Plastics Waste Management and Plastics Recycling

“Plastics Waste Management and
Plastics Recycling”
http://polymerandpaint.blogspot.com
Polymers
Polymers
•• Chemical
Chemical Industry
Industry Output
Output
•• –– US
US $$ 1.6
1.6 Trillion
Trillion
•• Commodity
Commodity Polymers
Polymers Output
Output
•• –– US
US $$ 100
100 Billion
Billion
•• 6%
6% of
of Chemical
Chemical Output
Output
Most Favoured Materials

Polymer Industry Landscape
People - Knowledge & Information
Applications /
Materials Machinery / Products /
Process Markets
 Intricate designs
 New Materials  Higher Productivity
 Superior Performance
 Improved Catalysts  Larger Capacities
 Superior Properties  Lower costs
…with frontier technologies

Increase in Knowledge Quotient (KQ)
1970’s 1980’s 1990’s
• Technical products
• Simple household
• Intricate designs
article
• Packaging requirements • Functional need
• Basic design
• Specific designs • Higher value
• No specific need
• Better value • Higher KQ
• Low value
• Low KQ • High KQ
… adding value
Recycling of Plastics Waste
- A Challenge
 Recycling of Plastics is an undaunted challenge
and task as there are about 10-12 main polymer
types and thousands of different resin grades
and blends available for commercial
applications.
 In addition to this, polymers have become

increasingly multi-component through the use of
multi-layers, laminates and composites.
 Furthermore, many polymers are rarely additive

free. Normally they contain additives,
formulates and modifiers such as fillers,
pigments, antioxidants and flame-retardant,
which can further interfere with the recycling
process. http://polymerandpaint.blogspot.com
Recycling of Plastics Waste -
Global Paradigm Shift
 In the 90’s, - Emphasis was on mechanical

recycling of plastics.
 Presently - An integrated approach to plastics

recycling including feed-stock recycling,
incineration with energy recovery.
 Demand for post consumer recyclates is

increasing steadily due to the implementation of
recycle legislation, favourable cost of recyclates,
advancement in recycling technology and
expanded collection network.
Plastic Product – Classification
(Based on Life Span)
Short Life
Long Life
Carry bags
Chairs
Woven Sacks
Crates
Bottles
Disposable cups Pipes
Syringes etc., Profile
Bio medical Automobile
plastic products components
IT-Components
etc
Options for Recycling of
Plastics Waste
Recycle Repair/Reuse Incineration
- Mechanical Ex: Household & - Energy

Recycling Industrial recovery
containers are Ex. Heat,
reused many times Oil etc.,
- Mixed waste - Carry bags, Water

recycling bottles etc.,
- Chemical - Repaired buckets,

recycling Woven sacks
- Shelter for huts
etc.,
Flow Diagram for Recycling of
Consumer Waste
Consumer Waste
Household Waste Hotel/Hospital Waste Street Waste Dump yard
Scrap Dealers Rag pickers
Scrap wholesalers
Grinding,
Recyclers Sorting & Cleaning Cleaning, Drying
Sold to processors/ Granulation & Lump formation &

Product conversion to end Packaging grinding
Flow Diagram for Recycling of
Industrial Waste
Industrial Waste
End Users Street Waste
Scrap Dealers Scrap pickers
Scrap wholesalers
Grinding,
Recycler Sorting & Cleaning Cleaning, Drying
Sold to processors/ Granulation & Lump formation &

Product conversion to end Packaging grinding
Essential Elements of
Recycling of Plastics Waste
 A stable supply source which involves reliable

collection and sortation
 An economical, proven and environmentally

sound recycling process and
 End-use applications for the recycled polymer

which yield economic market values and capture
consumer confidence.
Technology Options for Recycling of
Plastics Waste
In – House recycling in processing industries
Product to Product approach
Monomer to Monomer
Mixed plastics to oil
Mixed plastics to plastics lumbers
Mixed plastics to energy
In-house Recycling in
Processing Industries
PLASTIC RAW PROCESSING

