POSTED: 02 February 2016
21st Century Alchemy in NY
Long journey toward and long journey going forward. The Nulife team is delighted to report that metallic lead (Pb) is being extracted from CRT glass in our first U.S. CRT recycling furnace. There have been many significant moments but this has to be the one; after many years of planning to bring the technology to the U.S. recycling industry and demonstrate that lead is a valuable resource that can truly be extracted out of CRT glass. With all the anticipation, debate and discussion surrounding CRT glass, this significant moment can only strengthen the view that this material is certainly a commodity with inherent value and a future.
POSTED: 13 January 2016
SCOTT OF DUNKIRK
Dunkirk facility, New York not Antarctica!
Snow forecast for the whole week.
Furnace remains hot.
POSTED: 7 January 2016
HAPPY NU YEAR
An exciting moment indeed for all the team as the first glass flows from the forehearth.
To summarise the last few weeks following the gas start up it is worth noting that commissioning the furnace is a phased and lengthy process. During this period refractory is put through an expansion schedule; all the electrical systems are live tested and any potential glitches resolved; PLC control systems to operate the furnace are fine tuned. All these calibrated phases are required before a single pound of glass is loaded into the furnace.
As the gas burners remain on, the initial loading of panel glass into the furnace is done according to a planned glass batching schedule. Gradually as the volume of material is increased the electrodes are activated and the switch from gas to electricity occurs. The gas burner removed, the furnace operates solely on electricity.
POSTED: 15 DECEMBER 2015
THE HEAT IS ON
At 3.00pm EST, Dunkirk NY had its own significant moment as the first U.S. Nulife Glass CRT recycling furnace began its heat up. The initial stages of the furnace commissioning is a very critical and exciting time. After many months of construction and project challenges the furnace is on.
The heat treating engineers arrived in the early hours to set up their gas monitoring equipment and lengthy gas pipes to connect the furnace to the propane supply. Meanwhile the Nulife team were doing final checks on the water flow system and prepare the heat up and expansion schedule. The process is methodical and takes place hourly during the heat and furnace expansion. The bracing bolts are checked for movement and slight adjustments are made by hand or using a torque wrench to control the bolt tension.
Following custom, for our Western New York furnace it seemed fitting to have the Buffalo mascot that was gifted to us, as well as our customary protective talisman.
POSTED: 14 DECEMBER 2015
COUNT DOWN TO WARM UP
Quantum leaps have been made over the last few days as things prepare to hot up at the Nulife facility in Dunkirk. The Nulife team are making final checks on the water flows for the cooling system as well as final testing on the electrical control wiring. All systems are go as the propane gas was delivered today in preparation for the furnace commissioning process. The engineers will begin the furnace heat up tomorrow. Exciting times indeed as the long awaited Nulife first USA based CRT recycling plant is commissioned.
POSTED: 10 DECEMBER 2015
CRITICAL FINAL STAGES
The electrical team continue diligently to install the essential cables and wiring for the furnace.
The control panel for the thermocouples arrived from the UK end of last week and is currently being installed and wired up. Whilst our software team in the UK continue work on all the programming required to operate the furnace.
Meanwhile ancillary equipment for preparing and handling the glass cullet is in the final stages of production. Some equipment was delivered yesterday and the Nulife team are assembling and running trials.
POSTED: 4th December 2015
Electrical install is progressing well, with the interconnections from the melter switch gear and primary transformers scheduled for completion today.
POSTED: 25th November 2015
The long awaited melter thyristor cabinets arrived at the facility last week and so the complex electrical install continues...
Our Nulife team meanwhile are wiring up the electrode thermocouples and assisting with the install of the electrical conduit from the secondary transformer to the the main switch gear.
POSTED: 17th November 2015
With the recent flurry of CRT industry press and certification downstream approval being challenged it would be all too easy to be distracted and consumed by opinion that requires a lengthy, considered and thought out response.
So with this in mind, our work focus is fully on the completion and commissioning of our CRT recycling furnace. The progress may outwardly appear to be slowing up as the blogs are less frequent but our team tirelessly push on making daily adjustments and correcting discrepancies that naturally occur when working from plan to reality. Thermocouples that provide furnace temperature readings are being fitted with respective wiring completed this week; the muffle elements and connectors that provide heat to the forehearths have also been fitted.
