in Fluorescent Tubes 20 7.3 CCME Canada Wide Standard for Mercury Containing Lamps 20 7.4 Composition of CFLs 21 7.5 Reported Fluorescent Lamp Recycling Rates 22

8 Fluorescent Lamp Recycling Infrastructure in Ontario 23

8.1 Fluorescent Lamp Recycling Infrastructure in Canada 23 8.2 Lamp Crushers 24 8.3 Considerations Regarding Future Fluorescent Lamp Recycling Capacity Demands 25 8.4 FLR, Ayr, Ontario 25

8.4.1 Capacity and Current Throughput of FLR Plant 26


8.4.2 Lamp and Tube Processing at FLR 27 8.4.3 Ability to Process Additional Lamps and CFLs 28 8.5 International Marine Salvage Inc (Raw Materials Company), Port Colborne, Ontario 29 8.6 Capacity to Process Fluorescent Tubes and CFls in Ontario 29 8.7 Lead Time Required to Increase Processing Capacity For Both Tubes and Bulbs 31

9 Summary and Conclusions 33

9.1 Discards and Processing Capacity Requirements 33 9.2 Current Processing Capacity and Expansion Potential 33 9.3 Mercury in Fluorescent Lamps 34

Appendix A Construction of Ontario Residential Lighting Profile Percentage Model and Development of Ontario Residential Annual Light Bulb Unit Sales Profile, 2003 to 2015 A1

Appendix B Current Penetration of CFLs in Ontario Residential Market A9 Appendix C Reported Fluorescent Light Recycling Rates A12


List of Tables

Table Number

Table Title Page

ES1 Fluorescent Lamp Processing Capacity Requirements ES1 3.1 Estimate of Sockets Per Household in Ontario in 2003 5 3.2 2005 and 2006 Ontario Fluorescent Bulb and Tube Shipments – Retail and Professional Estimates 4 3.3 Assumed Percentage of Different Light Bulbs in Ontario 2003 to 2015 - 100% Replacement of Incandescents

by CFLs by 2013 7

3.4 Assumed Percentage of Different Light Bulbs in Ontario 2003 to 2015 7 3.5 Number of Existing Residential Sockets in Ontario - 100% Replacement of Incandescent by CFLs by 2013 7 3.6 Number of Existing Residential Sockets in Ontario - 50% Replacement of Incandescents by CFLs by 2013 8 4.1 Reported Lamp Life 9 4.2 Annual Hours of Operation By Room-Type By Home -Type for the Residential Sector 11 5.1 Annual Sales of Fluorescent Light Bulbs in Ontario 2003 to 2015 - 100% Replacement of Incandescents by

CFLs by 2013 14

5.2 Annual Sales of Fluorescent Light Bulbs in Ontario 2003 to 2015 - 50% Replacement of Incandescents by CFLs by 2013

14

6.1 CFL Discards - Zero storage after first life 16 6.2 CFL Discards - 50% storage for one year after first life 16 6.3 CFL Discards - 100% storage for one year after first life 16 6.4 Fluorescent Tube Discards 17 6.5 Fluorescent Lamp Processing Capacity Requirements 17 7.1 Weight of Mercury Containing Lamps 18 7.2 Mercury Content of Various Lighting Types 18 7.3 Composition of a Compact Fluorescent Light and Fluorescent Lamps 22 7.4 Composition of 1.2 Metre Fluorescent Tubes 22 9.1 Fluorescent Lamp Processing Capacity Requirements 33

List of Figures

Figure Number

Table Title Page

8.1 Schematic of FLR Recycling Process 28


Page ES-1 August, 2007

Executive Summary

This report addresses the province’s capacity to manage and properly recycle current and anticipated fluorescent light bulbs and tubes and the disposition of mercury from fluorescents. The focus of the estimates was compact fluorescent lights (CFLs) and fluorescent tubes generated by residences and small businesses, which will be subject to Phase 2 of the MSHW Plan in the Province of Ontario. The lighting efficiency standards announced by the Federal and Provincial governments which will come into effect in 2012 may significantly affect the number of CFLs used and eventually disposed in the Province. Two scenarios were modeled to provide a range of values – 50% and 100% replacement of current incandescent sockets with CFLs. CFLs contain 2 to 5mg of mercury and fluorescent tubes contain 8 to 12mg of mercury bound into the phosphorous powder coating on the bulb glass. In 2008, discarded CFLs in Ontario will contain 8 to 30 kg of mercury and discarded fluorescent tubes will contain 24 to 36 kg of mercury. Discards and processing capacity requirements for 60% and 75% collection rates are shown in Table ES-1.

Table ES-1: Fluorescent Lamp Processing Capacity Requirements (Millions of Units per Year)

Year CFLs

Discarded Fluorescent

Tubes Discarded

Processing Requirement

(60% Collection)


(75% Collection)

2008 4-6 3 4-5 5-7 2010 9-14 3 7-10 9-13 2012 15-23 3 11-16 13-19 2014 21-37 3 14-24 18-30

The table shows that processing capacity for 7-10 million fluorescent lamps would be required by 2010, assuming a 60% collection rate. Should the collection rate increase to 75%, processing capacity for 13-19 million lamps would be required by 2012, increasing to a requirement for 18-30 million units by 2014. FLR in Ayr, Ontario is the only full service fluorescent light processor in Ontario at this time. Marine Salvage operates a consolidation site in Port Colborne, but sends all fluorescent lights to Bethlehem Apparatus in Pennsylvania for processing. The mercury laden powder from FLR is also sent to Bethlehem Apparatus for processing. Both FLR and Marine Salvage indicate a willingness to expand their operations should supply of discarded CFLs and fluorescent tubes increase. A third company, RLF in Quebec, currently serves the Eastern Ontario market and can provide additional capacity if required.


Page ES-2 August, 2007

Mercury from fluorescent lights collected in Ontario is triple distilled in a retort system at Bethlehem Apparatus in Pennsylvania and is sold into the marketplace as liquid mercury for specialized electronic related applications.


Page 1 August, 2007

1. Introduction

The Program Plan for Phase 1 of the Municipal Hazardous or Special Waste (MHSW) Program was submitted to the Minister of the Environment on 24th May, 2007 by Waste Diversion Ontario (WDO). As outlined in correspondence from the Minister to WDO dated December, 2006, fluorescent light bulbs and tubes will be included in Phase 2 of the MHSW Program. Waste Diversion Ontario received a letter from the Minister of Environment on 14th June, 2007 requesting that WDO undertake a review of:

o The province's capacity to manage and properly recycle current and anticipated fluorescent light bulbs and tubes.

o The recovery and disposition of mercury from fluorescents. Kelleher Environmental was engaged by Waste Diversion Ontario to provide research support with the various tasks which need to be completed to address the Minister’s request. These tasks included:

• Developing a Lifespan Model to estimate the anticipated discard rate for fluorescent lights in Ontario from residential and small industrial, commercial and institutional (IC&I) sources, and

• Documenting the current capacity to process discarded fluorescent lights in

Ontario. A Project Task Group was formed to review preliminary data sources and results, as well as the approach and methodology employed in the study. Members of the Project Task Group included:

• John Baillie, Vice President, EEMAC (Electrical Equipment Manufacturers Association of Canada), Electro Federation of Canada (EFC)

• Raegan Bunker, Manager, Program Delivery, Ontario Power Authority • Wayne Edwards, Vice President, EEMAC (Electrical Equipment Manufacturers

Association of Canada), Electro Federation of Canada (EFC) • Ken Elsey, President & CEO, Canadian Energy Efficiency Alliance (CEEA) and • Joanne St. Godard, Executive Director, Recycling Council of Ontario (RCO).

A project review meeting was held on 23rd July, 2007. Task Group members reviewed and provided comment on assumptions used in the modeling. Task Group members also provided additional data to the Project Team following the meeting.


Page 2 August, 2007

2. Residential and Small IC&I Fluorescent Light Lifespan

Model

A Fluorescent Bulbs and Lamps Lifespan Model was constructed for this project. The Lifespan Model has a similar construction and operates in a similar way to product flow models developed to meet needs of various clients. These include:

• Alberta Recycling Management Authority (computers, printers, monitors, televisions)

• Environment Canada (batteries, WEEE) • ITAC (computers, printers, monitors, telephones and faxes) • EPSC (computers, printers, monitors, televisions).

The Lifespan Model estimates the rate at which a product will be discarded using the following inputs:

• historical and projected annual unit sales data; • assumptions on the first lifespan of the product (the time it takes for the first

owner to no longer use it); and • assumptions on storage and reuse of the product at the end of its first life.

The Lifespan Model can be custom designed to meet different client needs. For WDO, the Lifespan Model was designed to create separate product Lifespan profiles for:

• Fluorescent tubes used in the Ontario residential sector; • Fluorescent tubes used in the small IC&I sector in Ontario; • Compact fluorescent lights (CFLs) used in the Ontario residential sector; and • Compact fluorescent lights (CFLs) used in the small IC&I sector in Ontario.

The following sections describe assumptions used to develop the discard estimates from the Lifespan Model.


Page 3 August, 2007

3. Profile of CFLs and Fluorescent Tubes in Ontario

Households and Small IC&I Establishments 3.1 Approach to Developing CFL and Fluorescent Tube Sales Profile The first step in constructing the Lifespan Model was to identify historical, current and projected annual unit sales of CFLs and fluorescent tubes into the residential and small IC&I market in Ontario. No comprehensive source of data on annual unit sales was available for the period from 2001 to 2015 (the period for which sales data were required to populate the Lifespan Model). Therefore, a sales profile was constructed using a number of sources and assumptions. The general approach to develop the sales estimates was as follows:

o Create a profile of residential lighting by type (incandescent, CFL, etc) in Ontario residences in 2003 using Natural Resources Canada data collected through the Survey of Household Energy Use (SHEU);

o Use 2003 data as a basis to create an Ontario Residential Lighting Profile for the years 2001 to 2015; and

o Use the Profile and other data sources to create Ontario residential annual fluorescent light bulb unit sales estimates.

The annual unit sales estimates were then used in the Lifespan Model to estimate annual discards of CFLs and fluorescent tubes. The various steps taken to construct the profile are described in detail in Appendix A, and are summarized in this section. 3.2 Residential Lighting Sockets in Ontario Natural Resources Canada and Statistics Canada carried out a Survey of Household Energy Use (SHEU)1 in 1997 and 2003. The 2003 data was presented in greater detail and was used as the basis of the initial lighting profile developed for this study. Ontario-specific information from the SHEU was used to construct a profile of lighting bulb use in Ontario in 2003, shown in Table 3.1 and described in Appendix A. The methodology estimated 106 million sockets in Ontario households in 2003.