PRODUCTS
MATERIAL MACHINE
INSPECTION
QUALITY
5-10% REJECTION PRODUCTS
GRINDING
OTHER REGROUND
STORAGE
PRODUCTS WASTE
WASTE
(RUNNERS/
TRIMMINGS)
Product … to… Product
Approach
PRODUCT
RECLAMATION CONSUMER
WASTE
TRANSPORTATION
Monomer... To ... Monomer
Approach
Depolymerisation MONOMER
Polymerisation
RECLAMATION POLYMER
Manufacturing
TRANSPORTATION OF
PRODUCTS
WASTE
CONSUMER
Ex: PET & PMMA

Chemical Recycling of PET
(Glycolysis)
ETHYLENE CATALYST
GLYCOL (ANTIMONY
EXCESS
GLYCOL OXIDE)
PET WASTE
GLYCOLISED
REACTOR OLIGOMERS OLIGOMERS
REACTOR
(UNDER HIGH FILTER (UNDER
PRESSURE & VACUUM)
TEMP)
POLYMER
STRANDS BY
APPLYING N2
PRESSURE
COOLING
GRANULES GRANULATOR TROUGH
Depolymerisation of PMMA Scrap
Thermal Degradation Process
MS REACTOR 400o C IMPURE

PMMA
IN ABSENCE OF CONDENSER
SCRAP OXYGEN MONOMER
VAPOUR DARK BROWN
MONOMER
LIQUID
REGENERATED FRACTIONAL
MONOMER DISTILLATION
(89 TO 93% PURITY) COLUMNS
NOTE : FURTHER DISTILLATION IMPROVES THE PURITY
Thermolytic Process Approach
PLASTIC
Hydrolysis*
Pyrolysis
MONOMER
PETROCHEMICAL
FEED STOCK
ENERGY
* Water is used as Chemical agent to depolymerise PET
Plastics Waste to Fuel Oil
 M/s. Koen Tech Co. Ltd, Korea has developed a plant for
converting plastics waste to fuel oil, similar
technologies are available in Japan
Process cut line
SOLVENT GAS *
Plastic Waste Cracking
Mixed Oil
* Gas is condensed and sent to extraction tower
Mixed Plastics Waste to Plastic
Lumbers
INTRUSION MOULDING
(or)
EXTRUSION FLOW MOULDING
 Producing “Plastic Lumbers”
 Profiles - from mixed / contaminated plastic waste
EXTRUSION ROTATING MOULDS
Plastic Lumbers
 Cost of plant varies from approximately US $ 0.34

million to US $ 1 million depending upon the capacity
Innovative Strategy for Converting
Plastics Waste into “Wealth”
 Swiss based technology available to convert

mixed waste (except nuclear waste) into gas and
refined into commercially useful by-products.
 Technologies for mixed waste plastics recycling

commingled with non-plastics waste are
available Worldwide.
 A proprietary technology available from Israel

can recycle a mixture of HDPE, LDPE, PVC, PS,
PET (unsorted) and newspapers in the ratio of
upto 50%.
 Post Consumer waste(PCW) into plastics wood/
lumber is popular world over with variations in
technology.
 Plastics wood lasts more than 25 years and costs
30% less than redwood.
 Recycling of blends is one of the most
technologically significant area. Few examples are -
 Recyclable blends of either PS or HIPS with 2-
30wt% PP, and 5-20 wt% Styrene Ethylene
Butadiene Styrene (SEBS), have good impact
and flexural strength.
 Blends of PS and Polyolefins (PE or PP) and
Styrene Butadiene Rubber(SBR) or block
copolymer, were reported recyclable.
 Polystyrene, 10-90% wt% PS, was blended
with 10-90wt% Polyolefins (e.g. LLDPE), and 5-
40% SEBS (Comprising atleast 50% styrene).
The system showed good resistance to impact
and yellowing.http://polymerandpaint.blogspot.com
Value Added Applications of Different
Types of Recycled Plastics Material
Name of Some uses of virgin

Some uses of recycled plastic
Plastic plastic
Soft drink and mineral Multi-layer soft drink bottles,
PET
water bottles carpet fibres fleecy jackets
Waste bins, detergent bottles,
crates, agricultural pipes,
Milk crates, bottles for
kerbside recycling crates.
HDPE shampoo and cleaners
Plastic lumber, Plant pots,
milk and cream bottles
Traffic cones, Toys, Outdoor
furniture
Clear cordial and juice
Rigid Detergent bottles, tiles,
bottles, plumbing pipes
PVC plumbing pipe fittings.
and fittings
Value Added Applications of Different
Types of Recycled Plastics Material
Name of Some uses of virgin

