Periodic Reporting for period 1 - ALR4000 (Automated LCD Recycling series 4000)
Berichtszeitraum: 2019-10-01 bis 2021-04-30
The Problem
Over 200m LCD displays are sold per annum (p.a.) making them one of the fastest growing waste streams on the planet. The WEEE directive requires the mandatory removal of the components containing the hazardous substances mercury and liquid crystals. With limited options on the market to achieve this, most recyclers undertake the disassembly by hand. Votechniks ALR4000 technology solves this problem through high-speed depollution of LCDs, allowing their subsequent shredding to recover the valuable materials. Compared to market alternatives, the ALR4000 is cheaper to acquire, more efficient to operate, generating significant revenue for the recycler, solving the problems associated with mercury and liquid crystals, reducing risk for the facility, and putting recycling back in the hands of the SME recyclers.
Importance for Society
The risk posed by waste LCDs to EU citizens is great, so much so, that the EU legislated for the mandatory depollution of these devices at end of life. Mercury and liquid crystals within LCDs, from which the device gets its name, are hazardous. Mercury is considered by WHO as one of the top ten chemicals of major public health concern having toxic effects on the nervous, digestive and immune systems, and on lungs, kidneys, skin & eyes. Exposure to mercury in even small amounts may cause serious health problems. While liquid crystals are showing potential to be persistent, bioaccumulative contaminants and have toxic properties. These substances threaten the air quality of our cities and the health of those at recycling facilities while their leakage from landfill can contaminate soil and water. There the need for a cost effective solution for LCD depollution is great.
Objectives
The ALR4000 technology and project is at the heart of the green deal to achieve zero pollution and foster the circular economy.
The objectives of the project are outlined herein:
• To build out and commission the ALR4000 machine at full scale. A self-contained plant equipped with industrial vision, robotic handling, integrated Industry 4.0 and an on-board environmental system. The ALR4000 is utilizing state of art robotics and automation to deliver the most advanced technology available on the market.
• To undertake 3 market replications of the ALR4000 technology acting as demonstrations site for international delegations to view the technology in live operation for industry and national public open days.
Over 200m LCD displays are sold per annum (p.a.) making them one of the fastest growing waste streams on the planet. The WEEE directive requires the mandatory removal of the components containing the hazardous substances mercury and liquid crystals. With limited options on the market to achieve this, most recyclers undertake the disassembly by hand. Votechniks ALR4000 technology solves this problem through high-speed depollution of LCDs, allowing their subsequent shredding to recover the valuable materials. Compared to market alternatives, the ALR4000 is cheaper to acquire, more efficient to operate, generating significant revenue for the recycler, solving the problems associated with mercury and liquid crystals, reducing risk for the facility, and putting recycling back in the hands of the SME recyclers.
Importance for Society
The risk posed by waste LCDs to EU citizens is great, so much so, that the EU legislated for the mandatory depollution of these devices at end of life. Mercury and liquid crystals within LCDs, from which the device gets its name, are hazardous. Mercury is considered by WHO as one of the top ten chemicals of major public health concern having toxic effects on the nervous, digestive and immune systems, and on lungs, kidneys, skin & eyes. Exposure to mercury in even small amounts may cause serious health problems. While liquid crystals are showing potential to be persistent, bioaccumulative contaminants and have toxic properties. These substances threaten the air quality of our cities and the health of those at recycling facilities while their leakage from landfill can contaminate soil and water. There the need for a cost effective solution for LCD depollution is great.
Objectives
The ALR4000 technology and project is at the heart of the green deal to achieve zero pollution and foster the circular economy.
The objectives of the project are outlined herein:
• To build out and commission the ALR4000 machine at full scale. A self-contained plant equipped with industrial vision, robotic handling, integrated Industry 4.0 and an on-board environmental system. The ALR4000 is utilizing state of art robotics and automation to deliver the most advanced technology available on the market.
• To undertake 3 market replications of the ALR4000 technology acting as demonstrations site for international delegations to view the technology in live operation for industry and national public open days.
Summary of work performed to date:
- Design of the ALR4000 upgraded system completed including process flows, technical drawings, solidworks model, mechanical and fabrication inventories, integration of mercury ventilation system, digital 4.0 and robotics handling system.
- System build: build of individual stations with in the machine for liquid crystal panel removal and CCFL mercury tube removal, build of machine internal structure, fabrication of machine guarding, development of the automation programme are completed. Final assembly is on going with systems testing & CE mark certification.
- KMK Irish host site preparations in place and environmental assessment of the ALR4000 under the EN 50625 drafted and scheduled.
- Concept level design of the online platform is completed.
- Brand development and machine aesthetics completed.
- Commercial contract regarding manufacturing and sales are completed.
- End user pack on commercial aspects is designed and completed.
- Intellectual property and business plan reviews are underway.
- Website designed completed.
- Keynote speech at E-waste conference 2020 on the ALR4000 project and technology undertaken and invited back to present again updated results at the 2021 conference.