1 Source: Survey of Household Energy Use (SHEU) - Detailed Statistical Report, 2003, Cat No. M144-120/2003ENatural Resources Canada


Page 4 August, 2007

EFC staff confirmed at a meeting on 23rd July, 2007 that a value of 102 million sockets (an earlier estimate) was reasonable for planning purposes. The updated estimate of 106 million sockets was considered reasonable as the basis for modeling. The estimated 106 million light sockets in Ontario in 2003 were divided by 4.3 million households in Ontario in 2003 to identify an average of 25 lighting sockets per household in 2003. 3.3 Available Fluorescent Lighting Sales Data for Ontario Sales data for CFLs and fluorescent tubes to residential and small IC&I establishments in Ontario in 2005 and 2006 were provided by Electrical Equipment Manufacturers Association of Canada through Electro Federation of Canada. These values are presented in Table 3.2.

Table 3.2: 2005 and 2006 Ontario Fluorescent Bulb and Tube Shipments Retail and Professional Estimates

Retail Professional

2005 2006 2005 2006 units units units units Tubular Fluorescent 1,500,000 2,000,000 1,642,000 1,400,000 CFL w/ ballast 4,566,425 9,667,000 460,000 853,000 Total 6,066,425 11,667,000 2,102,000 2,253,000

It was assumed for the analysis that 90% of retail sales were for residential lighting installations and 10% were for small IC&I installations. Professional sales were assumed to be 100% for small IC&I installations. 3.4 Lamp Types in Residential Sockets Data outlined in Table 3.1 were used to estimate the number of sockets occupied by different types of lamps (incandescent, CFL, etc) in the residential sector in Ontario. This was converted into a “% of sockets” value. The setting of lighting efficiency standards was announced by both the Federal and Provincial governments in April, 2007. These standards are expected to rapidly increase the uptake of CFLs, which are more energy efficient, and result in a move away from incandescents over time.


Page 5 August, 2007

Table 3.1: Estimate of Sockets per Household in Ontario in 2003 (Using 2003 SHEU Data)

Incandescent Halogen CFL Fluorescent Tubes

Range of # of

bulbs in use

Avg # of bulbs in

use # hhlds % # bulbs

Range of # of

bulbs in use

Avg # of bulbs in

use # hhlds % # bulbs # hhlds % # bulbs # hhlds % # bulbs

Total Sockets

0 0 0 0% - 0 0

2,135,416 55% -

2,603,295 67% -

1,485,316 38% -

1 to 10 5

844,065 22% 4,731,078 1 to 5 3

1,183,529 31%

3,963,364 854,828 22%

2,857,804

1,849,321 48%

6,179,379

11 to 20 15

1,335,649 35%

22,459,380 6 + 6 552,285 14%

3,698,948 419,631 11%

2,805,765

545,093 14%

3,642,781

21 to 30 25

906,229 24%

25,397,568

31 + 35

768,828 20%

30,165,561

100%

82,753,587 100%

7,662,312

5,663,569 100%

9,822,160

105,901,629 Notes: Range refers to the number of bulbs used in the household. Does not indicate amount of time used. # hhlds refers to the number of households that participated in this survey. In Ontario there were actually 4.321 million hhlds in 2003. Source: Survey of Household Energy Use (SHEU) - Detailed Statistical Report, 2003, Cat No. M144-120/2003ENatural Resources Canada http://oee.nrcan.gc.ca/publications/statistics/sheu03/pdf/sheu03.pdf Number of Household in Ontario in 2003 was 4,321,283. Calculated from 2001 Census with 1.2 % annual growth.


Page 6 August, 2007

The rate at which incandescent bulbs (the most common bulbs currently in households) will be replaced by CFLs between now and 2012 was modeled as part of this study, to identify the rate at which CFLs would be discarded over time. Two market transformation scenarios were modeled:

• All residential light fixtures which currently have incandescent bulbs will have CFLs by 2013 (the year after the lighting efficiency standards come into effect), and

• Half of incandescent light fixtures will convert to CFLs while the remainder will migrate to new, energy efficient incandescent bulbs (currently being designed by lighting manufacturers) or other types of energy efficient bulbs.

The latter scenario also takes into account the fact that CFLs are not suitable for some applications (e.g. oven lights or lights in enclosed spaces). The percentage of light fixtures with fluorescent tubes and halogen bulbs was assumed to remain constant at 9% and 7% of the total sockets in a household from 2006 to 2015 to simplify the analysis. The remaining 84% of sockets was assumed to be split between incandescent and CFL installations, with varying percentages of each lighting type. Tables 3.3 and 3.4 show the estimated percentage allocation of sockets to different lamp types in Ontario residences between 2003 and 2015. Tables 3.5 and 3.6 show the estimated numbers of sockets with different lamp types in Ontario from 2003 to 2015, taking household growth into account. 3.5 CFLs and Fluorescent Tubes in Small IC&I Locations Sales data provided by EFC for 2005 and 2006 were used to create a profile which was flat-lined from 2005 back to 2003 and from 2006 forward to 2015 to create data for the Lifespan Model. Data were not available on 2003 and 2004 sales and industry predictions on future market growth were not available on which to develop a more detailed projection. 3.6 New Lighting Designs Which Might Impact on Analysis The modeling takes into account the fact that current incandescents may be replaced (fully or partially) by CFLs over time. Two factors may impact on the market movement:

o An increase in the use of LEDs for specialized applications. At this time LED designs are typically used in specialized applications such as kitchen task lighting or decorative lighting.


Page 7 August, 2007

o Development of high efficiency incandescents which can meet the new federal

and provincial energy efficiency standards.

Table 3.3 Assumed Percentage of Different Light Bulbs in Ontario 2003 to 2015

100% Replacement of Incandescents by CFLs by 2013

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Incandescent 79% 77% 75% 70.5% 60.5% 50.5% 40.5% 30.5% 20.5% 10.5% 0% 0% 0% CFL 5% 7% 9% 13.5% 23.5% 33.5% 43.5% 53.5% 63.5% 73.5% 84% 84% 84% Fluorescent Tube 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% Halogen 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% Total 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

Table 3.4 Assumed Percentage of Different Light Bulbs in Ontario 2003 to 2015


Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Incandescent 79% 77% 75% 70.5% 60.5% 58% 54% 51% 48 % 45% 42% 42% 42% CFL 5% 7% 9% 13.5% 23.5% 26% 30% 33% 36% 39% 42% 42% 42% Fluorescent Tube 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% Halogen 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% Total 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

Table 3.5 Number of Residential Sockets in Ontario

100% Replacement of Incandescent by CFLs by 2013 (1000s of Units)

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Incandescent 82,754 84,183 82,980 78,938 68,554 57,909 46,999 35,819 24,364 12,629 - - -

CFL 5,664 7,653 9,958 15,116 26,628 38,415 50,481 62,830 75,469 88,403 102,244 103,471 104,712

Fluorescent Tube 9,822 9,840 9,958 10,077 10,198 10,320 10,444 10,570 10,696 10,825 10,955 11,086 11,219

Halogen 7,662 7,653 7,745 7,838 7,932 8,027 8,123 8,221 8,319 8,419 8,520 8,623 8,726

Total Sockets 105,902 109,328 110,640 111,968 113,312 114,671 116,048 117,440 118,849 120,276 121,719 123,179 124,658


Page 8 August, 2007

Table 3.6

Number of Residential Sockets in Ontario 50% Replacement of Incandescents by CFLs by 2013

(1000s of Units)

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Incandescent 82,753 84,182 82,980 78,937 68,553 66,509 62,665 59,894 57,047 54,124 51,121 51,735 52,356

CFL 5,663 7,652 9,957 15,115 26,628 29,814 34,814 38,755 42,785 46,907 51,121 51,735 52,356


Halogen 7,662 7,652 7,744 7,837 7,931 8,027 8,123 8,220 8,319 8,419 8,520 8,622 8,726

Total Sockets 105,901 109,328 110,640 111,968 113,311 114,671 116,047 117,440 118,849 120,275 121,719 123,179 124,658


Page 9 August, 2007

4. Lifespan and Storage Data CFL and fluorescent tube discards are calculated by the Lifespan Model based on historical annual unit sales combined with product lifespans, which dictate when products need to be replaced. This section briefly documents available data on CFL and fluorescent tube lifespans identified through the study research and the assumptions used in the Lifespan Model. 4.1 Reported Lifespan of Different Lighting Types Light bulb lifespans are generally reported as hours, presented in Table 4.1. These lifespans were agreed through correspondence among Project Task Group members following the 23rd July, 2007 meeting.

Table 4.1: Reported Lamp Life

Lamp Hours2 Pollution Probe 3 Natural Resources Canada4

Years Used in Lifespan Model

Incandescent 1,000 1,000 std

2,500 long life 1,000 high efficiency

1

Halogen 3,500 to 5,000 4

CFL 6,0005 to 18,000 5,000 to 10,000 4.3 based on OEB6 average

Fluorescent Tubes 20,000 to 36,000 12,000 to 20,0007 3-4 (avg 3.5) based on EFC input

HID 6,000 to 40,000 20,000 to 27,000

Induction & LED 50,000 ( 6 years) to 100,000

Ceramic Metal Halide 10,500 to 12,000

The lifespan of a CFL relative to an incandescent light bulb is of particular importance in this study, where this information is needed to model how CFLs will replace incandescents over time. Various sources on CFL lifespan relative to incandescents are quoted below: 2 Presentation: “Technology Review - Energy Efficient Alternatives”. National Lighting Summit June 27 2007. Roy Hughes P Eng LC. BC Hydro Powersmart. 3 Hilkene et al: Bac kground Study on Increasing Recycling of End-of-life Mercury-containing Lamps From Residential and Commercial Sources in Canada, Pollution Probe Foundation and Hilkene International Policy, October, 2006 4 http://www.energyguide.com/esu/RefContent.asp?bid=PNM&id=17 5 Source: Energy Efficient Procurement Workshop, Mumbai Sept 2005 6 Ontario Energy Board 7 T8 (1” diameter) and T12 (1.5” diameter)


Page 10 August, 2007

• According to the Office of Energy Efficiency (USA) CFLs can last up to 5 years

based on 3 hours of use per day8.

• Compact fluorescent bulbs last at least nine times longer than standard incandescent bulbs. Compact fluorescents are rated for 10,000 hours and incandescents are typically rated for 1,000 hours. If you have a bulb that is on eight hours a day, a compact fluorescent will last 3.4 years. If a standard incandescent were used, it would have to be replaced 10 times9.

• A 15 W CFL replaces a 60 W incandescent and its median lifespan is 10,000

hours10.

• The average lifespan of an incandescent bulb is 750 to 1000 hours. CFLs on the other hand can last up to 15,000 hours11.

• Ordinary (incandescent) light bulbs have a low initial cost, but are not very

energy efficient, as only 5 percent to 8 percent of the energy that goes into the fixture produces light, while the rest is dissipated as heat. Halogen light bulbs in some wattages can use 15 percent less energy and last two to four times longer than incandescent bulbs. Fluorescent tubes use 60 percent to 80 percent less energy and last 10 to 20 times longer than incandescent bulbs, but are not compatible with standard light sockets. CFLs, on the other hand, are compatible with standard light sockets, consume 67 percent to 75 percent less energy than incandescent bulbs and last up to10 times longer12.