POSTED: Armistice - Veterans Day
PAUSE FOR THOUGHT
The long awaited main transformer arrived yesterday; this is a critical component for the electrical system. Meanwhile many other tasks have been accomplished: hanging the charger door; mounting the glass charger onto the furnace platform; assembling the security cages for all the transformers and finally all the melter electrodes are installed. These took some careful planning and skilful handling; no photos to show as the build progresses pictorial reporting becomes sensitive. What remains is lot of wiring and connecting to to bring it all live.
POSTED: 3rd NOVEMBER 2015
After several industrious, noisy productive weeks, the plant seems eerily quiet today. The furnace crown was completed last Thursday and Friday morning after finalising the last details our refractory contractors packed up their tricks and headed home for Halloween. Our treat is to see a job well done and the furnace built.
With the water cooling system in place, this leaves the main power and electrical systems and mechanical auxiliary equipment to be installed.
POSTED: 22nd OCTOBER 2015
Contractors continue the conduit install for the primary power cables, that when connected to the furnace will draw hydro electric power produced by Niagara Power Project. Nulife's Dunkirk facility was awarded the allocation in 2013 and the final contract for the allocation from NYPA was recently signed.
Meticulous work to finalise the melter refractory was completed today, and so the crown build commences. The furnace is shaping up. Meanwhile the Nulife team trial the water system for leaks and continue essential auxiliary equipment install.
POSTED: 18th OCTOBER 2015
As the furnace build progresses so our updates need to be mindful of the years of research, trials and design - understandably. This does not however diminish the report of the daily undertakings.
The main melter refractory install and forehearths are complete and the insulation brick laying is underway. The electrical contractors continue bringing primary power cables to the transformers and auxiliary material handling equipment is designed and being manufactured.
POSTED: 11th OCTOBER 2015
Essential plumbing takes place underneath the furnace keeping the upper platform clear; whilst our team continue with install of the electrical trays in preparation for the main power cables that will connect to the furnace. Our refractory contractors continue with the meticulous detail required prior to completing the forehearth and refractory install. Very productive week.
POSTED: 8th OCTOBER 2015
Three days of silence is not indicative of lack of activity, In fact quite the opposite. Long days for our refractory contractors who have been skilfully installing the insulation brick, back up refractory and furnace blocks. This type of work requires precision, patience and focus to achieve a perfect fit. Work continues on the water system with the drilled ring main in position reminiscent of a very long flute; our team fit all the valves and taps .
POSTED: 5th OCTOBER 2015
Still catching up with last week - the refractory sub-layer was poured and levelled and allowed to cure over the weekend. Work resumes today with the install of the forehearth and riser insulation bricks.
The Nulife team continue mapping out the water cooling system with the tundish return pipework all fitted and tested for leaks and cable tray assembly in progress.
POSTED: 4th OCTOBER 2015
Summarising last week's exciting progress: the remaining furnace support columns were bolted down and painted in Nulife green. All the sillimanite blocks were checked on site, whilst the furnace refractory inspection took place off site in PA.
Our refractory contractors arrived to set up their equipment and cast the furnace foundations. Whilst electrical contractors began installing the main power cables from the transformer through to the switchgear.
POSTED: 30 SEPTEMBER 2015
Our furnace specialist has returned to the facility to ensure the build is on schedule for the imminent refractory installation. Main stairs were fitted yesterday and the furnace enclosure measured up and marked out. First set of water cooling jackets that arrived from the UK and the electrodes were inspected and assembled; water pump station was also finished and now needs connecting to the tank and ring main.
POSTED: 25 SEPTEMBER 2015
IN THE PIPELINE
Work on the water cooling system required for the furnace electrodes has started; yesterday the ring main was completed, trial fitted and in position. The main valve locations have also been marked up and work on the pump station is in progress. Platforms are finished with all welding and fabrication completed of the new sections. The charger platform handrails and top sections of the furnace painted.