- Design of the ALR4000 upgraded system completed including process flows, technical drawings, solidworks model, mechanical and fabrication inventories, integration of mercury ventilation system, digital 4.0 and robotics handling system.
- System build: build of individual stations with in the machine for liquid crystal panel removal and CCFL mercury tube removal, build of machine internal structure, fabrication of machine guarding, development of the automation programme are completed. Final assembly is on going with systems testing & CE mark certification.
- KMK Irish host site preparations in place and environmental assessment of the ALR4000 under the EN 50625 drafted and scheduled.
- Concept level design of the online platform is completed.
- Brand development and machine aesthetics completed.
- Commercial contract regarding manufacturing and sales are completed.
- End user pack on commercial aspects is designed and completed.
- Intellectual property and business plan reviews are underway.
- Website designed completed.
- Keynote speech at E-waste conference 2020 on the ALR4000 project and technology undertaken and invited back to present again updated results at the 2021 conference.
Economic Impacts
Summary of developments to date contributing to key economic impacts expected from the ALR4000 are described herein.
The ALR4000 machine is designed to process a minimum of ~125,000LCDs per annum in one cycle shift on a productive working year of 260 days. Each ALR4000 machine can therefore process approx. 0.5% of the EUs volume of LCDs arising per annum allowing each machine to impact on the market significantly. The economic impact for the recycling is great where the ALR4000 allows the recycler to liberate significant revenue from valuable materials contained within LCDs per annum making LCD recycling profitable.
Societal & Environmental Impact
LCDs represent one of the fastest growing waste streams on the planet. The risk posed by these to EU citizens is great, so much so, that the EU legislated for the mandatory depollution of these devices at end of life. Mercury and liquid crystals, from which the device gets its name, are hazardous. These substances threaten the air quality of our cities and the health of those at recycling facilities while their leakage from landfill can contaminate soil and water. By depolluting these LCDs, each machine makes a direct contribution to the UN Sustainable Development Goals (SDG):
SDG Goal 3 Reducing risk of death and illness due to exposure to hazardous substances:
- Each ALR4000 captures ~10t of CCFL mercury tubes and 78t of liquid crystals glass sheets p.a.
- Creating a safe working environment for all at recycling facilities.
SDG Goal 8: Introducing disruptive high value add technology into a labour intensive sector :
- ALR4000 capacity: 125,000 LCDs p.a. which is equivalent to 12 FTE p.a.;
- ALR4000 requires 1 operator, future proofing facilities against pandemic shutdowns.
SDG Goal 9: Deployment of an innovative technology:
- Each ALR4000 processes 0.5% of LCDs arising in the EU
- Augmenting the recycling infrastructure for a clean & safe environment.
SDG Goal 11: Reducing the impact of air quality on cities:
- ALR4000 has built in carbon filtration system to capture any air born mercury emissions
- Reducing mercury releases from local waste management facilities
Each ALR4000 machine is directly enabling the circular economy agenda of the green deal by making LCD recycling profitable for the recycler while being safe and protecting the environment from pollution.
Summary of developments to date contributing to key economic impacts expected from the ALR4000 are described herein.
The ALR4000 machine is designed to process a minimum of ~125,000LCDs per annum in one cycle shift on a productive working year of 260 days. Each ALR4000 machine can therefore process approx. 0.5% of the EUs volume of LCDs arising per annum allowing each machine to impact on the market significantly. The economic impact for the recycling is great where the ALR4000 allows the recycler to liberate significant revenue from valuable materials contained within LCDs per annum making LCD recycling profitable.
Societal & Environmental Impact
LCDs represent one of the fastest growing waste streams on the planet. The risk posed by these to EU citizens is great, so much so, that the EU legislated for the mandatory depollution of these devices at end of life. Mercury and liquid crystals, from which the device gets its name, are hazardous. These substances threaten the air quality of our cities and the health of those at recycling facilities while their leakage from landfill can contaminate soil and water. By depolluting these LCDs, each machine makes a direct contribution to the UN Sustainable Development Goals (SDG):
SDG Goal 3 Reducing risk of death and illness due to exposure to hazardous substances:
- Each ALR4000 captures ~10t of CCFL mercury tubes and 78t of liquid crystals glass sheets p.a.
- Creating a safe working environment for all at recycling facilities.
SDG Goal 8: Introducing disruptive high value add technology into a labour intensive sector :
- ALR4000 capacity: 125,000 LCDs p.a. which is equivalent to 12 FTE p.a.;
- ALR4000 requires 1 operator, future proofing facilities against pandemic shutdowns.
SDG Goal 9: Deployment of an innovative technology:
- Each ALR4000 processes 0.5% of LCDs arising in the EU
- Augmenting the recycling infrastructure for a clean & safe environment.
SDG Goal 11: Reducing the impact of air quality on cities:
- ALR4000 has built in carbon filtration system to capture any air born mercury emissions
- Reducing mercury releases from local waste management facilities
Each ALR4000 machine is directly enabling the circular economy agenda of the green deal by making LCD recycling profitable for the recycler while being safe and protecting the environment from pollution.