• A good quality incandescent bulb lasts 1,000 hours on average. A CFL lasts 5 to

15 years under normal use. CFLs last 6000 to 10,000 hours and some are designed for 20,000 hours. A Westinghouse LED bulb has a lifespan of 80,000 hours13.

Table 4.2 presents data on how many hours light fixtures are used in different rooms of US homes, measured by the US Department of Energy.

8 HIlkene et al: Bac kground Study on Increasing Recycling of End of Life Mercury Containing Lamps from Residential and Commercial Sources in Canada. Prepared by Hilkene Intl Policy and Pollution Probe. For NRCan and Env Can Oct 31, 2005. 9 Pennsylvania Dept of Environmental Protection. (http://www.p2pays.org/ref/01/00149.pdf) Accessed July 19,2007 10 Internet Source: Triple Pundit. Ask Pablo Lightbulb Philanthropy. Accessed June 28, 2007. www.triplepundit.com/pages/askpablo-lightbulb-philanthrop-002437.php 11 . (http://blogs.howtogeek.com/mysticgeek/2007/06/25/compact-fluorescent-light-bulbs/) Accessed July 19, 2007. 12 Bac kground Study on Increasing Recycling of End of Life Mercury Containing Lamps from Residential and Commercial Sources in Canada. Prepared by Hilkene Intl Policy and Pollution Probe. For Natural Resources Canada and Environment Cananda Oct 31, 2005. 13 Popular Mechanics. “Brighter Better Light Bulbs”. Published June 2004



Table 4.2: Annual Hours of Operation By Room-Type By Home-Type for the Residential Sector14

Room Mobile Home

Single Family

Detached

Single family

Attached

Multi-family 2-4

Units

Multi-family >4

Units

Bathroom 603 669 617 647 577 Bedroom 403 406 408 442 423 Closet 314 513 382 264 183 Dining Room 888 829 885 1088 1080 Family Room 626 772 676 441 453 Garage 667 720 665 0 0 Hall 519 616 542 462 414 Kitchen 994 1210 1089 921 888 Living Room 948 864 921 1040 1015 Office 385 708 676 435 401 Other 267 435 299 0 0 Outdoor 981 1027 989 0 0 Utility Room 487 888 673 448 370

The table shows that hours of use vary, with the highest number of hours of use being in kitchens and living rooms, as would be expected. For this study, an average of 1,000 hours of use per year was chosen for incandescents, resulting in a lifespan of one year per incandescent on average. For CFLs, an average lifespan of 4.3 years was used in the Lifespan Model, as this is the value used by the Ontario Energy Board for TRC15 calculations. EFC members of the Project Task Group confirmed that 4.3 years was a reasonable assumption for a CFL lifespan. EFC members of the Project Task Group also suggested that a lifespan of 3 to 4 years should be used for fluorescent tubes. Their research shows that schools replace fluorescent tubes on a three year cycle, and offices on a 3 to 4 year cycle. Fluorescent tubes are not replaced when they are totally spent, rather when the strength of the light they provide begins to weaken, therefore before their theoretical lifespan has been reached16. This is consistent with the Washington State Department comment that:

Fluorescent tubes provide overhead lighting in offices, businesses, and at home in the kitchen, workshop, office, bathroom and laundry room. Fluorescent lights last about four years.

14 Source: US Lighting Market Characterization. Volume 1: National Lighting Inventory and Energy Consumption Estimate. Table D-4. US Dept of Energy. Sept 2002. 15 Total Recovery Cost (TRC) – a measure of the cost of energy efficiency measures used by the Ontario Energy Board 16 Discussion Wayne Edwards, EFC



4.2 Storage Assumptions In some Lifespan studies (particularly long life products such as televisions), discard estimates are sensitive to assumptions on how long products are stored after they have reached the end of their first life. For this study, no data were available on how long consumers would store a discarded CFL or fluorescent tube before it was discarded or recycled. To incorporate some storage into the analysis, a sensitivity analysis was carried out on three storage assumptions:

o No CFLs and fluorescent tubes are stored before discard o 50% of CFLs and fluorescent tubes are stored for 1 year before discard and o 100% of CFLs and fluorescent tubes are stored for 1 year before discard.

4.3 Reuse Assumptions In some Lifespan studies (particularly for products such as computers and televisions), discard estimates are sensitive to assumptions on what percentage of products are reused after they have reached the end of their first life. It was not considered likely that CFLs or fluorescent tubes would be reused after their first useful life was over, therefore a 0% reuse assumption was made. 4.4 Use of Lifespan, Storage and Reuse Assumptions to Construct the Lifespan Model The lifespan of products indicates when they need to be replaced. At that time, a new product is purchased and the old one is at the end of its (first in the case of items reused) useful life. Lifespan assumptions in this section were used to construct an annual unit sales profile for CFLs and fluorescent tubes in Ontario from 2001 to 2015. The sales information was combined with other data to estimate the discard rate for these products.



5. Annual Sales Estimates

An annual sales profile was constructed for CFLs and fluorescent tubes combining the profile in Section 3 with the lifespan assumptions in Section 4. 5.1 Annual Residential Light Bulb Sales Estimates By Type, 2003 to 2015 Tables 5.1 and 5.2 show the annual residential lighting bulb unit sales estimates calculated in this study to populate the Lifespan Model. The annual sales are made up of three separate factors:

• Replacement of previously purchased and installed light bulbs; • Purchases which replace one type of light with another (e.g. sales that “swap”

incandescents with CFLs); and • Light bulbs related to new households.

Table 5.1 shows the substantial year on year increase in CFL sales required to meet the significant market transformation necessary between now and 2013, if lighting efficiency standards are to be met by a replacement of current incandescent bulbs by CFLs. Industry sources represented by EFC have expressed a concern that there is not sufficient manufacturing capacity to meet the scenario of a 100% changeover to CFLs from incandescent lighting. Fluorescent tubes would remain at 9% of total lighting fixtures and this proportion would remain unchanged during the study period. Halogens were assumed to continue to occupy 7% of lighting fixtures (unchanged 2006 to 2015). New lighting designs (e.g. LED, ultra-efficient incandescents) may alter these assumptions over time. 5.2 Sales of Fluorescent Lamps to Small IC&I Establishments EFC sales data for 2005 and 2006 were used to develop a simple sales profile for the small IC&I sector, flat-lining the data back from 2005 to 2003 and forward from 2006 to 2015 taking population growth into account.



Table 5.1

Annual Sales of Fluorescent Light Bulbs in Ontario 2003 to 2015 100% Replacement of Incandescents by CFLs by 2013

(1000s of Units)

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

CFL 3,623

3,632

4,110

8,700

17,310

19,576

22,161

27,605

39,408

51,491

64,474

64,057

76,711

Fluorescent Tube

1,318

1,334

1,350

1,800

1,822

1,843

1,866

1,888

1,911

1,934

1,957

1,980

2,004

.

Table 5.2 Annual Sales of Fluorescent Light Bulbs in Ontario 2003 to 2015

50% Replacement of Incandescents by CFLs by 2013 (1000s of Units)

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

CFL 3,623

3,632

4,110

8,700

12,724

15,460

15,012

19,098

26,169

33,979

39,072

39,369

43,407

Fluorescent Tube

1,318

1,334

1,350

1,800

1,822

1,843

1,866

1,888

1,911

1,934

1,957

1,980

2,004



6. Fluorescent Lamp Discards Over Time

6.1 Fluorescent Lamp Discards Tables 6.1 to 6.3 present estimated discards of CFLs in Ontario from small IC&I and residential sources in two year intervals from 2008 to 2014. Discards are calculated by the Lifespan Model based on historical sales (outlined in Section 5) combined with product lifespans (outlined in Section 4). The discard estimates were developed for two scenarios:

• 100% replacement of incandescents by CFLs by 2013, and • 50% replacement of incandescents by CFLs by 2013.

The 100% replacement of incandescents with CFLs scenario leads to a much higher discard estimate for fluorescent light bulbs (14 million units per year in 2010 and 37 million units per year by 2014) with no storage. This scenario should be considered the conservative upper estimate of the number of CFLs likely to be discarded. Other lighting options are likely to compete for the market gap created by the phase out of inefficient incandescent bulbs and this upper limit estimate of CFLs used and discarded may not occur. While companies are working on super-efficient incandescent lamp designs, these products are not sufficiently developed to be considered in this analysis. The discard estimates were also developed for three storage scenarios (0%, 50% and 100% of discards are stored for one year), to provide a range of values for planning purposes. The zero storage estimate yields the highest discard values, and assuming that 100% of discarded CFLs are stored for one year yields the lowest discard estimate. The data show that a range of approximately 4 to 6 million CFLs could be discarded in Ontario in 2008. These values increase to approximately 9 to 14 million CFLs by 2010 and could reach 20 to 37 million CFLs per year by 2014. The lower estimate assumes a 50% replacement rate of CFLs by incandescents and 100% storage of discarded CFLs for one year. The higher estimate assumes 100% replacement of incandescents by CFLs and no storage.



Table 6.1: CFL Discards

Zero storage after first life (Units in Thousands)

2008 2008 2010 2010 2012 2012 2014 2014

50%

Incand to CFL

100% incand to

CFL

50% Incand to

CFL

100% incand to

CFL

50% Incand to

CFL

100% incand to

CFL

50% Incand to CFL

100% incand to

CFL CFL Residential 5,016 5,016 10,249 12,424 15,574 21,663 23,565 35,166

CFL Small IC&I 1,086 1,086 1,607 1,607 1,868 1,868 1,914 1,914 Total CFL Discards 6,102 6,102 11,856 14,031 17,442 23,531 25,479 37,080

Table 6.2: CFL Discards 50% storage for one year after first life

(Units in Thousands) 2008 2008 2010 2010 2012 2012 2014 2014 50%

Incand to CFL

100% incand to

CFL

50% Incand to

CFL

100% incand to

CFL

50% Incand to

CFL

100% incand to

CFL

50% Incand to

CFL

100% Incand to

CFL CFL Residential

4,125 4,345 8,770 10,431 14,274 19,300 21,250 31,177

CFL Small IC&I 946 946 1,480 1,480 1,858 1,858 1,902 1,902 Total CFL Discards

5,071 5,291 10,250 11,911 16,132 21,158 23,152 33,079

Table 6.3: CFL Discards 100% storage for one year after first life

(Units in Thousands) 2008 2008 2010 2010 2012 2012 2014 2014

50%

Incand to CFL

100% Incand to

CFL

50% Incand to

CFL

100% incand to

CFL

50% Incand to

CFL

100% incand to

CFL

50% Incand to

CFL

100% Incand to

CFL CFL Residential 3,233 3,674 7,292 8,438 12,974 16,937 18,935 27,187

CFL Small IC&I 806 806 1,353 1,353 1,848 1,848 1,891 1,891 Total CFL Discards 4,039 4,480 8,645 9,791 14,822 18,785 20,826 29,078



Table 6.4 shows the estimated discards of fluorescent tubes by residential and small IC&I sources in Ontario from 2008 to 2014 in 2 year intervals. About 3.3 million fluorescent tubes will be discarded by residential and small IC&I sources in Ontario in 2008, increasing to 3.5 million by 2014.