POSTED: 23 SEPTEMBER 2015
GOOD DAY TODAY
Nulife team erect the last of the lower platforms albeit not as straight forward as hoped, a lot of cutting and fabricating was required for it all to fit! This however allowed for a substantial amount of the remaining floor plates to be fitted. More furnace components arrived on site, as well as a visit from our refractory suppliers who spent some time finalising details on site.
Small glitches occur, like the supplier who is no longer able to supply what you require or fabricated components don't actually fit; finding the solutions and overcoming the hurdles all part of a good day.
POSTED: 22 SEPTEMBER 2015
PIECING THE PUZZLE
Deliveries of the various furnace components are shipping in from near and far, including the lead chutes, remaining electrode extensions and refractory material. Our team continue piecing together the last platform sections and complete painting the top section of the furnace. Behind the scenes, installation of ancillary equipment is underway with the water feed system to the furnace, as well as design and planning for scraper conveyors, hoists and electrical layouts.
POSTED: 18 SEPTEMBER 2015
FROM STRUCTURE TO FORM
Nulife team have been busy cutting and welding chequer plate to create the furnace charger platform. Handrails have been installed as well the steel work receiving a coat of heat resistant paint.
POSTED: 17 SEPTEMBER 2015
First delivery of our bespoke refractories arrived yesterday from our U.S. supplier; including the sillaminate blocks, andalusite bricks and the crown block work.
POSTED: 8th September 2015
This latest post is coming to you directly from our Dunkirk facility after returning from the E-Scrap Conference in Orlando, Florida. The trade show was an opportunity for us to update our clients and the recycling industry first hand on our furnace build progress; for those who didn't attend the conference apologies for our blogging absence.
Latest report from our UK supplier, the electrode water-cooling jackets are fabricated and ready to be shipped.
Posted: 30th August 2015
SETTING THE STAGE
Our steel contractors have completed their part of the installation project, with the last modified platform pieces installed, now waiting for remaining new steels to be delivered.
Meanwhile the forehearth cases where the glass will flow from are suspended and the risers due to be installed shortly.
Posted: 26th August 2015
BRIDGING THE GAPS
Nulife team modify the platform steels and install first set of stairs to the charger platform. Furnace structure shaping up...
Posted: 23rd August, 2015
Posted: 20th August, 2015
Yesterday the Nulife team installed the platform steel pieces and the last few sections are due to be fitted today. The electrical contractors have started installing conduits in preparation for bringing the main power supplies to the furnace equipment.
Posted: 19th August, 2015
Painting of furnace column supports has started, treating the steel with heat resistant paint.
Posted: 14th August, 2015
Apologies for the seven-day silence... meanwhile our Nulife team have prepared and sorted all the steels for the furnace platform. They have shimmed up the columns so they now sitting firmly on the ground and not appearing to float in space; installed the two main platform columns so the top beams could be located and fixed.
Posted: 7th August, 2015
FURNACE BEAMS ON THE HORIZON
The steel crew finalise and secure furnace door lifting beams as well as roof and forehearth support beams. Our Nulife team continues the refurbishment of essential furnace components.
September 1-3, 2015, Orlando, Florida
Please visit us at our booth #206 to find out more about the first U.S. CRT recycling furnace currently being built at Nulife's site in Dunkirk, NY and our recently opened second U.S. facility in Bristol, VA.
For more information visit:
Posted: 6th August, 2015
Everyone very excited about the steel build progress. Monday the large containment tank was delivered and installed.
Posted: 4th August, 2015
BRACE YOURSELF FURNACE STRUCTURE GOES VERTICAL
Posted: 30th July, 2015
OUR DUNKIRK FACILITY HAS BEEN A HIVE OF ACTIVITY THESE LAST FEW WEEKS, SO MUCH SO THAT THIS NEWS POST CAN'T KEEP UP!
In summary the first delivery of all new and modified steel work arrived on site.
Initially progress was slow as the site floor had to be re-marked following last week's torrential flooding in Dunkirk; but the first columns are now up thanks to the dedicated crew who are erecting all steel work. Most of the base steels are fitted and modifications to buckstay and bracing steels have been completed.
Electricians have now fully installed lighting and power to the furnace office and maintenance workshop; whilst our Nulife team is busy assisting with the furnace build and managing daily operations.
