A Project Report On

Eco-Friendly Plastic Recycling Technique

Submitted in the partial fulfillment of the Requirement for the award of the Bachelors of Technology In Mechanical Engineering Submitted By Ashwani Kumar (90681175598) Sudhanshu Nagpal (81404114083) Under the guidance of C.L. Arora (Prof. Applied Science SBBSIET)

SANT BABA BHAG SINGH INSTITUTE OF ENGINEERING AND TECHNOLOGY (December 2011)

Certificate
This is to certify that Project entitled Eco-Friendly Plastic Recycling Technique is submitted in Partial fulfillment for the award of degree B. Tech (Mechanical Engineering) of Punjab Technical University, Jalandhar has been successfully completed by Ashwani Kumar (90681175598) & Sudhanshu Nagpal (81404114083). He has done a satisfactory work under my Supervision/Guidance

Prof. C.L Arora Dr. K.D. Mannan (Project Guide) (H.O.D.Mech. Dept.)

Er. Sumit Nijjar (Project Co-ordinator)

ACKNOWLEDGEMENT

We express our sincere gratitute to our Project guide C.L Arora (Prof. Applied Science SBBSIET). For his valuable guidance, proper advice, constructive suggestion under his tutelage. We would like to convey our Gratitute to Lt. Gen. (Retd.) J. S. Dhillon VSM. Deputy Director SBBSEC with those expert guidance and support, this job would have been compelling. We do not find words with which we can express our feeling of thanks to entire faculty and staff of Sant Baba Bhag Singh institute of Engineering & Technology for their help, inspiration and moral support, which went a long way in successfully completion of our project. We are also thankful to our family members and friends for their support and encouragement.

Ashwani Kumar (90681175598) Sudhanshu Nagpal (81404114083)

Table Of Content
1. Introduction to the Project 2. Aims / Objectives 3. How safe is Plastic to use for food packaging and bottles for drinks and beverages 4. Migration of chemicals from plastics 5. Plastic Recycling 6. Challenges in Plastic Recycling 7. Policy Measures in India 8. Plastic Recycling Techniques 9. Experimental Setup 10. Experimental Procedure 11. Use of plastic waste in Bitumen Roads 12. Conclusion 13. Refrences

Introduction
Plastic waste is major cause of pollution these days. The management of the solid waste is reaching a world crisis due to the plastic content being a major constituent. Economic growth and change in life style are resulting into rapid increase in generation of solid waste in the world. It is becoming very difficult to handle this waste on large scale. When burnt in the open it emits many poisonous, polluting gases. Littered plastic spoils the beauty of the city. When plastic goes into drains it chokes them. Even the water bodies on the earth are not safe from this pollution and soon the aquatic life may be endangered by it. The solid waste is used for land fillings but the plastic content in it makes land filling faulty due to non biodegradable nature of the plastic.

Out of the two types of plastic the thermoplastic is that which melts on heating and it constitutes about 80% of the total plastic waste. It is this content which can be recycled and thus we can reduce pollution due to plastic. The other type of plastic waste, thermosetting plastic, constitute about 20% of the total plastic waste can not be recycled because it does not melt.

If we are able to segregate the plastic waste, it can be recycled by primary recycling making articles from which waste has been generated or secondary recycling making other articles. Since segregation is very difficult on this scale, it is convenient to think of recycling of the mixture of different types of thermoplastic.

Aims / Objectives

The disposables, which generate waste and cause environmental problems, when their life ends, include mainly the following: Plastic packaging / carry bags/ bottles/ containers / trash bags Plastic waste from health & medicine. Plastic from hotels and catering industry Plastic from air, rail and road travel.

In the Last sixty years this waste has increased from 5 Million tones to more than 100 Million tones, the world over11. In India over the years countrywide network for collection of the plastic waste through rag picker, waste collectors, waste dealers and recycling enterprises, is increasing many fold. Lacs of tones of plastic waste are being recycled in India, every year, which is about 60% of the plastic waste generated. This level of recycling is highest in the world. The corresponding figures for Europe are 7%, Japan 12%, China10%, South Africa 16.5%. The balance unutilized waste remains uncollected, lying strewn on the ground littered in open drains or in the garbage dumps. Though plastic waste contain the

highest rate in the recycled market it causes environmental problems, poses health hazarded in addition to being public nuisance. The basic question is whether plastic be recycled at all for repeated use. In India it is a must because recycling of plastic waste is a major activity through which lacs of families earn their livelihood; A decision to suddenly to restrict this sector will have serious economic and social repercussions other major factor is that price. The rate of virgin plastic is more than double of the recycled plastic. The problem settles down to the systematic and scientific management of the plastic waste through (ISWM) Integrated Solid Waste Management. System based on 3R` (reduction,reuse,recycle) given in UNEP (United Nation Environment Programme) of 2009, diverting from land fill to resource by doing improvement in source, segregation , collection, transportation, treatment, energy recovery and final disposal. Comprehensive data on present and anticipated waste estimation support policy frame work, knowledge and capacity to develop plans instead of importing machines. India having a late comers advantage can benefit from experience of developed countries.