Table 6.4: Fluorescent Tube Discards (Units in Thousands)

2008 2010 2012 2014 2008 2010 2012 2014 2008 2010 2012 2014

Sector No storage

No storage

No storage

No storage

50% storage

50% storage

50% storage

50% storage

100% storage

100% storage

100% storage

100% storage

Fluorescent Residential 1,451 1,704 1,855 1,899 1,388 1,640 1,844 1,888 1,326 1,576 1,833 1,877

Fluorescent Small IC&I 1,830 1,660 1,643 1,683 1,873 1,702 1,634 1,672 1,915 1,745 1,625 1,662

Total Fluorescent Discards

3,281 3,364 3,498 3,582 3,261 3,342 3,478 3,560 3,241 3,321 3,458 3,539

6.2 Processing Capacity Requirements

Table 6.5 presents the range of discard estimates as well as processing requirements for 2008 to 2014 based on a 60% collection rate and a 75% collection rate.

Table 6.5: Fluorescent Lamp Processing Capacity Requirements (Millions of Units per Year)

Year CFLs

Discarded Fluorescent

Tubes Discarded


(60% Collection)


(75% Collection)

2008 4-6 3 4-5 5-7 2010 9-14 3 7-10 9-13 2012 15-23 3 11-16 13-19 2014 21-37 3 14-24 18-30

The table shows that processing capacity for 7 to10 million fluorescent lamps would be required by 2010, assuming a 60% collection rate. Should the collection rate increase to 75%, processing capacity for 13 to19 million lamps would be required by 2012, increasing to a requirement for 18 to 30 million units by 2014.



7. Weight and Composition of Fluorescent Bulbs and Tubes

The mercury content of CFLs and fluorescent tubes is of greatest interest to consumers and the government, therefore this section focuses on this one aspect of CFLs and fluorescent tubes. Other components of both lighting types include glass, metals, and phosphoric powder with mercury entrained in the glass coating. 7.1 Weight of Fluorescent Tubes The weight of a CFL is reported as 142 grams17 . Reported weights of other fluorescent and mercury containing lamps are presented in Table 7.1

Table 7.1: Weight of Mercury Containing Lamps

Lamp Type Environment Canada18

Electro Federation of Canada FLR

4 foot tube 0.3125 kg 0.245 kg 8 foot tube 0.625 kg 0.53 kg 0.29 kg19 HID 0.22 kg 0.22 kg High Pressure Sodium 0.22 kg 0.15 kg

7.2 Mercury Content of Fluorescent Lamps Table 7.2 presents mercury content data from Environment Canada’s Mercury and The Environment website.

Table 7.2: Mercury Content of Various Lighting Types

Lamp Type Mercury content (mg)20 CFL 1-25 Fluorescent U-Tubes 3-12 Fluomeric Lamps 2 Linear Fluorescent Lamps Mercury reduced Non-mercury reduced

3-12 10-50

Mercury vapour lamps 75-watt 1500 watt

25 225

Metal Halide lamps 75-watt 1500 watt

25 225

Sodium Vapour lamps 35-watt 1000 watt

20 145

Source: Environment Canada’s Mercury and the Environment Program (www.ec.gc.ca)

17 www.lamptech.co.uk – weight of Philips Tornado Asian Compact Fluorescent 18 http://www.on.ec.gc.ca/epb/fpd/fsheets/4021-e.html viewed 16th August, 2007 19 Hilkene et at ( P 29 Pollution Probe report) 20 www.ec.gc.ca/MERCURY/SM/EN viewed 16th August, 2007



7.2.1 Mercury Content of CFLs The Environment Canada website reports the mercury content of CFLs as ranging from 1 mg to 25 mgs per bulb. Most sources quote the mercury content in the average CFL as being about 5 milligrams or less. This amount would fit on the tip of a ballpoint pen, according to the U.S. Environmental Protection Agency. Manufacturers have committed to cap the amount of mercury in most CFLs to 5 milligrams or 6 milligrams per bulb. The majority of Philips Lighting's bulbs are reported to contain less than 3 milligrams, and some have as little as 1.23 milligrams21. Other sources quote the amount of mercury in CFL glass tubing at about 4 mg22. EEMAC23 staff confirmed that a value of 2 to 5 mg of mercury per CFL is a reasonable planning value. 7.2.2 Mercury and PCB Content of Fluorescent Tubes Fluorescent tubes serve as overhead lighting in offices, businesses, and at home in the kitchen, workshop, office, bathroom and laundry room. . Different sources quote different amounts of mercury contained in fluorescent tube lamps, listed below:

o Standard brand fluorescent lamps (long tubes) manufactured by SLI lighting contain less than 0.01 to 0.05 percent mercury by weight24.

o The 1.2 m (4 foot) tube accounts for 75% of Canadian market share of mercury

containing lamps. A typical 2006 era 4 foot (120 cm) T12 fluorescent lamp (i.e., F32T12) contains about 12 mg of mercury25.

o According to surveys conducted by the National Electrical Manufacturer’s

Association (NEMA), the average mercury content of a four foot lamp has reduced substantially in the last twenty plus years and was:

o 48.2 mg in 1985; o 22.8 mg in 1994; o 11.6 mg in 1999 and o 8.3 mg in 2001.

o In a study of four foot fluorescent lamps by Maine’s Department of Environmental

Protection, the average amount of mercury in T8 and T12 lamps manufactured in the year 2000 by three of the nation’s largest manufacturers (GE, Sylvania and Phillips) was found to vary between 3.2 mg and 6 mg per lamp depending on the vendor and model. The typical T8 lamp sold today has between 3 and 8 mg of

21 ENN “Mercury in Energy-Saving Bulbs Worries Scientists” March 29, 2007. Lisa Von Ahn, Reuters. 22 US EPA, Fact Sheet “Mercury in Compact Fluorescent Lamps (CFLS)” 23 Wayne Edwards, EEMAC, July, 2007 24 Product Safety Data Sheet. Fluorescent lamps. “white” standard brand Florescent Lamps for general Lighting. SLI Lighting, Erlangen, Germany. 25 [5] http://lightingdesignlab.com/articles/mercury_in_fl/mercurycfl.htm



mercury. Maine reported that a 10 year old 4 foot T8 lamp may contain up to 25 mg26 of mercury.

o In 1995, Philips Lighting introduced a low mercury fluorescent lamp containing

4.4 mg of mercury (USEPA 1999a)27.

7.2.3 Ballasts in Fluorescent Tubes28

Fluorescent lamps, like other discharge lamps (e.g. low pressure sodium lamps) require a ballast to function. Ballasts are devices that supply a high voltage to initiate a discharge arc and then limit the current to stabilize the discharge arc under normal operation29.

The ballast can either be integral to a CFL unit or a separate component. The CFL with integrated ballast was developed as an alternative to the incandescent light bulb to offer more energy efficient lighting options to consumers.

Fluorescent tubes have external ballasts. Ballasts manufactured and distributed in the United States prior to 1979 contain polychlorinated biphenyls (PCBs), which is a hazardous material. Since many magnetic ballasts have a service life of 25 years or longer, many of these ballasts are still in existence. If a ballast label is marked "NO PCBs", then it is not a PCB ballast; if there is no such marking, then the ballast is assumed to contain PCB fluid30.

7.3 CCME Canada Wide Standard for Mercury Containing Lamps The Canada Wide Standard for Mercury Containing Lamps is a largely voluntary approach undertaken by lamp manufacturers to reduce the amount of mercury in lamps over time. In the paper issued as the basis of the standard in 200131, CCME quoted the fact that mercury containing lamps emit 180 kg/year of mercury vapour to the atmosphere during their life cycle: 40 kg/year (or 22% during lamp manufacturing, transport, landfilling and incineration, and 140 kg/year (78%) indirectly through power plants. Waste lamps were reported to contribute 1,150 kg/year of mercury to landfill bound to the phosphor in the glass.

26http://www.dep.state.fl.us/waste/quick_topics/publications/shw/mercury/Mercury_CFL_Dynamics-final.pdf 27 USEPA 2002. Use and Release of Mercury in the United States, Chapter 3; Manufacturing Processes Involving Mercury. 28 http://www.lightsearch.com/resources/lightguides/wastedisposal.html 29 Lafevre et al International Energy Agency (IEA): Barriers to Technology Diffusion: The Case For Compact Fluorescent Lamps, Organization for Economic Co-Operation and Development (OECD Environmental Directorate , October, 2006 30 Handling and disposal instructions for ballasts with PCBs can be found on this EPA web page: www.epa.gov/pcb/guidance.htm 31 Canadian Council of Ministers of the Environment: Canada Wide Standard for Mercury Containing Lamps; Endorsed by CCME Council of Ministers, April 30-May1, 2001, Winnipeg



The manufacturers of mercury containing lamps had reduced the mercury content of standard 4 foot T12 lamps, with the average content declining from 48 mg/lamp in 1985 to 12 mg/lamp in 2000. At that time about one third of the market was composed of T8 lamps, which are more energy efficient than the older T12 lamps. The Canada Wide Standard (CWS) set a 70% reduction by 2005 and an 80% reduction by 2010 in the average content of mercury in all mercury containing lamps sold in Canada, measured against a 1990 baseline. Partners in the CWS are required to submit reports in 2004, 2007 and 2012, documenting progress towards the CWS. In its October 19th, 2004 update on mercury reduction, Electro Federation of Canada reported that the average mercury content of all mercury containing lamps sold in 2003 was 11.4 mg per lamp. This represents a 73.5% reduction from the 1990 baseline of 43 mg per lamp, and exceeds the 2005 CWS target of 70% reduction32. 7.4 Composition of CFLs CFLs are made up of the following components33 (all values are approximate):

o Ballast o Plastic casing o Integrated circuit board o Copper - 5.25 cm2 o Solder (lead) - undetermined amount o Five capacitors o Sixteen resistors o Micro chip o Transformer o Nine diodes o Epoxy glue o Glass - 253 cm2 (surface area measurements) o Inert gas (Argon) - 69 cm3 (volume based on surface area measurements above) o Conductor wire - 37 cm o Mercury o Phosphorus coating - 5mg o Fluorides o Antimony o Manganese o Nuisance dusts

Table 7.3 presents the typical composition of a CFL and a fluorescent tube. The

information was obtained from a Product Safety Data Sheet produced by SLI Lighting. 32 Canada Wide Standards for Mercury (Mercury Emissions, Mercury Containing Lamps and Mercury for Dental Amalgam Waste) – A Report on Progress, June 1005 33 33 http://www.care2.com/c2c/groups/share_detail/7516/341513 (Accessed July 17 2007)



Table 7.3: Composition of a Compact Fluorescent Light and Fluorescent Lamps34

Material Composition of CFL Composition of Fluorescent Tube

Glass 75% to 90% 75% to 95% Mercury < 0.015% <0.01% to <0.05% Lead oxide 0.2% to 2% 0.2% to 2% Aluminum oxide 0% to 2% 0%-2.0% Fluorescent phosphor 0.5% to 3% May contain 0.5 to 3% Misc compounds (fluoride, manganese as dust, tin as dust, etc)

0% to 0.1% 0 to 0.1% per compound

Based on a reported weight of 142 grams for a CFL35, each CFL should contain less than 2mg of mercury. This is at the lower end of the range of 2 to 5 mg per CFL reported by a number of sources. By comparison, a regular incandescent bulb is made up of the following components36 (all values are approximate):

o Insulation o Epoxy o Glass -113 cm2 (surface area measurements) o Inert gas (Argon) - 113 cm3 (volume based on surface area measurements

above) o Conductor wire - 16cm o Support wires - 3cm o Tungsten filament

The composition of a 4 foot (1.2 metre) fluorescent tube is presented in Table 7.4. This information was compiled from Environment Canada and EFC.