Challenging few days, but all the team keep pushing forward.
NULIFE'S CRT GLASS RECYCLING FURNACE IS NOW TAKING SHAPE
Posted: 28th July, 2015
More than a year in planning, design and modifications, Nulife's CRT glass recycling furnace is now taking shape and becoming a reality.
The glass de-leading furnace previously installed at Nulife's test site in Manchester, England, was shipped to Nulife's Dunkirk site last year, during this time various imported furnace components have been customized for U.S. compatibility.
Additional furnace parts are on order and in fabrication, including electrical components, refractories and other timeline critical components.
Our UK furnace technology specialists and designers recently returned from a business trip to the USA meeting with our specialist suppliers to ensure production is on track and finalising delivery schedules.
With existing steel furnace parts being re-engineered off site, contractors have been on site to mark out centrelines in preparation for the foundation furnace steel parts to be installed this coming week.
Whilst the new CRT recycling furnace build has been much anticipated a lot has been going on behind the scenes at our Dunkirk facility.
Plans to construct a new CRT negative air pressure dismantling room is in progress, as well as refurbishment of offices and employee facilities.
For the last month contractors along with Nulife employees have been digging and laying foundations for new access roads around the site.
For further updates - WATCH THIS SPACE
BRISTOL, Va. - A ribbon-cutting ceremony Thursday signaled the formal start of operations at Nulife Glass, but it will be some time before actual recycling can begin. The Manchester, England-based firm plans to construct a large electric furnace and recycle old cathode ray tube TVs and computer monitors inside the former Crowley Dairy property at the corner of Gate City Highway and Catherine Street. Nulife recently acquired the vacant, 12-acre site
We are currently recruiting for our U.S. facilities in Dunkirk, NY and Bristol, VA.
Where We Operate?
Nulife Glass Group head office, Manchester
Nulife Glass CRT recycling facility, NY
Nulife Glass CRT recycling facility, VA
Nulife Glass Recycling Group designs, builds and operates furnaces incorporating their novel and innovative recycling technology. Nulife Glass provides a complete sustainable recycling service for CRT glass.
Nulife Glass' CRT recycling furnace technology is capable of processing up to 10 tonnes of funnel glass per day, equivalent to the glass from approximately 60 tonnes of televisions.
This unique CRT recycling furnace extracts the toxic lead from the glass in a safe and environmentally sustainable way. The process creates no waste and avoids export of hazardous material around the globe.
Nulife Glass offers update on furnace progress. Nulife Glass says testing is underway on its New York CRT glass recycling furnace...
The world's only remaining glass-to-glass recycling outlet for CRTs has idled its panel and funnel furnaces in Bharuch, India...
By Bobby Elliott, E-Scrap News
Old TVs weighing on municipalities
Path to the TV graveyard gets more involved
EPA seeks input on key e-scrap issues
Sims closes operations in Canada... Skurnac, SRS' president, blames EPRA virtual monopoly
Sims Recycling Solutions closes New Jersey facility
CRT imports posing a major health, environmental hazard: Toxics Links
Creative Recycling Systems shuts down Tampa site
Between 2013 and 2022 an estimated 6.2 million tons of devices containing cathode ray tube (CRT) displays will find their way from our basements, closets and guest bedrooms into the U.S. e-scrap stream.
Leading the way to clean CRT recycling
Nulife For County Business
Nulife Opens CRT Leaded Glass Recycling Plant New York
Unwanted Electronic Gear Rising in Toxic Piles
SWEEEP Opens Lead Recovery Furnace
Sittingbourne firm finds solution to recycling TVs...
...one-of-a kind leaded glass furnace
Nulife, SWEEEP partner on new CRT furnace
UK glass furnace removes lead from CRT glass
2012 LCD TV Forecast Lowered to 216M Units...
Arubis Buffalo, FMC, Nulife Glass OK'd for low-cost power...
Ray of Light for CRT Recycling
Cathode Ray Tubes may have disappeared from our shops, but the number entering the waste stream is yet to peak in Europe...
