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Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Liquid Crystal DisplayLiquid Crystal Display
ReRe--use and Recycling use and Recycling
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Table of ContentTable of Content
Ø Introduction of the ReLCD project
Ø Alternative technologies• Jet Cutting• Laser Cutting• Sawing
Ø Manual DismantlingØ Processing CostsØ Quality assessmentØ Total processing costsØ Conclusion
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
ProjectProject
Ø Full Title: Liquid Crystal Display Re-use and Recycling
Ø Acronym: ReLCD
Ø Program: Co-operative Research Project, FP6
Ø Start: March 8, 2004
Ø Duration: 24 Months
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Consortium Consortium
SME Partner:
Ø Ecotronics (AT) – Coordinator
Ø Active Recycling (UK)
Ø RelektrA (DE)
Research Partner:
Ø SAT (AT)
Ø Gaiker (ES)
Ø BZF (HU)
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
LCD LCD –– Market Market
Global LCD-Sales Figures (in m)
8,849
19,619
46,247
60,640
76,659
31,368
0,000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
2004 2005 2006 2007 2008 2009
From 2004 until 2009 LCD sales will rise 54% per yearSource: Elektonik Praxis, Feb. 2006
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Goals of the Project (1)Goals of the Project (1)
Ø To find a cheap and fast test methodology to verify if the obsolete or excess LCDs are still working
Ø To develop a technology to refurbish the working LCDs and re-integrate them into repair and in exemptions also in production processes
Ø To find a test method to detect hazardous substances in LC-mixtures
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Goals of the Project (2)Goals of the Project (2)
Ø To develop an eco-efficient disassembly and recycling technology for the non-working LCDs
Ø To research possible enhancements to the existing LCD design and production in order to come to a more sustainable life-cycle of LCDs (publication of guidelines)
Ø Building up a pilot plant incorporating and testing the developed technologies
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Work PlanWork Plan
5 Work Packages:
Ø WP 1: LCD Test & Refurbishment
Ø WP 2: Technology of LCD Disassembly & Recycling
Ø WP 3: Design & Evaluation of Disassembly & Recycling System
Ø WP 4: Guidelines for Sustainable LCD Design, Production & Recycling
Ø WP 5: Project Management
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
User GroupUser Group
• Coolrec• Electrocycling
• Flextronics• Indumetal Recycling • LG
• Nokia
• Samsung
• Sony
• STENA Technoworld
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
IntroductionIntroduction
Ø Backlight Lamps contain mercury
• Hazardous
• Separation
Ø Tendency to non-hazardous lamps
• Process for the next 5-8 years
Ø Possible ways to separate the lamps
• Cutting
• Manual dismantling
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Water Jet CuttingWater Jet Cutting
Ø Processing Parameter• Pressure 2000 bar
• Cutting speed§ Border area: 50 – 60 mm/min
§ Rest: 550 – 800 mm/min
• Mean Processing Time ~ 2,7min
Ø Disadvantage:• Investment costs (EUR 130.000)
• Maintenance costs
Jet Cutter of Bay-Logi (Miskolc)
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Water Jet CuttingWater Jet Cutting
Ø Disadvantage:• Investment costs (EUR130.000)
• Maintenance costs
Ø Cutting surface:
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
LASER CuttingLASER Cutting
Ø Processing Parameter• Power: 2,5 kW
• Cutting speed: 1,5 m/min
• Cutting gas: 10bar Nitrogen
• Mean Processing Time ~ 1 min
Ø Disadvantage:• Investment costs (EUR340.000)
• Emissions
Laser Cutter of BAY-ATI (Budapest)
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
LASER CuttingLASER Cutting
Ø Disadvantage:• Investment costs (EUR340.000)
Ø Cutting surface:
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Circular SawCircular Saw
Ø Processing Parameter• Cutting speed 1,2 m/min• Mean Processing Time ~ 0,9 min
Ø Disadvantage:• Durability• Emissions• Vibrations• Sharp chips
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Circular SawCircular Saw
Ø Disadvantage:• Vibrations
• Durability of saw blade
• Emission
• Sharp chips
Ø Cutting surface:
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Manual dismantlingManual dismantling
Ø Processing Parameter• Mean Processing Time ~
1,5 min
Ø Advantages:• Low investment cost• 40% disassembly friendly
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Processing CostsProcessing Costs
Ø Investment costsØ Personnel Costs
Ø Maintenance costs:• Manual disassembly: tools• Jet Cutting: sand and water, nozzle• Laser Cutting: cutting and laser gas• Circular Saw: saw
1st Year
0
1
2
3
4
2500
5000
7500
1000
0
1250
0
1500
0
1750
0
2000
0
2250
0
2500
0
2750
0
3000
0
Items per Year
Eu
ro/# Manual Disassembly
Laser Cutting
Circular Saw
Jet Cutting
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Quality assessmentQuality assessment
Ø Hazardous materials (red)Ø Non-hazardous materials (green)Ø Damage ratio of lamps about 1,5% for all
investigated processes
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Total cost situationTotal cost situation
Parameter:Ø 5.000 t per yearØ Material revenue:
• Hazardous -720€/t• Non-hazardous -69 €/t
Current SituationØ Material revenue:
• Hazardous -720€/
Ø Total Costs: 3.600.000 €Ø Saving Potentials:
• 12% (1,7min dismantling time)• 16% (1,4min dismantling time)• 8% (Laser cutting)
4.557.3266324.3683.802.460570.620207378.000Circular SawIV
3.338.4655854.4152.614.099476.441165459.089Laser cuttingIII
5.776.3028114.1894.904.940232.2236321119.256Jet cuttingII
3.301.014834.9172.904.169205.0904214177.882Manual disassemblyI
[EUR][t][t][EUR][EUR]Employees[#][#/a]
Resulthazardous Non-hazardousAll Systems1 Systemof systemsCapacity
TOTALMaterialsProcessing CostsNumberParallelMax.
METHOD
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Saving potentialsSaving potentials
Parameter:Ø 900 t per yearØ Material revenue:
• Hazardous -720€/t• Non-hazardous -69 €/t
Current SituationØ Material revenue:
• Hazardous -750€/
Ø Total Costs: 675.000 €Ø Saving Potentials:
• 12% (1,7min dismantling time)• 16% (1,4min dismantling time)• 11% (Laser cutting)
11675000600.9241459.089Laser cuttingIII
16675000569.0802216.000Manual disassembly(1,4min)II
12675000594.1833177.882Manual disassembly(1,7min)I
[%][EUR][EUR][#][#/a]
Potentialtreatment costsResultsystemsCapacity
SavingsCurrentTOTALParallelMax.
METHOD
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Summary & ConclusionSummary & Conclusion
Ø No alternative method to manual dismantling• Low investment• Mean Processing Time ~ 1,5 min
Ø Nowadays about 40% of the LCDs are disassembly friendly• Investigations of 50 different types / 10 manufacturer
Ø High investment costs for alternative methods result to inefficient processes and high financial risk
• Laser cutting: EUR 340.000• Water Jet Cutting: EUR 130.000
Ø Material compositions of the panels result to difficulties in cutting processes
• Durability of tools• Vibrations• Emissions
Austrian Society for Systems Engineering and AutomationReLCD – Liquid Crystal Display Re-use and Recycling
Summary & ConclusionSummary & Conclusion
Ø Pre-treatment result to a reduction of the total treatment costs
• 12% at the moment
• 20% can be expected for the future
Ø Material recycling is preferable to incineration because of environmental aspects
Ø Pre-treatment necessary to fulfil requirements of WEEE directive
• Notebook: 40% LCD
• Recycling quota 65% / Recovery quota 75%