Table 7.4: Composition of 1.2 Metre Fluorescent Tubes

Material Weight (EC) Weight (EFC)37 Glass 260g38 230g Metals 20g39 2g aluminum

0.5g steel Phosphor powder 10g40 Mercury 0.0116g41 0.0114g

34 Source: SLI Lighting Product Safety Data Sheet 35 Weight of Philips Tornado Asian CFL 36 http://www.care2.com/c2c/groups/share_detail/7516/341513 (Accessed July 17 2007) 37 Hilkene et al, P 40 (Pollution Probe Report data from EFC) 38 Hilkene et al (P 22 Pollution Probe Report, Feb 2005 interview Tom Maxwell, FLR and P 40 data from EFC) 39 ibid 40 ibid 41 www.ec.gc.ca/MERCURY/SM/EN viewed 16th August, 2007



8. Fluorescent Lamp Recycling Infrastructure in Ontario

8.1 Fluorescent Lamp Recycling Infrastructure in Canada Five companies currently recycle spent mercury-containing lamps in Canada. These five companies are:

• Environmental Lamp Disposal Ltd., • Fluorescent Lamp Recyclers Inc. (FLR), • Nu-Life Industries Inc., • PROECO Corporation and • Recyclage de Lampes Fluorescent AAZ Inc (RLF).

A sixth company, International Marine Salvage Inc, located in Port Colborne, Ontario, consolidates fluorescent lamps for shipment to Bethlehem Apparatus in Pennsylvania. Environmental Lamp Disposal Ltd.42 Environmental Lamp Disposal Ltd. is located in the City of Edmonton and offers a pickup program within the province of Alberta. It also accepts delivered lamps from anywhere in Canada. Environmental Lamp Disposal Ltd. does not break lamps prior to feeding them into its machine to eliminate the possibility of airborne contaminates during handing. The company utilizes a cold water and vacuum process to collect contaminants during the recycling process. This process has been independently monitored and emission levels have been documented to be well below the maximum allowable levels for water and air quality set by local governmental regulations. Fluorescent Lamp Recyclers Inc. (FLR) FLR is located in Ayr, Ontario. It is the only full service fluorescent lamp processing facility located in Ontario, and is described in detail in Section 8.4. Nu-Life Industries Inc.43 Nu-Life Industries is located in Aldergrove, British Columbia. Using its specially designed fluorescent lamp machine, lamps are disassembled into their components: glass, used in the manufacture of fibreglass; endcaps, used by smelters; and, mercury-containing phosphor powder, which is sent for removal of mercury through a distillation process. 42 RCO Fluorescent Lamp Stewardship Pilot Project, March 2007 43 ibid



PROECO Corporation44 PROECO Corporation is a fully licensed recycling and disposal facility located in Edmonton, Alberta that has run a fluorescent tube recycling program for more than 10 years. On receipt, the fluorescent lamp tubes are transferred to a processing area for recycling. Once the lamps are inserted into a self contained lamp crushing unit, emissions are controlled by a High Efficiency Particle Air (HEPA) and carbon filtration system. The components are then separated and the residuals are sent for recovery and recycling. PROECO Corporation has partnered with Alberta Environment's Action on Waste program. Recyclage de Lampes Fluorescent AAZ Inc. (RLF)45 RLF is a fully licensed lamp recycling subsidiary of ChemTECH Environment Inc. RLF was established in 1996 in Coteau-du-Lac, Quebec, and offers a lamp recycling service to clients in Quebec, eastern Ontario and the north eastern United States. RLF has been providing fluorescent lamp recycling services for 10 years. The company currently provides a pick-up service in eastern Ontario (Ottawa to Kingston, but not as far as Toronto) for all fluorescent lamps (CFLs, tubes, HID, mercury, sodium, flood lights, projector lamps, etc). The lamps are crushed at their facility and separated into glass, metal and mercury entrained in the phosphor powder, which is sent to Bethlehem Apparatus for recycling. The plant currently has capacity to process 2,500 tubes (or CFLs) per hour (100,000 per week, or 5 million per year), and can increase capacity by a factor of 2 or 3 by adding extra shifts. There are carbon filters on the crushing machine to capture mercury vapour, and additional carbon filters on the exhaust air from the processing facility, which operates at 4 air changes per hour. International Marine Salvage Inc. International Marine Salvage Inc is located in Port Colborne, Ontario. The company consolidates fluorescent lamps for shipment to Bethlehem Apparatus in Pennsylvania. Operations are discussed in Section 8.5. 8.2 Lamp Crushers There is a separate category of fluorescent lamp recyclers referred to as “lamp crushers”. These companies have equipment such as Bulb Eater™ which crush and shred fluorescent lamps on a small scale, onsite. The shredding equipment is located on top of a container such as a barrel or drum, and lamps are hand-fed through the shredding equipment. The shredded material is collected in the drum or container on which the shredding equipment is located. A 55 gallon container can reportedly hold

44 ibid 45 ibid



1,350 4 foot fluorescent lamps. The shredded materials are stored in barrels or drums for transportation to more comprehensive processing facilities. Emissions from the shredding operation are captured through various filters located on the top of the drum. A three stage filtering process removes hazardous particulates and gases. Bulb Eater™ claims to capture 99.99% of the vapours released in lamp crushing. The company quotes a 2005 study that showed non-detectable levels of escaped mercury vapour after crushing 1,500 lamps46. Benefits of the system listed in Bulb Eater™ promotional material include EPA and OSHA compliance, freeing up valuable storage space normally filled with boxes of spent whole lamps, reduced handling and related labour costs47. Concerns have been expressed by some regarding escape of mercury during the bulb crushing operation. 8.3 Considerations Regarding Future Fluorescent Lamp Recycling Capacity Demands Return-to-retail pilots were implemented as part of the BC Hydro Powersmart CFL market transformation program. Home Hardware, Canadian Tire and other retailers were involved in the BC Hydro Powersmart CFL return to retail pilot. The BC retailers are reportedly sending the recovered lamps to a processor in Edmonton. Discussions are currently underway regarding return to retail for CFLs in Ontario. For example, IKEA has a return to retail program for CFLs. FLR (the only comprehensive processor located in Ontario at this time) is offering retailers special packaging options for returning product to its processing facility. CLFs recovered through these return to retail programs may utilize the existing available spare processing capacity. The Ontario Power Authority (OPA) will be implementing a program to replace T12 with T8 lamps in residential settings. They plan to wind down their CFL promotion programs (as part of the Every Kilowatt Counts program) as they feel that the message has been sufficiently communicated through the Suzuki campaign as well as their own campaigns. All of this activity will increase the number of fluorescent lights to be processed from Ontario residential and small IC&I generators, and will increase demand for spent fluorescent lighting processing capacity. 8.4 FLR, Ayr, Ontario FLR began business addressing PCB contamination problems for a range of customers in the early 1990s. One of the products they handled was PCB containing ballasts for

46 www.aircycle.com/news viewed 17th August, 2007 47 Ibid



fluorescent and other lighting fixtures. FLR saw an opportunity to provide more full service one-stop-shopping to their clients by offering to also manage fluorescent lighting. FLR has its own fleet of transport vehicles to pick-up fluorescent lamps stored in the original cardboard boxes from the replacement tubes or specialized collection containers supplied to various client sites by FLR. These containers are picked up by FLR trucks and are delivered to FLR's recycling facility in Ayr, Ontario. The company specializes in treating all mercury containing lamp waste including fluorescent tubes, mercury vapour, metal halide, high-pressure sodium, high intensity discharge and compact fluorescents. The FLR plant was visited on 11th July as part of this research project. Tom Maxwell of FLR dedicated 2 hours to discuss plant operations and provide Glenda Gies, WDO, and Maria Kelleher, Kelleher Environmental, with a plant tour. The paragraphs below provide a description of the FLR plant and current capacity, developed through notes from the site visit, clarified through emails with Tom Maxwell, and supplemented with information provided by Jo-Anne St. Godard of the Recycling Council of Ontario. 8.4.1 Capacity and Current Throughput of FLR Plant FLR reports their processing equipment has capacity for 100,000 lamps per day. However, they are currently processing 20,000 to 30,000 units per day or 5.2 to 7.8 million lamps per year. The most recent annual report under their Certificate of Approval listed 3.4 million lamps processed in 200648. Of their current throughput of fluorescent lamps and CFLs, approximately 90% are fluorescent tubes and less than 5% are CFLs. The current Ministry of Environment (MOE) Certificate of Approval for processing/transfer at the FLR facility stipulates the following:

o Storage limit of 100,000 whole mercury lamps o Storage limit of 50 tonnes of crushed mercury bearing lamps o Storage limit of 50 containers totaling 30 tonnes of liquid mercy product

The Certificate of Approval lists four optional operational phases with associated varying levels of financial assurance depending on the quantity of materials to be stored. FLR is currently moving from Phase 3 to Phase 2. The move reflects improved efficiency of operations at the site and less storage of product prior to shipment. The shift from Phase 3 to Phase 2 does not affect fluorescent operations. The Certificate of Approval for Air requires carbon filters on air discharges from fluorescent processing equipment and from the fluorescent storage area.

The plant currently operates 24 hours per day 5 days per week 52 weeks per year.

FLR experienced an electrical fire in a forklift in early August, 2007. About 4 or 5 skids containing about 2,000 lamps were stored next to the forklift and were involved in the fire. The local district MOE staff calculated that the lamps affected by the fire contained 48 Conversation Glenda Gies and Bob Miller, local MOE district office, 1st August, 2007



approximately 1 oz of mercury based on 8 ml in ‘green’ bulbs and 20 mg in regular bulbs. Processing equipment was not affected by the fire. Facility cleanup was required for soot removal. Local district MOE staff report that FLR is a well managed facility and that management are receptive to suggestions for improvements based on best practices. FLR staff indicated during the 11th July, 2007 site visit that their facility is audited by approximately 50 clients each year. The Certificate of Approval does not require FLR to track the quantity of mercury managed and recovered at FLR, shipment of mercury products from FLR, the location where the mercury is sent and how mercury is managed at its final destination. 8.4.2 Lamp and Tube Processing at FLR Figure 8.1 presents a flowchart of the process steps which occur at FLR. The various lamps FLR accepts (fluorescents, CFLs and mercury vapour lamps/HID lamps) are currently processed using the same set of equipment which is fed through an automated conveyor for tubes and a manual feed system for CFLs and mercury vapour lamps. The fluorescent lamps and the small number of CFLs and mercury vapour lamps currently processed go through the following processing steps:

• Automated feed o Lamps move on conveyor to a negative pressure containment area.