WEEE art installation marks digital switchover
...the exhibition, titled '1001 TV Sets', will help raise awareness of the need to recycle waste electrical and electronic equipment (WEEE)...
Electronics Industry, Green Group Team Up With Crowd-Sourcing Pioneer to Address Important E-Waste Recycling Challenge
CRT processors hit proposed rule change
CES 2012: LCD TV Displays To Dominate
Industry data suggests that CRT-type televisions will be all but gone by next year...
Guiyu lead contamination raises alarm
Exclusive: World first in CRT glass recovery
SWEEEP buys the first CRT glass furnace from Nulife Glass
CRT recycling innovation for SWEEEP Kuusakoski
India Flat Panel TV Shipment CAGR Forecasted at 39% Through 2015
First Federal Criminal Charges Brought Against Recycler for Exporting Toxic e-Waste
First Federal Criminal Charges Brought Against Recycler for Exporting Toxic e-Waste
JAPAN: Dumped CRT TVs pile up as this weekend's digital switchover approaches
2011 TV Market Outlook Reduced in Latest Forecast
...total TV market is increasingly defined by the replacement of CRT TVs with flat panel TVs...
...Ancai Hi-tech To Invest 460M Yuan In PV Glass Project. Color tube facilities in its colored glass factory ceased production...
...Global CRT TV shipments continue to contract at a rate of about 30% Y/Y each quarter.
Asahi Glass Company, Limited announced that it will discontinue cathode-ray tube(CRT) glass business
CRT TVs soon to disappear
LCD kills off CRT in Russia
Ban on Import of Second Hand Computers
LG ELECTRONICS TO HALT PRODUCTION OF CRT TVS IN S.KOREA
Europe breaking electronic waste export ban
CRT-TV's Last Bastion Falling.
2010 to be the last year Indian consumers spend more on CRT-TVs than LCD-TVs
EA secures prosecution over hazardous WEEE exports
FPD TVs to completely replace CRT TVs by 2014
China FPD TV Market on Track to Surpass 50M by 2012
Global TV market technology: Decline of CRT market share versus plasma and LCD.
Samsung to stop making CRT TVs sooner rather than later?
WEEE study in Germany shows need for action
CRT TV shipments will continue to fade from the market, falling by 36% in 2010
Companies that Illegally Exported Electronic Waste to Hong Kong Agree to Pay Over $21,000 Penalty
Hazardous conditions for India's e-waste workers
Man held after tonnes of illegal e-waste are exported to Africa
Environment Agency to crackdown on e-waste dumping
LCD TV Outlook Improves; CRT Demand Plummets.
China's Skyworth to halt CRT TV sets production
Left in the Flat-Screen Dust Old-Model TVs Are So Toxic, You Can't Give 'Em Away. Literally.
EU’s click of death for old family friends. AFTER more than 70 years as a fixture in Britain’s living rooms, the cathode ray television is to face the final fade-out, as part of the European Union’s battle against climate change...
Sony: UK consumers hoard small electrical products instead of recycling them
Large-scale raids on suspected illegal WEEE exports
Samsung Exits CRT Monitor Business
Environment Agency cracks down on illegal e-waste operators
DisplaySearch Report Reveals China TV Market Entering the Flat Panel TV Era. According to DisplaySearch, flat panel TVs will replace CRT TVs when the FPD price is approximately twice that of a similar-size CRT...
E-waste in Ghana – Anti-dumping legislation soon. ...available data shows that as much as 75% of the 8.7 million tons of e-waste generated in the European Union cannot be accounted for, despite stringent regulations for recycling e-waste. In the US the figure is said to be about 80% or more...
CRT monitors are heavy, bulky, consume a lot of power and take up half your desk.
Not surprisingly, LCDs are increasingly pushing them off the table and into the bin…
Illegal shipments of e-waste on the increase, new report warns
SVTC’s film on E-Waste in India
Andrea Height, Deputy Editor, MRW Blog on the Ecobuild exhibition
Environment Agency makes first e-waste arrest
“…Of the 1.9 billion televisions in households worldwide at the end of ’07 only 8% were LCDs and we believe at some point almost all will become LCDs. The CRT market is collapsing and LCD is the product of choice…”