Some uses of recycled plastic
Plastic plastic
Garden hose, shoe
Flexible Hose inner core, industrial
soles, blood bags and
PVC flooring
tubing.
Garbage bags, garbage
LDPE Composite bins, crates
bins, black plastic sheet
Drinking straws,
PP icecream containers Composite bins, crates
hinged lunch boxes
Coat hangers, office
Yoghurt containers,
PS accessories rulers, video/CD
plastic cutlery
boxes
Indian Experience and Success in
Plastics Waste Recycling
 Estimate suggests that around 2500
mechanical recycling industries are spread
over the length and breadth of the country
involving around 3 lakh people.
 The statistical informations on Indian

scenario are enumerated as follows.
Volume Recycled - 1.2 MMT
No. of units - 2500
Pelletizers - 3200
Turnover (USD in Million) - 1124
Value Add (USD in Million) - 360
Ragpickers Employed - 130 K
Employment - 300 K
PP/HDPE Woven Sacks to Pots
(Indian Experience)
PP/HDPE
WOVEN SORTING CLEANING &
SHREDDING
SACKS (MANUALLY) DRYING
SMALL
PIECES
GRINDER EXTRUSION MIXER

LUMPS DRIED SMALL
PIECES
FLAKES
EXTRUSION PELLETS BLOW MOULDING
POTS
PET/PE Multilayer Film Waste to
Moulded Products
(Indian Experience)
PET/PE VIBRATING
AGGLOMERATION
MIXED WASTE SCREEN
SHRED / EXTRUDE EXTRUDE
MIX COMPATIBLISER +
FINISHED DRY
FILLER AND EXTRUDE /
PRODUCTS
MOULD
Material Wise Break-up for Various
Plastics Materials Recycling in India
Material Kilo Tons

LLDPE/LDPE/HDPE - 300
Polypropylene (PP) - 240
PET - 110
Polystyrene - 150
Flexible PVC - 180
Rigid PVC - 160
Miscellaneous (Industrial
Waste of Engineering
Plastics/Foam Waste, Etc.) - 60
Total - 1200
Plastics Recycling Centres in India
Indian Experience of Value Addition
in Plastics Recycling
Indian Experience of Value
Addition in Plastics Recycling
Rain Coat Film
in PET Recycling
Applications for Recycled PET Bottles
Fibres
• In staple form for fillings e.g., anoraks,

bedding, cushions and furnishings.
• Industrial fibres for belting, webbing,
scouring/cleaning pads, filters, cleaning cloths
and geotextiles.
• Other textiles like carpets, upholstery fabrics,
interlinings, protective clothing and other
garments.
Strapping
• Binding and strapping tapes, mainly for

securing bales or bulky articles on pallets.
Sheet
• Recycled PET granules can be extruded as sheet for
thermoforming applications
• Blister packaging,
• Boxes and Trays,
• Shallow pots and cups.
Blow moulding
Primarily into bottles for non-food applications.
Applications through Different Routes
of Recycling PET
Route - I FIBRES
100% Recycled PET Bottle Flakes to Fibres through

Bottle Flake Extrusion Granules Spinning Fibres
Route II
100% Bottle Flake into fibres by Chemical route and
Melt blending pumping through extruder/gear pump
Route III
20% Recycled PET Bottle Flakes + 80% (PTA+MEG) to
Fibres through Glycolysis & Polymerisation and Melt
pumping by gear pump into Fibres
Applications through Different Routes
of Recycling PET
GRANULES FOR PRODUCING PET BOTTLES
(FOOD GRADE) & BOX STRAPPING
Route - I
100% Recycled PET Bottle Flakes into granules
through Chemical route
Route II
20% Recycled PET Bottle Flakes + 80% (PTA+MEG) to
granules(Pellets) through Glycolysis & Polymerisation
and compounding
Successful Innovation of an Indian
Company in PET Recycling
 Unique process developed to produce resin with