• Manual feed o CFLs and mercury vapour lamps are manually fed directly into the

negative pressure containment area. • Lamps are broken in the negative pressure machine to allow separation of glass,

aluminum, brass, and phosphor-mercury powder. • Individual components are cleaned, tested for mercury content and then

forwarded to downstream recycling outlets. • The broken glass is transported to Nexcycle Industries in Guelph where it is

processed prior to sale to Owens Corning as feedstock in the manufacture of fiberglass products.

• The metals are transported to Woznuk Brothers Metal Recycling in Cambridge for further processing and sale to metal smelters.

• CFL bases are transported to Sims (formerly Noranda) for metal recovery. • Phosphoric powder is separated from glass via mechanical separation. • The phosphoric powder is heated in a retort unit to separate the mercury from the

phosphor powder either at FLR or at Bethlehem Apparatus:

o If processed at FLR, the mercury is collected from the retort process, allowed to cool to liquid form and is then transported to Bethlehem Apparatus in Hellertown, Pennsylvania, in one tonne containers.

o Depending on supply, demand and economics, phorphoric powder may be shipped through Marine Salvage Inc. to Bethlehem Apparatus where the mercury is separated via a similar retort process.

o Bethlehem Apparatus triple distills the mercury for sale as a product.



Figure 8.1: Schematic of FLR Recycling Process

CRUSHER

SEPARATOR

USED FLUORESCENT LAMPS

PHOSPHOR POWDER& METALLIC MERCURY GLASSMETAL

THERMALSEPARATION

TRIPLEDISTILLATION

PHOSPHORPOWDER

RECOVEREDMERCURY

RECYCLE RECYCLE

REUSE

CLEAN MERCURY

REUSE

8.4.3 Ability to Process Additional Lamps and CFLs FLR reported planning for modifications to their plant to process mercury vapour/HID lamps independently of other fluorescent lamps. Equipment to support separate processing of mercury vapour/HID lamps is expected to be installed in the third quarter of 2007. By segregating mercury vapour/HID lamps for separate processing, capacity for fluorescent tubes and CFLs will be increased.

Should supply of CFLs increase, FLR has indicated they would add processing equipment dedicated to CFLs and these will be segregated from tubes. Should FLR install dedicated CFL processing equipment, processing capacity for fluorescent tubes and for CFLs will both increase.



8.5 International Marine Salvage Inc (Raw Materials Company – RMC), Port Colborne, Ontario

Raw Materials Company (RMC) is a division of International Marine Salvage Inc. It is Canada's largest and Ontario's only processor of multiple battery types. The company is located near the U.S.-Canada border at Fort Erie-Buffalo, 90 minutes from Toronto and accessible by major highways. Raw Materials Company recycles in excess of 30 million pounds annually. RMC has been handling mercury wastes for 13 years. Their core business is related to battery recycling (mostly dry cell batteries) and other mercury containing waste materials49. RMC is permitted by the Ontario Ministry of Environment to collect and process air depolarized zinc batteries, nickel cadmium batteries, lead acid batteries, alkaline cells, magnesium batteries, silver oxide batteries, lithium batteries, mercury oxide batteries as well as all other mercury bearing wastes which include contaminated soils, elemental mercury, fluorescent light tubes, mercury containing switches, thermometers and devices. The Certificate of Approval includes a maximum storage limit of 20,000 lbs of tubes on site at one time. At RMC’s current business volume, this limit is not reached. RMC accept any size of fluorescent shipment from a single box to transport trailer loads. RMC do not break fluorescent lamps at their facility. Rather, fluorescent lamps are packaged for shipment to Bethlehem Apparatus in Pennsylvania, one of only two companies in the US with integrated mercury management facilities. Bethlehem Apparatus are the main supplier of clean mercury to the market. RMC indicate they have considered installing a lamp breaker at their Port Colborne facility and could do so with six months notice, based on market demand. They currently have identified a source of lamp breaking equipment but are deferring a decision to proceed pending timing of Phase 2 of the MHSW Plan and other factors which would suggest increased market demand. 8.6 Capacity to Process Fluorescent Tubes and CFls in Ontario Two facilities in Ontario currently provide fluorescent lamp recycling services:

• FLR, Ayr, Ontario which provides processing on-site, and • Raw Materials Company, a division of International Marine Salvage of Port

Colborne, Ontario, which provides consolidation of fluorescents for shipment to Bethlehem Apparatus in Pennsylvania.

49 Conversation Maria Kelleher and James Ewles, Vice Pres of International Marine Salvage (1-905-835-1203) 17th August, 2007



FLR FLR’s current clients include commercial and industrial accounts, energy retrofit companies, property management companies, automotive companies and a number of ISO certified industrial locations. Increased awareness of the need to properly manage fluorescent lights from re-lamping projects will likely increase the number of lamps sent to FLR in the coming years. FLR is the only processor in Ontario with approved capacity to process fluorescent lamps and bulbs. The company currently has a Certificate of Approval which allows it to store up to 100,000 lamps on the property at any one time. FLR rate their processing capacity at 100,000 lamps per day. The company reports that it currently operates at 20% to 30% of rated capacity, processing 20,000 to 30,000 lamps per day. Assuming a 5 day per week, 52 week per year operation, FLR currently processes 5.2 to 7.8 million lamps per year. If the plant were processing at full capacity, the plant could reportedly process 25 million lamps per year. Plant management indicated that they could quickly ramp up to provide additional processing capacity if guaranteed an assured supply of material. RMC Raw Materials Company, a division of International Marine Salvage, currently provides storage and consolidation services for fluorescent lamps with shipment of the lamps to the US for processing. Plant management indicated they would be willing to install a lamp crushing machine if they have confidence that the market needs the service. RLF RLF is a fully licensed and approved lamp recycling subsidiary of ChemTECH Environment Inc. based in Coteau-du-Lac, Quebec. The processing facility currently has capacity to handle 100,000 lamps per week (5 million per year). The company has indicated that it can easily expand capacity one or two fold by adding operating shifts on existing equipment. Summary Modeling for this project indicates that 9 to 14 million CFLs and about 3 million fluorescent tubes will be discarded by residential and small IC&I sources in Ontario in 2010. It is expected that a percentage of these lamps and bulbs will be delivered to MHSW collection locations throughout the province and will require processing. At a 60% collection rate, processing capacity to address 5 to 8 million CFLs and 2 million fluorescent tubes from the residential and small IC&I sector will be required in 2010. If



the collection rate increases to 75% in 2012, processing capacity requirements must also increase to 11 to 17 million CFLs50 and 2.5 million fluorescent tubes. In addition to required capacity for processing fluorescents from the residential and small IC&I sectors, capacity will also be required for fluorescent lamps from larger IC&I businesses. FLR’s reported current processing capacity of 25 million lamps per year, if technically achievable, would be sufficient to support their existing large IC&I customers (5.2 to 7.8 million lamps per year) as well as 60% collection from residential and small IC&I generators (5 to 8 million CFLs and 2 million fluorescent tubes in 2010). However, Ontario would benefit from having two recyclers based in the province with capability to process fluorescent lamps and properly manage the mercury contained in the fluorescent lamps. These benefits include:

• Increased competition in the marketplace; • Back up capacity if one plant were to experience unscheduled operational

problems; and • Back up capacity for regularly scheduled maintenance shut downs.

RMC has indicated a willingness to establish a full service processing facility in Ontario should market conditions appear favourable. Capacity can also be provided by adding additional shifts at the RLF (Recyclage de lampes fluorescent AAZ Inc) processing facility in Quebec, although this would be most suitable for lamps generated in eastern Ontario because of haulage distances. 8.7 Lead Time Required to Increase Processing Capacity For Both Tubes and Bulbs The capacity of the existing FLR plant can be increased through extra shifts, longer hours of operation and additional efficiency of de-packaging operations which currently represent a handling system bottle-neck. However, these approaches to increasing capacity will reach their limit and additional equipment will be required to add new processing capacity. FLR reports the following lead times for expansion:

• One to two months for preparation and design • Up to one year for an amendment to their Certificate of Approval • Two months for equipment installation and commissioning.

International Marine Salvage has indicated that 6 months would be required to purchase and install lamp crushing equipment at Raw Materials Company. It has been assumed that an amendment to their Certificate of Approval (for air emissions) would be required.

50 75% of estimated 15 to 23 million CFLs discarded



Should additional capacity be required rapidly in the Province to address an increased volume of fluorescent tubes and CFLs, amendments to FLR and/or RMC’s Certificates of Approval will be required. Prompt processing of these applications would ensure timely addition of new fluorescent processing capacity.



9. Summary and Conclusions

9.1 Discards and Processing Capacity Requirements Table 9.1 shows the anticipated discards of CFLs and fluorescent tubes in Ontario from 2008 to 2014, and the processing capacity required at 60% and 75% collection rates:

Table 9.1: Fluorescent Lamp Processing Capacity Requirements

(Millions of Units per Year)

Year CFLs Discarded

Fluorescent Tubes Discarded


(60% Collection)


(75% Collection)

2008 4-6 3 4-5 5-7 2010 9-14 3 7-10 9-13 2012 15-23 3 11-16 13-19 2014 21-37 3 14-24 18-30

An anticipated 4 to 6 million CFLs and 3 million fluorescent tubes will be discarded by residents and small businesses in Ontario in 2008. The number of CFLs increases substantially from 2008, reaching 21 to 37 million CFLs in 2014, whereas the number of fluorescent tubes remains fairly constant throughout this planning period.

At a 60% collection rate, processing capacity to address 5 to 8 million CFLs and 2 million fluorescent tubes from the residential and small IC&I sector will be required in 2010. If the collection rate increases to 75% in 2012, processing capacity requirements must also increase to 11 to 17 million CFLs and 2.5 million fluorescent tubes. 9.2 Current Processing Capacity and Expansion Potential Ontario has one full service fluorescent light recycler at this time. FLR of Ayr, Ontario with a reported processing capacity of 25 million lamps per year. FLR currently operates at 20% to 30% of rated capacity, therefore any operational limits at full capacity have not been identified. As fluorescent tubes comprise the majority of their current feedstock, FLR has expressed a willingness to install specialized CFL handling equipment if demand is evident. A second company, Raw Materials Company, a division of International Marine Salvage of Port Colborne, Ontario, currently receives and transfers fluorescent lamps to a US processor. RMC has expressed an interest in installing fluorescent lamp processing capacity if the market demand is evident. A third, Quebec-based company, RLF, currently serves the eastern Ontario market and can increase processing capacity by adding shifts. Increased collection of fluorescent lamps from large IC&I sources is likely to occur with increased public awareness of lighting efficiency standards and diversion options. Some



portion of the reported capacity will likely be required to manage these lamps and will reduce the capacity available to manage lamps from the residential and small IC&I sectors. Ontario would benefit from having two recyclers based in the province with capability to process fluorescent lamps and properly manage the mercury contained in the fluorescent lamps. These benefits include increased competition in the marketplace and back up capacity. 9.3 Mercury in Fluorescent Lamps CFLs contain 2 to 5 mg of mercury and fluorescent tubes contain 8 to 12 mg of mercury bound into the phosphorous powder coating on the bulb glass. In 2008, discarded CFLs in Ontario therefore will contain 8 to 30 kg of mercury and discarded fluorescent tubes will contain 24 to 36 kg of mercury. Mercury recovered from recycled fluorescent tubes and lamps is currently sent to the US for processing and/or refining. Two companies in the US, Bethlehem Apparatus and Goldstein, have the equipment required to process mercury. Mercury currently recovered in Ontario is transported to Bethlehem Apparatus. Mercury is triple distilled through a retort system and sold for specialized applications.