How safe is Plastic to use for food packaging and bottles for drinks and beverages
Food packaging keeps food safe from contamination and damage during distribution / storage, so helps to provide fresh food to the consumers. Plastic additives are incorporated into polymers during the manufacturing process to confer specific properties to the polymer for specific applications i.e. making rigid and clear containers that show off the contents and appeal to the consumers also many drinks and beverages coming up in plastic bottles can be dangerous There are seven groups of plastic polymers each with specific properties that are used world wide for many packaging applications (Table I). Each group of plastic polymers can be identified by its plastic identification code (PIC) usually a numbers or a letter abbreviation for example polypropylene can be identified by the number 5 and the letter PP. The PIC appears inside a three chasing arrow recycling symbol (Table 1). The symbol is used to indicate whether the plastic can be recycled into new products.

Plastic Identification Codes Plastic Identification Code Type of plastic polymer Polyethylene Terephthalate(PE T, PETE) Common Packaging Applications Soft drink, water and salad dressing bottles; peanut butter and jam jars

Properties

Clarity, strength, toughness, barrier to gas and moisture.

High Density Polyethylene (HDPE)

Stiffness, strength, Milk, juice and water bottles; toughness, yogurt and margarine tubs; resistance to trash and retail bags. moisture, permeability to gas.

Polyvinyl Chloride Versatility, clarity, (V) eases of blending, strength, toughness.

Juice bottles; cling films

Low Density Polyethylene (LDPE)

Ease of processing, strength, toughness, flexibility, ease of sealing, barrier to moisture.

Frozen food bags; squeezable bottles, e.g. honey, mustard; cling films; flexible container lids.

Polypropylene (PP)

Strength, toughness, resistance to heat, chemicals, grease and oil, versatile, barrier to moisture.

Reusable microwaveable ware; kitchenware; yogurt containers; margarine tubs; microwaveable disposable take-away containers; disposable cups and plates.

Migration of chemicals from plastics

Chemicals that are used in the manufacture of plastic packaging or containers can migrate into foods during use. The quantities of migrating chemicals5-6 will depend largely on (i) (ii) (iii) Nature of food Contact temperature Contact time.

Table II show, some of the important chemicals which migrate from the plastic in to the contents.

Table -II

Sr. No . 1

Plasti c

Monomer

Structure of Polymer

what migrates

PET

Acetaldehy de (CH3CHO)

HDPE

CH2 CH2

Antioxidant *

PVC

CH2 CH Cl

Plasticizers (lead,cadiu m, mercury)

LDPE

CH2 CH2

Carcinogen s, Anti Oxide*

PP

BHT, Chima ssorb81, Irganox PS800, Irganox101 0

PS

Traces found nearly everyones body fat. in

Other s

Depends on the used. plastic

Anti Oxide *:-

i.

Butylated hydroxy toluene (BHT)

ii.

Chinas orb 81

iii.

Irganox PS 800

iv.

Irganox

1076

Plastic Recycling

Municipal solid waste in India contains 1-4 per cent by weight of plastic waste. Indias rate of recycling of plastic waste is the highest (60%) in the world as compared to other countries (China 10%, Europe 7%, Japan 12%, South Africa 16%, and USA 10%). As a source of hazard to environment, plastic account for 16% of chlorine in the environment and have 54 carcinogens, polythene bags for disposal if burnt irresponsibly releases highly toxic gases like phosgene, carbon monoxide, chlorine, sulphur dioxide, nitrogen oxide, besides deadly dioxin. Polymers are gradually replacing natural materials like metal, timber and fibers and thereby conserving the natural environment. Polymers are now finding diversified uses through blends and alloys and giving higher standards of performance and life cycles to various products.

Plastics waste forms a wide range. Predominantly it is film packaging and polythene carry bags, followed by blow molded containers, and broken and discarded molded items. The range is wide and includes - discarded PVC chappals/shoes in varied colors and grades of plastics material.

- discarded PVC mineral water bottles/PET mineral water and liquor bottles and PS ice cream/ cold drink cups/disposable catering plates and grays and expanded PS and PE foam packaging. - PE, PVC, PP films, packages, shopping bags, and medicine foils, used and discarded molded items like containers and range of household nondurables, combs, ball point pens, tooth brushes etc. - Broken plastics articles - mostly of PE, PVC, PS, PP, ABS, Nylon, PET, etc.