80% PTA - MEG and 20% PCR bottles on Chemical
Recycling Route, named as GreenPET.
 Combination of Glycolysis and Polymerization
with Virgin Raw Materials.
 Final Polymer quality is as good as Virgin
Polymer.
 Superior to “Salt and Pepper” approach.
 Process under Patent.
GreenPET has been certified by US FDA &
Suitable for High Blow Moulding applications
Contd.
Process Sequence of Recycling PET
Bottles by Combination of Mechanical
& Chemical Route...
Separation of
clear PET
Bottle
Hot Soda bottles
Clean
*PET screw
water Water Water Crusher
Bottles conveye
spray bath Bath
r
Passing
through
Metal
Pneumatic Spin Density separator
Prewash Prewash
Conveyor Spin wash Floatation
Dryer tank 2 tank 1
tank
Cleaned PET
Flakes

20% Glycolysis 100% food
Storage 80%
Meterin
silo with
g system
Recycled + (PTA+ grade
Dryer flake MEG) GreenPET
Polymerisation
* In the developed system labels (paper or PVC), caps,

Aluminium based closures, etc., are manually separated.
Commingled & contaminated
Plastics Waste Recycling
Commingled Intermediate
Shredding Mixing
Plastic
Grinding Storage Blending Moulding
Waste
Company in Commingled Plastics
Waste Recycling
 Unique process developed to produce

environmentally Wood substitute(Chipboard) for
numerous furniture applications, pallets, interior
decoration, doors, signages, etc.
 Composition of the product
 Proprietary process developed by Indian
company using multi-layered paper waste
polyethylene and aluminum foil to produce
wood substitute “Eco” products
Company in Commingled Plastics
Waste Recycling
Properties of “Eco” Chipboard
 100% termite and borer - resistant, denser than
wood, maintenance free
 Excellent insulation and sound proofing quality &
can be recycled
 It can be painted, laminated, Polished like other
wooden material
 It can be sawn, moulded-cut, glued screwed, etc.
like other Wood based board.(high compression
strength)
 Thermoformable, Formaldehyde-free
 Resistance to acids, alkalies, solvents and other
chemicals
 Cost effective http://polymerandpaint.blogspot.com
Comparison
(“Eco”Chipboard Vs Conventional wood-based board)
S. Block Particle Natural Eco
Property Plywood MDF
No. Board Board Wood Chipboard
1 Acoustics X X  X  
Water
2 X X X X X 
Resistance
Design
3 X X X   
Creativity
4 Economy X X  X X 
5 Machining X X X   
Physical
6 Limited Limited Limited Seasoned Limited High level
Properties
Contd.
Comparison
(“Eco”Chipboard Vs Conventional wood-based board)
S. Block Particle Natural Eco
Property Plywood MDF
No. Board Board Wood Chipboard
Attractive
7 X X X X X 
Surface
Termite/
8 Borer X X X X X 
Resistance
Peels/ Contracts Contracts
9 Stability Peels Warps Stable
Warps / Expands / Expands
Thermo-
10 X X X X X 
formability
Compression
11 Limited Limited Limited Normal Normal High Level
Strength
Few Furniture Applications
Interior for Showrooms
Signages
Temporary Structures, Such as
Site Office, Mass Housing,
Rehabilitation Houses, Post, Etc
Economy Doors(Water Resistant)
Highly Durable Poly Pallets
Value added Recycled
products from Commingled
Plastics Waste
Regranulation of Mixed
Waste
Output Capacity of 2000kg per hour
4 stage process
Stage 1: Shredded waste plastics are separated from
metal and mineral impurities by magnetic
and screen separation technique.
Stage 2: The Shredded Waste plastics are separated
from Organic and Inorganic impurities.
Stage 3: The Shredded waste plastics of less than
1g/cm3 (PVC, PS, PET…) are separated and
dried
Stage 4: Granulation by extruder with twin force
feeder and degassing unit.
Innovative Centrifugal
technology for Separation of
Waste
Innovative Centrifugal
technology for Separation of
Waste
• Excellent separation of Plastics of different
density.
• Fine separation independent of size or form
of the flake
• High throughput due to quick separation
(300 - 5000 kg per hour.
• Low energy-consumption
• Low ground-noise.
• Trouble-free integration into all plastic-
recycling systems.
Innovative Stationary NIR
Spectrometer for Online
Plastics Identification
• Recycling of household, engineering

electronics and automotive waste plastics
• Contact free and Non-destroying
measurements
• Measuring time with few milliseconds
• Independent of surface, moisture and
contamination
• 7 signal online-outputs for sorting machines
Innovative Stationary NIR
Spectrometer for Online
Plastics Identification
Innovative Free-flowing
agglomerate from mixed
plastics waste materials
Advantages at a glance
• Fully automatic non-stop operation