Under the MHSW Plan, annual audits of processors are proposed as part of the Plan’s tracking process. The final destination of each material, including mercury, would be identified and downstream processing and market locations would be confirmed as part of the due diligence effort.


Appendix Page 1 August, 2007

Appendix A

Construction of Ontario Residential Lighting Profile Percentage

Model and Development of Ontario Residential Annual Light Bulb Unit Sales Profile, 2003 to 2015

The first step in constructing a sales profile for fluorescent bulbs and tubes was to identify how many light sockets are present in Ontario households and how frequently existing light bulbs are replaced. A.1 Residential Lighting Sockets in Ontario Natural Resources Canada and Statistics Canada carried out a Survey of Household Energy Use (SHEU)51 in 1997 and 2003. The 2003 data was presented in greater detail and was used as the basis of the initial lighting profile developed for this study. Ontario-specific information from the SHEU was used to construct a profile of lighting bulb use in Ontario in 2003, shown in Table A.1. The SHEU data was presented in bands (e.g. 11 to 20 light bulbs per household). The average of each range was multiplied by the total number of households reporting in the range to estimate the total number of light bulbs or sockets in Ontario households in 2003. The methodology estimated 106 million sockets in Ontario households in 2003. EFC staff confirmed at a meeting on 23rd July, 2007 that a value of 102 million sockets (an earlier estimate) was reasonable for planning purposes. Therefore the updated 106 million value was considered reasonable for planning estimates. A.2 Historical and Projected Sockets per Household

The 1997 SHEU indicated 40.9 sockets per household in Ontario in 1997. The 1997 SHEU survey provided the following information about the distribution of lighting types used in Canadian households:

“The average Canadian house is fitted with 40.9 light bulbs; 36.5 of them indoors and 4.4 outdoors. Most of these, whether used indoors or outdoors, are incandescent bulbs. The rest are fluorescent (3.5 per house) and halogen (1.6). These two types of bulbs remain a minor part of the market, regardless of house characteristics or household profile. The only exception to this observation seems to be in Quebec, where recently built houses use about 50 percent more light bulbs than older ones. For example, houses built prior to 1961 are fitted with 33 light bulbs, and houses built after 1982 are fitted with 48 bulbs. Even In newer houses, the proportion of fluorescent bulbs or halogen bulbs is no higher than in older buildings.

51 Source: Survey of Household Energy Use (SHEU) - Detailed Statistical Report, 2003, Cat No. M144-120/2003ENatural Resources Canada



The average household had 2.7 halogen bulbs, or 8 percent of indoor bulbs. The number of light fixtures in a house is directly related to household income, because of the obvious link between income and the area of the house. The average number of light bulbs used more than doubles between households with an annual income below $20 000 (25.7) and households with an income of $80 000 or more (57.0).”52

The estimated 106 million light sockets in Ontario in 2003 were divided by 4.3 million households in Ontario in 2003 to identify an average of 25 lighting sockets per household in 2003. A linear decrease was applied from 1997 to 2003 to lower the average sockets per household from 41 to 25. A constant rate of 25 sockets per household was assumed from 2003 to 2015. A.3 Percentage of Different Types of Light Bulbs in the Light Sockets The percentage of each type of light bulb in Ontario households in 2003 was calculated from the SHEU results presented in Table A.1. More limited data from the 1997 SHEU survey was used to estimate the percentage breakdown in 1997. No data were provided for fluorescent tubes and halogens in the 1997 survey. However, the survey identified that 91% of bulbs were incandescents and 1% were CFLs in 1997. For this study, it was assumed that the remaining 8% was split between fluorescent tubes and halogens. An assumption of 1% halogens and 8% fluorescents was made for 1997 (halogens were less common then), and a linear increase to 2003 was assumed. Available information on the penetration of CFLs into the Ontario residential marketplace from different sources is presented in Appendix B. CFLs were reported to be installed in 1% of residential lighting sockets in 1997 and in 5% of residential lighting sockets in 2003. Most of this increase was assumed to occur in 2002 and 2003 when awareness of energy efficiency, and various incentives provided by electrical utilities, increased CFL sales. The percentage of incandescents in residential light sockets was adjusted in each year so that the total added to 100%.

52 Natural Resources Canada Office of Energy Efficiency 1997 Survey of Household Energy Use–Chapter 7. http://oee.nrcan.gc.ca/publications/infosource/pub/energy_use/sheu_e/sheu_7.cfm



Table A.1: Estimate of Sockets per Household in Ontario in 2003 (Using 2003 SHEU Data)

Incandescent Halogen CFL Fluorescent Tubes

Range of # of

bulbs in use

Avg # of bulbs in

use # hhlds % # bulbs

Range of # of

bulbs in use

Avg # of bulbs in

use # hhlds % # bulbs # hhlds % # bulbs # hhlds % # bulbs

Total Sockets

0 0 0 0% - 0 0

2,135,416 55% -

2,603,295 67% -

1,485,316 38% -

1 to 10 5

844,065 22% 4,731,078 1 to 5 3

1,183,529 31%

3,963,364 854,828 22%

2,857,804

1,849,321 48%

6,179,379

11 to 20 15

1,335,649 35%

22,459,380 6 + 6 552,285 14%

3,698,948 419,631 11%

2,805,765

545,093 14%

3,642,781

21 to 30 25

906,229 24%

25,397,568

31 + 35

768,828 20%

30,165,561

100%

82,753,587 100%

7,662,312

5,663,569 100%

9,822,160

105,901,629 Notes: Range refers to the number of bulbs used in the household. Does not indicate amount of time used. # hhlds refers to the number of households that participated in this survey. In Ontario there were actually 4.321 million hhlds in 2003. Source: Survey of Household Energy Use (SHEU) - Detailed Statistical Report, 2003, Cat No. M144-120/2003ENatural Resources Canada http://oee.nrcan.gc.ca/publications/statistics/sheu03/pdf/sheu03.pdf Number of Household in Ontario in 2003 was 4,321,283. Calculated from 2001 Census with 1.2 % annual growth.



A.3 Available Fluorescent Lighting Sales Data for Ontario Sales data for CFLs and fluorescent tubes to residential and small IC&I establishments in Ontario in 2005 and 2006 were provided by Electrical Equipment Manufacturers Association of Canada through Electro Federation of Canada. These values are presented in Table A.2.

Table A.2: 2005 and 2006 Ontario Fluorescent Bulb and Tube Shipments Retail and Professional Estimates

Retail Professional

2005 2006 2005 2006 units units units units Tubular Fluorescent 1,500,000 2,000,000 1,642,000 1,400,000 CFL w/ ballast 4,566,425 9,667,000 460,000 853,000 Total 6,066,425 11,667,000 2,102,000 2,253,000

It was assumed for the analysis that 90% of retail sales were for residential lighting installations and 10% were for small IC&I installations. Professional sales were assumed to be 100% for small IC&I installations. A.4 Future Sales of CFLs and Fluorescent Tubes The setting of lighting efficiency standards was announced by both the Federal and Provincial governments in April, 2007. These standards are expected to rapidly increase the uptake of CFLs, which are more energy efficient. The rate at which incandescent bulbs (the most common bulbs currently in households) will be replaced by CFLs between now and 2012 was modeled as part of this study, to identify the rate at which CFLs would be discarded over time. The estimates were complicated by the fact that incandescents and CFLs have very different lifespans. This challenge was addressed as follows:

• A theoretical Ontario Residential Lighting Profile (% of Sockets) was constructed as part of this project to identify the annual percentages of different light bulbs in Ontario household sockets year by year from 2001 to 2015.

• The Ontario Residential Lighting Profile was then used to create an Ontario Residential Annual Light Bulb Sales Profile needed for the Lifespan Model.

Household values used for the Ontario Residential Lighting Profile Percentage Model and the Ontario Residential Annual Light Bulb Sales Profile are presented in Table A.3. 2001 values were obtained from 2001 Census Canada. A 1.2% growth rate has been assumed from 2001 to 201553. 53 The number of households in the province will grow at an average annual rate of 1.2% (Toronto Star, Sept 2006).



Table A.3: Households in Ontario

2001 2002 2003 2004 2005 2006

4,219,410 4,270,043 4,321,283 4,373,139 4,425,617 4,478,724 Results of the modeling exercise are presented in Tables A.4 and A.5 and are explained below. A.5 Future Residential CFL Market Penetration Scenarios Modeled Two market transformation scenarios were modeled:

• All residential light fixtures which currently have incandescent bulbs will have CFLs by 2013 (the year after the lighting efficiency standards come into effect); and

• Half of incandescent light fixtures will convert to CFLs while the remainder will migrate to new, energy efficient incandescent bulbs (currently being designed by lighting manufacturers) or other types of energy efficient bulbs.

The latter scenario also takes into account the fact that CFLs are not suitable for some applications (e.g. oven lights or lights in enclosed spaces). Residential sales of CFLs in Ontario are estimated at 4 million units in 200554. This is made up of:

• replacements of CFLs in place in 2001 (estimated at 1.9 million); and • new conversions from incandescent to CFL in 2005 (the remaining sales, i.e. 2.1

million new CFL installations). This is a simplistic way to estimate new installations, but is of sufficient accuracy for the analysis. The assumption used translates to 9% of total sockets in Ontario in CFLs in 2005. The same approach was used for 2006 sales provided by EFC. Total CFL sales were estimated at 9.7 million55, of which 90% (8.7 million) are assumed to be residential. Replacements for CFLs are estimated at 3.5 million (replacement of installations in place in 2002, shown in the Lifespan Model), plus creation of an additional 5.2 million CFL sockets (or 13.5% of the total). A linear increase from 13.5% of sockets to 84% of total sockets in 2013 was used to model the elimination of incandescents by that time. A linear rate of change was applied between these two years to identify the percentage of each type of light bulb in households in Ontario for each year from 1997 to 2003.