Challenges in Plastic Recycling

When compared to other materials like glass and metal materials, plastic polymers require greater processing to be recycled.[citation needed] Plastics have a low entropy of mixing, which is due to the high molecular weight of their large polymer chains. A macromolecule interacts with its environment along its entire length, so its enthalpy of mixing is large compared to that of an organic molecule with a similar structure. Heating alone is not enough to dissolve such a large molecule; because of this, plastics must often be of nearly identical composition in order to mix efficiently.

When different types of plastics are melted together they tend to phaseseparate, like oil and water, and set in these layers. The phase boundaries

cause structural weakness in the resulting material, meaning that polymer blends are only useful in limited applications.

Another barrier to recycling is the widespread use of dyes, fillers, and other additives in plastics. The polymer is generally too viscous to economically remove fillers, and would be damaged by many of the processes that could cheaply remove the added dyes. Additives are less widely used in beverage containers and plastic bags, allowing them to be recycled more often. Yet another barrier to removing large quantities of plastic from the waste stream and landfills is the fact that many common but small plastic items lack the universal triangle recycling symbol and accompanying number. A perfect example is the billions of plastic utensils commonly distributed at fast food restaurants or sold for use at picnics.

The use of biodegradable plastics is increasing. If some of these get mixed in the other plastics for recycling, the reclaimed plastic is not recyclable because of the variance in properties and melts temperatures.

POLICY MEASURES IN INDIA

Various policy measures are being taken to check the nuisance caused by plastic waste in India, through there is no definite policy and legislation framed in respect of mitigating the plastic waste in the country. These are Regulations and legislation: (a) Until recently there has been no definite environmental policy and legislation framed in respect of plastic waste in India. The plastics waste gets generated, collected, traded, and reprocessed by known methods into useful products, thereby supplementing supply of raw materials, and at economic price. However, a HP Non-biodegradable Garbage (Control) Act, 1995, has been introduced by the Government of Himachal Pradesh. The Act appropriately envisages prohibition of throwing or depositing plastic articles in public places and to facilitate the collection through garbage in identifiable and marked garbage receptacles for nonbiodegradable, placed at convenient places. Haryana State has announced a Bill (1997) on Non-biodegradable Garbage on similar lines as that of Himachal Pradesh. The National Plastics Waste Management Task Force of the Ministry of Environment and Forests, Government of India, has recommended a strategy and action Programme of Plastics Waste Management in India. (b) Ministry of Environment and Forests, Government of India have issued criteria for labeling `plastic products as `Environmental Friendly under its `Ecomark Scheme, in association with the Bureau of Indian Standards. One of the requirements for plastic products is that the material used for packaging shall be recyclable or biodegradable. (c) The Bureau of Indian Standards, New Delhi (BIS) has issued guidelines on recycling of plastics waste including code of practices for collection, sorting through conventional practices continue to be adopted

and accepted, need has been voiced to upgrade these, both by the authorities and NGOs. However, while formulating Indian standard specifications for various plastic products, used for critical applications like plastic piping system, water-storage tanks, packaging for food articles, a clause is included which reads no recycled plastics waste shall be used. An exercise has also been carried out by the Ministry of Environment and Forest in association with Bureau of Indian Standards to include use of recycled plastic waste wherever appropriate in the manufacture of plastic products and this should be specified accordingly in the relevant Indian Specifications. (d) The Prevention of Food Adulteration Department of the Government of India, has issued directives to various catering establishments to use only food-grade plastics, while selling or serving food items. Rules have specified use of `food grade plastic, which meets certain essential requirements and is considered safe, when in contact with food. The intention is to check possible contamination, and to avert the danger from use of recycled plastic. The Scheme announced in February, 1995 is being implemented in cooperation with Bureau of Indian Standards (BIS) which has formulated a series of standards on this subject. The Bureau of Indian Standards Sub-committee PCD 12.17 is charged with formulating guidelines, codes and specifications for recycling of plastics. Two documents, viz., Guidelines for Recycling of Plastics and `Recycled Plastics for Manufacture of Products, Designation have been finalized. (e) The Central Pollution Control Board, New Delhi had assigned a study on Status of Waste Plastics Recycling in NCR Delhi to Shri Ram Institute for Industrial Research Delhi. Among the conclusions of this study, the following deserve particular mention:

