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Plant Specifications
How much glass can a converter unit process?
We offer a range of units capable of processing from 10 to 20 tonnes of leaded glass per day.
How big is the plant?
This depends on the capacity of the converter and what you intend to do with the cleaned glass. The 10 tonne per day converter is 8 meters long and 4 meters wide. The height of the unit is 4 - 6 meters depending on whether it is sited above a catch pit or located direct onto the building floor. Additional space is required for crushing of the glass prior to loading into the converter and if you are using the treated glass to manufacture products such as tiles, you will need space for glass handling equipment.
How is the plant laid out?
Ideally you should have space for a linear flow of glass through the process from CRT splitting, crushing, charging into the converter and handling the treated glass. However, there is no reason the CRT splitting and glass crushing can't be done away from the converter unit either elsewhere on your site or at an off-site location.
What power supply do I need at my site?
A 10 tonne converter consumes 6000KWh per day. A 3 phase 750KVA supply is required.
What other services do I need?
When the converter is being brought up to temperature during commissioning and following a shutdown a natural gas burner is required to create heat in the melting zone. A domestic size supply is sufficient for this. You also need access to water in order to top up the re-circulating cooling system but there are no discharges to drain so a sewer connection is not required.
Plant Operation
How many staff do I need to run this plant?
This depends on how you decide to operate. Maximum efficiency is achieved running the converter 24 hours per day 7 days per week so we suggest a shift team of 2 people per shift, 10 operators and 1 manager to oversee them. However, existing staff will be able to manage this whilst performing other tasks too.
What are the requirements for maintenance?
Our cash flow models include a provision for maintenance but provided the correct operating procedures are followed maintenance on the converter is minimal. The electrodes in the converter are a consumable item but our design allows them to be replaced without having to shut down the converter for a prolonged period of time.
Environmental
How clean is the treated glass?
Leach tests on the products made from the de-leaded glass show lead leaching below 40 parts per billion.
What permits do I need?
This depends on which country and state you operate in. In the EU CRT glass is classed as a hazardous waste and an environmental permit is required. In the US you will need to obtain the necessary permissions from the state regulators.
Are there any emissions, discharges or waste?
Our process produces no solid or liquid waste. Emission tests conducted on our R&D unit in the UK detected no lead or particulate emissions above the background level. Water used for cooling is re-circulated and there is no discharge. There is no waste, the only outputs from the converter are saleable products.
Are the chemicals used hazardous?
All of the chemicals used in the process are classified as non-hazardous in the EU and US.
How pure is the recovered lead?
Typically better than 99.7% pure provided optimum operating conditions are maintained.
How safe is the converter unit?
Safety has been a top priority all through the design process. The computer control system will shut off the power in the event of the temperature exceeding preset levels, the cooling water system has a backup in the event of pump failure and high performance insulation protects operators from exposure to excessive heat.
Nulife Glass Service
What does the Nulife Glass recycling system include?
This depends on what equipment you already have on site. We can provide just the converter and glass handling system or a full system including CRT splitting and glass granulation.
What products can I make from the treated glass?
The glass has been successfully used as an aggregates replacement in construction products such as floor screeds and worktops and to produce glass tiles. Other potential applications include road surfacing, grit blasting and production of higher value decorative glass products.
Commercial
Can I obtain exclusive rights to a whole country?
No - We do not believe that any single recycler has sufficient market share to justify a country wide exclusivity deal.
Can I obtain exclusive rights to a territory or region?
Yes - We are prepared to discuss exclusivity for a territory or region on a case by case basis.
Do I have to buy the whole system?
We offer two options. Firstly you can purchase a recycling system which you would own and operate. Alternatively if you can provide a contract committing to a guaranteed quantity of glass for a specified period of time we can set up a recycling plant next to your existing site and process the glass on your behalf on a toll basis.
Does the Nulife Glass system only work on CRT glass?
Our system will remove lead and other heavy metals from a range of glass materials such as lead crystal waste, x-ray shielding and crystal cutting waste.
What is the lead time for the plant?
Off-site construction takes 3-4 months depending on the plant specification. Onsite installation, commissioning and training of your staff takes 3 - 4 weeks.
Can the treated glass go back to make new CRTs?
No, this process is unique because it does not rely on the declining market for "glass to glass" recycling. Once treated there are many applications for the glass in large and sustainable markets.