54 Data provided to WDO 23rd July, 2007 by Electro Federation of Canada, representing Electrical Equipment Manufacturers Association of Canada (EEMAC). Assumed 90% of retail sales are residential. 55 Ibid



The percentage of light fixtures with fluorescent tubes and halogen bulbs was assumed to remain constant at 9% and 7% of the total sockets or bulbs in a household from 2006 to 2015 to simplify the analysis. The remaining 84% of sockets was assumed to be split between incandescent and CFL installations, with varying percentages of each lighting type to model a linear transition to eliminate CFLs or split lighting between CFLs and super-efficient incandescents by 2013, the year the lighting efficiency standards (scheduled for 2012) will be fully in place. A.6 Ontario Residential Lighting Profile Percentage Model - Number of Sockets in Ontario by

Lighting Type, 2003 to 2015 Tables A.4 and A.5 present the allocation of the Ontario residential lighting market to different types of lamps (incandescent, CFL, halogen and fluorescent tube) from 2003 to 2015 as a percentage of total sockets. Tables A.6 and A.7 convert the percentages into numbers of actual sockets, taking household growth into account. It was assumed that the relative penetration of fluorescent tubes would remain constant during the study period. EFC residential sales data for fluorescent tubes were simply flat-lined from 2006 to 2015, with an allowance for annual household growth. Sales of fluorescent tubes for 2003 to 2005 were flat-lined from EFC 2005 annual sales, again pro-rating by household numbers. The annual sales rates (reported by EFC at 1.35 to 1.8 million units in 2005 and 2006 respectively) were assumed to be sufficient to maintain fluorescent tubes at 9% of the light sockets in Ontario households between 2005 and 2015. A.7 CFLs and Fluorescent Tubes in Small IC&I Locations Sales data provided by EFC for 2005 and 2006 were used to create a profile which was flatlined from 2005 back to 2003 and from 2006 forward to 2015 to create data for the Lifespan Model. Data were not available on 2003 and 2004 sales and industry predictions on future market growth were not available on which to develop a more detailed projection. A.8 New Lighting Designs Which Might Impact on Analysis The modeling takes into account the fact that current incandescents may be replaced (fully or partially) by CFLs over time. Two factors may impact on the market movement:

o An increase in the use of LEDs for specialized applications. At this time LED designs are typically used for specialized applications such as kitchen task lighting or decorative lighting, and



o Development of high efficiency incandescents which can meet the new federal and provincial energy efficiency standards.

Table A.4 Assumed Percentage of Different Light Bulbs in Ontario 2003 to 2015


Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Incandescent 79% 77% 75% 70.5% 60.5% 50.5% 40.5% 30.5% 20.5% 10.5% 0% 0% 0% CFL 5% 7% 9% 13.5% 23.5% 33.5% 43.5% 53.5% 63.5% 73.5% 84% 84% 84% Fluorescent 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% Halogen 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% Total 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

Table A.5 Assumed Percentage of Different Light Bulbs in Ontario 2003 to 2015


Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Incandescent 79% 77% 75% 70.5% 60.5% 58% 54% 51% 48 % 45% 42% 42% 42% CFL 5% 7% 9% 13.5% 23.5% 26% 30% 33% 36% 39% 42% 42% 42% Fluorescent Tube 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% 9% Halogen 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% 7% Total 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

Table A.6 Number of Existing Sockets in Ontario

100% Replacement of Incandescent by CFLs by 2013 (1000s of Units)

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Incandescent 82,754 84,183 82,980 78,938 68,554 57,909 46,999 35,819 24,364 12,629 - - -

CFL 5,664 7,653 9,958 15,116 26,628 38,415 50,481 62,830 75,469 88,403 102,244 103,471 104,712


Halogen 7,662 7,653 7,745 7,838 7,932 8,027 8,123 8,221 8,319 8,419 8,520 8,623 8,726

Total Sockets 105,902 109,328 110,640 111,968 113,312 114,671 116,048 117,440 118,849 120,276 121,719 123,179 124,658



Table A.7

Number of Existing Sockets in Ontario 50% Replacement of Incandescents by CFLs by 2013

(1000s of Units)

Bulb 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Incandescent 82,753 84,182 82,980 78,937 68,553 66,509 62,665 59,894 57,047 54,124 51,121 51,735 52,356

CFL 5,663 7,652 9,957 15,115 26,628 29,814 34,814 38,755 42,785 46,907 51,121 51,735 52,356


Halogen 7,662 7,652 7,744 7,837 7,931 8,027 8,123 8,220 8,319 8,419 8,520 8,622 8,726

Total Sockets 105,901 109,328 110,640 111,968 113,311 114,671 116,047 117,440 118,849 120,275 121,719 123,179 124,658



Appendix B

Current Penetration of CFLs in Ontario Residential Market Penetration of CFLs into Ontario Households SHEU–2003 found that the average Canadian household used 26.4 light bulbs:

• Over three quarters (75%) of the light bulbs used by the average household were ordinary (incandescent) light bulbs.

• The remaining light bulbs used by the average household were comprised of halogen light bulbs (9 percent), fluorescent tubes (9 percent) and CFLs (5 percent).

A second, broader environmental survey (Statistics Canada, Households and the Environment Survey, 1994, 2006.) also explored CFL use in households. The 2006 Canadian survey found that close to 6 in 10 households now use compact fluorescent bulbs, and over 4 in 10 have a programmable thermostat, up considerably in recent years. The study quotes the following:

“Lighting technology has changed dramatically in recent years, and this change is apparent in the increase in the variety of energy-efficient lighting products available to Canadian households. With this increase in variety, Canadian households have a growing opportunity to control the amount of energy they consume to light their homes. For example, compact fluorescent light bulbs (CFLs), which are compatible with standard light sockets, consume less energy than ordinary incandescent light bulbs and last up to 10 times longer. In Canada, from 1994 to 2006, the share of households having at least one CFL went from 19% to 59% (Figure 3.2). Households in all provinces contributed to this increase. In 2006, British Columbia and Ontario had the highest percentage of households using CFLs (65% and 64% respectively). In Quebec, at the other end of this spectrum CFLs were found in half of all households. More than half (57%) of the households located in CMAs (central metropolitan areas) used CFLs in 2006. The Ontario portion of Ottawa - Gatineau had the highest rate of households using CFLs (70%). In contrast, only 44% of the households in the CMA of Montréal used the bulbs.”

A July 2006 survey for the Canadian Electricity Association indicates that 70% of Canadians have replaced at least one regular incandescent bulb with a compact fluorescent. Of these:

24% have replaced on average one to four bulbs; 23% have replaced five to seven bulbs; 28% have replaced eight to twelve; and 19% have replaced thirteen or more.



Over 29 million compact fluorescents have been sold in Canada in 2006, up from 13 million in 200456. Assuming Ontario represents 40% of the Canadian market, 5.2 million CFLs were sold in Ontario in 2004 and 11.6 million CFLs were sold in Ontario in 2006. Before 2001, in the USA, CFLs represented less than 1% of market share. Current market (April 2007) share of CFL bulbs in USA is approximately 6% while in the Pacific NW it is approximately 11%. A reported 4 billion57 light bulbs are sold in the US residential market each year. Pro-rating this value to Canada (10% of the size of the US market) yields an estimate of 400 million sold in Canada each year. The Ontario market (at 40% of the Canadian market) would therefore be about 160 million bulbs per year. In 2006, 150 million CFLs were sold in USA58. For 2007, Walmart alone has a target of selling 100 million CFls, and has developed a marketing strategy to make consumers aware of the benefits of CFLs. This goal is part of Walmart’s increased interest in greening its operations.

Philips Lighting, a major manufacturer of lighting products sold around the world, reports that for the first time in history, worldwide sales of incandescent lights have declined. In contrast, the sale of compact fluorescent lights is reaching new heights59.

General Electric Co. has stated that it is working on doubling the energy efficiency of incandescent lights and eventually developing versions comparable with CFLs. These bulbs, which the company hopes to begin marketing in 2010, will cost less than fluorescents but will have a shorter lifespan 60.

56 Natural Resources Canada The News Room - Bac kgrounder. 2007/35 (b) Accessed July 4 2007. http://www.rncan.gc.ca/media/newsreleases/2007/200735b_e.htm 57 Conversation Maria Kelleher and Wayne Edwards, EFC, 4th July, 2007 58 Source: ENN Mercury in Energy Saving Bulbs Worries Scientists. March 28 2007. Lisa Von Ahn, Reuters 59 Natural Resources Canada The News Room -Bac kgrounder. 2007/35 (b) Accessed july 4 2007. http://www.rncan.gc.ca/media/newsreleases/2007/200735b_e.htm 60 ENN “Mercury in Energy-Saving Bulbs Worries Scientists” March 29, 2007. Lisa Von Ahn, Reuters.



Figure B.1 Households with any energy-saving compact fluorescent light bulbs, by province, 1994 and 2006

(Source: StatsCan: Households and the Environment Survey 2006) Catalogue no. 11-526-XIE



Appendix C

Reported Fluorescent Lamp Recycling Rates Reported recycling rates for fluorescent lights are summarized in Table C-1.

Table C-1

Recycling Rates for Fluorescent Lights

Source Recycling Rate Comments NEMA 200061. 15 % Recycling rate in US in late 1990’s Association of Lighting and Mercury Recyclers (ALMR)

2% of residential in 200462 24% by 200463 for IC&I

650 million fluorescent tubes discarded 142 million residential discarded 372 million IC&I discarded 125 million recycled, most from IC&I 525 million disposed

Alberta 23% in 200264 CCME 7% in 2004 The CCME estimates that 60 million mercury containing lamps reach end of life each year in Canada. The 4 foot long tube accounts for 75% of the Canadian market. Each 4 foot fluorescent tube contains 0.26 kg glass, 0.02 kg of combined metals, 0.01 kg of phosphor powder and 11.6 mg of mercury. According to the Recycling Council of Ontario, recyclers received and processed 4,279,300 tubes or 7% of the available tubes in 2004, weighing 1,261 tonnes. About 1,240 tonnes were recovered in glass, metals, phosphor powder and mercury65, resulting in a 1.7% processing residue rate. Based on data from the 2006 Ontario Municipal Datacall, 50 municipal programs reported collecting 110,071 fluorescent tubes. As an estimated 3 million fluorescent tubes are discarded from the residential and small IC&I sector each year, the reported recovery through municipal programs translates to a collection rate of almost 4%. The 2006 Municipal Datacall did not request data on CFLs collected by municipalities. A question requesting the quantity of CFLs collected by municipalities is being added to the 2007 Municipal Datacall.

61 US EPA http://www.epa.gov/nrmrl/pubs/600r02104/600r02104prel.pdf (accessed July 16, 2007) 62 Association of Mercury Lamp Recyclers: National Mercury Lamp Recycling Rate and Availability of Lamp Recycling Services in the US, November 2004 63 www.almr.org 64 Hilkene et al: Bac kground Study on Increasing Recycling of End of Life Mercury containing Lamps from Residential and Commercial Sources in Canada. Prepared by Hilkene Intl Policy and Pollution Probe. For NRCan and Env Can Oct 31, 2005 (page 15) 65 ibid

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