- There is need to formulate and enforce code of good practice both for the processor and the consumer. In particular, standards need to be laid down for products from various plastics waste including the co-mingled one. - Directives should be imposed for a periodic air quality and health/hygienic check in the reprocessing units. (f) During September 1996, (and earlier during September, 1994) a National Conference on `Plastics and Environment was organized at New Delhi, by FICCI and Plats India Foundation. It was during the Conference that the Ministry of Environment and Forests, Government of India announced the setting up of National Plastics Waste Management Task Force, with representations of Department of Chemicals and Petrochemicals, Ministry of Urban Affairs, Municipal Corporation of Delhi, Plats India Foundation, The All India Plastics Manufacturers Association, All India Federation of Plastics Industry, NOCIL, IPCL, and experts from BMTPC, FICCI and CII. The Task Force has submitted its report (August 1997) and drawn Strategy and Action Programme for Plastics Waste Management in India. (g) A National Association of PET industry has recently been formed by PET manufacturers and users in India which is expected to look after the organised collection and recycling of PET bottles/containers waste.

Plastic Recycling Techniques

Before recycling, most plastics are sorted according to their resin type. In the past, plastic reclaimers used the resin identification code (RIC), a

method of categorization of polymer types, which was developed by the Society of the Plastics Industry in 1988. Polyethylene terephthalate, commonly referred to as PET, for instance, has a resin code of 1. Most plastic reclaimers do not rely on the RIC now; they use automatic sort systems to identify the resin, such as near infrared (NIR) technology. Some plastic products are also separated by color before they are recycled. The plastic recyclables are then shredded. These shredded fragments then undergo processes to eliminate impurities like paper labels. This material is melted and often extruded into the form of pellets which are then used to manufacture other products. Monomer recycling Many recycling challenges can be resolved by using a more elaborate monomer recycling process, in which a condensation polymer essentially undergoes the inverse of the polymerization reaction used to manufacture it. This yields the same mix of chemicals that formed the original polymer, which can be purified and used to synthesize new polymer chains of the same type. Du Pont opened a pilot plant of this type in Cape Fear, North Carolina, USA, to recycle PET by a process of methanolysis, but it closed the plant due to economic pressures. Thermal depolymerization Another process involves the conversion of assorted polymers into petroleum by a much less precise thermal depolymerization process. Such

a process would be able to accept almost any polymer or mix of polymers, including thermoset materials such as vulcanized rubber tires and the biopolymers in feathers and other agricultural waste. Like natural petroleum, the chemicals produced can be made into fuels as well as polymers. A pilot plant of this type exists in Carthage, Missouri, USA, using turkey waste as input material. Gasification is a similar process, but is not technically recycling since polymers are not likely to become the result. Heat compression Yet another process that is gaining ground with startup companies (especially in Australia, United States and Japan) is heat compression. [citation needed] The heat compression process takes all unsorted, cleaned plastic in all forms, from soft plastic bags to hard industrial waste, and mixes the load in tumblers (large rotating drums resembling giant clothes dryers). The most obvious benefit to this method is the fact that all plastic is recyclable, not just matching forms. However, criticism rises from the energy costs of rotating the drums, and heating the post-melt pipes.

Experimental Setup

Aim: To recycle the plastic without polluting the environment.

Requirement: Melting Chamber Stand for Melting chamber LPG Cylinder Gas Pipe Burner with Regulator Exhaust pipe for Gases

Melting Chamber: It is a chamber made up of metal sheet, in which waste plastic melt. This chamber is heated from the base with the help of LPG gas.

Stand for Melting Chamber: A stand is also provided for placing the melting chamber at the suitable height. Gas burner and regulator is fitted on this stand. This stand is made up of metal pipe.

LPG Cylinder: LPG cylinder is also needed for storing LPG.

Gas Pipe: Gas pipe is needed to supply gas from LPG cylinder to the Burner.

Burner & Regulator: Burner is also provided for the burning of the LPG and regulator is provided to regulate the LPG, it is very necessary to regulate the flame of LPG.

Exhaust Pipe for Gases: A exhaust pipe is also provided at the top of the melting chamber for the exhaust of the gases, which are harmful for environment and main cause of the air pollution. This exhaust pipe is further attached with a flexible pipe which is dipped in a water sump in which exhaust gases are mixed.

Experimental Procedure

1. First of all clean the melting chamber from inside. 2. Place melting chamber on the melting chamber stand and attach LPG cylinder with the burner through the pipe. 3. Fill the waste plastic from the above side of the melting chamber and closed the melting chamber with upper cover. 4. Attach a flexible pipe with the exhaust pipe, and dip this flexible pipe in a water sump, so that the exhaust gases will mix in the water without polluting the environment. 5. Ignite the burner and regulate the LPG with the help of regulator as required. 6. Slowly slowly the walls and base of the melting chamber is heated up and plastic waste in the chamber starts melting. 7. After sometimes the melted plastic will comes out through the outlet provided at the bottom. 8. This melted plastic will fall in the water tub placed on the floor and this liquefied plastic solidified in the water with the instant of seconds. 9. This plastic is used as Bitumen in construction of roads etc.