• Careful handling of plastics by processing
below melting temperature
• User-friendly process monitoring through
touch-screen control and simple menu
guidance
• Versatile, dry, and free-flowing recycled
material with a bulk density of up to 480
kg/m3
Advantages at a glance
• Flexible use of recycled material as a result

of its excellent dosability and storability
• Any thermoplastic sheeting and blisterpack
materials made of PE, PP, PA, PET and PVC
can be processed
• Also suitable for the compaction of foams,
fibers, and flow-moulded plastics
In Conclusion, Plastics Waste
Recycling Facilitate...
• Clean Environment
• Employment opportunities
• Economical Products
• Manufacturing of numerous recycled
products which substitute conventional
materials for cost effectiveness. viz.
Synthetic wood, garden furniture, pallets,
fencing post, etc.
• Business opportunities
Plastics Useful Source of Energy
Energy Value GJ / Ton

50
50
40
40
30
30
20
20 15
8
10
0
Plastics
Oil &
MSW
Coal
RDF
Wood
Gas
Plastics waste in municipal solid waste (MSW) can
improve the energy content for use as Reuse
Derived fuel (RDF) for incineration, a common
practice in major cities in Europe and Asia.
Plastics waste management by systematic
methodology for waste collection, recycling by
scientific methods, recovery of energy by
incineration under controlled conditions (practice
followed major cities of Europe and other
Developed countries), recovery by chemical
recycling are the best solutions for environment
protection.

Plastics Waste Management and Plastics Recycling

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“Plastics Waste Management and

Most Favoured Materials

…with frontier technologies

1970’s 1980’s 1990’s

 In addition to this, polymers have become

 Furthermore, many polymers are rarely additive

 In the 90’s, - Emphasis was on mechanical

 Presently - An integrated approach to plastics

 Demand for post consumer recyclates is

Recycle Repair/Reuse Incineration

- Mechanical Ex: Household & - Energy

- Mixed waste - Carry bags, Water

- Chemical - Repaired buckets,

Household Waste Hotel/Hospital Waste Street Waste Dump yard

Scrap Dealers Rag pickers

Sold to processors/ Granulation & Lump formation &

End Users Street Waste

Scrap Dealers Scrap pickers

Sold to processors/ Granulation & Lump formation &

 A stable supply source which involves reliable

 An economical, proven and environmentally

 End-use applications for the recycled polymer

Product to Product approach

Mixed plastics to oil

Mixed plastics to plastics lumbers

Mixed plastics to energy

PLASTIC RAW PROCESSING

Ex: PET & PMMA

MS REACTOR 400o C IMPURE

NOTE : FURTHER DISTILLATION IMPROVES THE PURITY

Plastic Waste Cracking

EXTRUSION ROTATING MOULDS

 Cost of plant varies from approximately US $ 0.34

 Swiss based technology available to convert

 Technologies for mixed waste plastics recycling

 A proprietary technology available from Israel

Name of Some uses of virgin

Name of Some uses of virgin

 The statistical informations on Indian

GRINDER EXTRUSION MIXER

EXTRUSION PELLETS BLOW MOULDING

SHRED / EXTRUDE EXTRUDE

Material Kilo Tons

Rain Coat Film

• In staple form for fillings e.g., anoraks,

• Binding and strapping tapes, mainly for

Primarily into bottles for non-food applications.

100% Recycled PET Bottle Flakes to Fibres through

 Unique process developed to produce resin with

* In the developed system labels (paper or PVC), caps,

 Unique process developed to produce

• Recycling of household, engineering

• Fully automatic non-stop operation

• Flexible use of recycled material as a result

Energy Value GJ / Ton

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