Use of plastic waste in Bitumen Roads

Plastics, a versatile material and a friend to common man become a problem to the environment after its use. Today, in India nearly 4 million tonnes of plastics are used and it is hoped to reach 12 million tonnes by 2010. Their visibility has been perceived as a serious problem and made plastics a target in the management of solid waste. Plastics are nonbiodegradable. They also have very long lifetime and the burning of plastics waste under uncontrolled conditions could also lead to generation of many hazardous air pollutants (HAPs) depending upon the type of polymers and additives used. However, the end-of-life plastics can be recycled into a second life application but after every thermal treatment, degradation of plastics takes place to a certain extent.

Polymer modified bitumen is emerging as one of the important construction of flexible pavements. The polymer modified bitumen show

better properties for road construction and plastics waste can find its use in this process and this can help solving problem of pollution. The studies on the thermal behavior and binding property of molten plastics promoted a study on the preparation of plastic waste-bitumen blend and its properties to find the suitability of the blend for road construction. An alternate method to use higher percentage of plastic waste in flexible pavement is by using plastic coated aggregate (PCA). This method is known widely as dry process. The aggregate coated with plastic was used as the raw material. The bitumen was not blended with plastic waste. Advantages: Better binding property Higher Softening point; withstands high temp. Lower penetration value; withstands higher load. No stripping Resists the permeation of water. Higher Marshall Stabilityincreased strength of road. Operation temperature range: 160-1700C. Cost less compared to bitumen road. Use of waste Plastics (MSW, road side etc.). Better disposal of waste plastics. Ten lakhs or one ton carry bags in one kilometre road.

CONCLUSION

The generation of waste plastics is increasing day by day. The major polymers namely polyethylene, polypropylene, polystyrene show adhesion property in their molten state. The plastic coated aggregate bitumen mix and plastic modified bitumen forms better materials for flexible pavement construction as the mixes shows higher Marshall Stability value and suitable Marshall Coefficient. Hence the use of waste plastics for flexible pavement is one of the best methods of easy disposal of waste plastics. The use of polymer coated aggregate is better than the use of polymer modified bitumen in many aspects. Foe example if all the roads in India (3.3 million km) are converted into plastic tar road, all the waste plastic available will be used on the road and the disposal of waste plastics will no longer be a problem. But as the burning of plastic waste creates health hazards and also air pollution, the use if this should be restricted to open areas or in lesser populated areas. Also; the workers involved should be provided with proper safety devices. These processes are socially highly relevant, giving better infrastructure. Let us grow with these newer technologies.

References

1. Idea TV GmbH. "Recycled plastic - the fashion fabric of the future". Innovations-report.com. Retrieved 2010-08-21. 2. 10:24 AM PT, November 13, 2009 (2009-11-13). "Trashy Chic: Recycled clothing from Playback - Brand X". Thisisbrandx.com. Retrieved 2010-08-21. 3."Reware's REWOVEN Technology Info: The Eco Narrative - Recycled PET". Rewarestore.com. Retrieved 2010-08-21. 4. "Billabong ECO Supreme Suede Boardshorts: Sustainable is Good Eco Products". Sustainableisgood.com. 2008-04-09. Retrieved 2010-08-21. 5. "Rip-Tide "Eco Tech" Fabric Made From Hemp, Recycled PET". TreeHugger. Retrieved 201008-21. 6. United Nations Report on Environment Programme 2009 7. "Let Peanuts Live! Mail Boxes Etc. Recycles as Part ofNational Effort; Recycle Loose-fill, Foam `Peanuts' AtParticipating Mail Boxes Etc. Locations. | North America > United States from". AllBusiness.com. Retrieved 2010-08-21. 8. Plastic trial procedure Oaktech Environmental website. Retrieved 9.11.06. 9. Agricultural plastics recycling process Agricultural plastics recycling website. Retrieved 07.11.08. 10. Plastic Composite Railroad Tie Facts Plastic Composite Railroad Ties website. Retrieved 01.21.08. 11. Management of Plastic Waste, the Hindu August21, 2001. 12. Financial Times, May 15, 2009 (article by Max Hogg) http://www.allbusiness.com/chemicals/chemical-overview/9060603-1.html 15.http://www.jbiglobal.com/products-and-services/plastic2Oil.aspx