1. Polymer & Plastic waste and Recycling
Dr. Manohar Singh Saini
Director,
Guru Nanak Dev Engg. College, Ludhiana
January 3, 2012

2. A Global Look at Plastics: Quantities, Uses and Benefits
Plastic products improve our daily lives and have made vast improvements in areas such as:
Transportation - Automotive, Aerospace, Space Exploration
Medicines - helping us all live longer, healthier lives
Electronics - information, communication, and entertainment
Building and Construction - durability, aesthetics, and high performance
Personal protection - children, athletes, police and firefighters
Innovative packaging - freshness, storage stability, and protection from bacteria
Recyclability and reuse (SPI created the international recycling symbols/numbers to facilitate recycling)

3. Benefits of Plastics Case Study: Transportation
During the oil crisis in the 70’s, automakers found that plastics made cars more energy efficient by reducing weight.
Plastics began finding their way into automobile components (bumpers, fenders, doors, etc.)
Plastics were also used for their
Durability
Corrosion Resistance
Toughness
Resiliency
Lightweight

4. Benefits of Plastics Transportation cont…
Plastics reduced the weight of the average passenger car built in 1988 by 66 Kgs.
That saves millions of gallons of fuel each year and will save the energy equivalent of 21 million barrels (2428 million litres) of oil over the average lifetime of those cars.

5. U.S. Plastic Resins Growth – 2004
Production grew in 2004 to 52 billion Kgs.
An increase of 8.1 percent over 2003.
Sales and captive use rose 6.9 percent, the highest growth rate since 1996, reaching 52 billion Kgs.
(Source: American Plastics Council)

6. Plastics is a complex industry
Processors – (four main processing methods)
Injection Molding
Extrusion
Blow Molding
Thermoforming
Equipment Suppliers
Raw Material Suppliers

7. Range of Products Polystyrene Foam Products Plastics Bags
Plastic Packaging Film and Sheet
Non-packaging Film and Sheet
Plastics Profile Shapes
Plastics Pipe & Pipe Fittings
Laminated Plate, Sheet and Shape
Polystyrene Foam Products
Urethane and Other Foam Products
Plastic Bottles
Plastic Plumbing Fixtures
Resilient Floor Covering
Plastics Products, Not Classified Elsewhere
This range of products includes consumer products, aerospace, automotive and medical products and devices that are used daily to improve lifestyles.

8. Uses of Plastics - Statistics

9. Today’s Reality
Plastic products have become an integral part of all our lives, and play an
irreplaceable role in our day-to-day activities.

10. Comparison with Other Industries United States
Plastics industry is the nation’s 4th largest
manufacturing industry (shipments):
Motor Vehicles and Equipment
Petroleum Refining
Electronic Components and Accessories
Plastics

11. Scope of the Plastics Industry United States
The U.S. plastics industry employed more than 1.4 million people.
Another 772,000 persons were employed by upstream industries that supplied the plastics industry.
Total of 2.2 million workers – about 2 percent of the U.S. workforce.

12. Scope of the Plastics Industry United States
Nearly 25,000 plastics industry establishments generated approximately $310 billion in shipments.
Another $83 billion was generated by upstream, supplying industries.
Total annual shipments from plastics activity to $393 billion

13. Plastics – Global Importance Import and Export
Plastic resins and plastic finished products are imported and exported at a significant level across the world, via the oceans and by other means.
Canada, Mexico, other Latin America and China account for dominant percentages of U.S. plastics industry exports and imports.

14. Growth of Plastics (per capita consumption 2001-2010)
North America Kgs Kgs
Latin America Kgs Kgs
Western Europe Kgs Kgs
Eastern Europe Kgs Kgs
Africa/Middle East Kgs Kgs
Japan Kgs Kgs
Southeast Asia Kgs Kgs
**Less than 2% of a barrel of crude oil is used in the production of plastics.
(Source: BASF AG)
Plastics will grow well into the future all around the world. By 2010, consumption of plastics in North America is projected to be 47% higher than it was in In the same timeframe, plastics consumption is expected to be nearly 83% higher in Southeast Asia, a region that’s home to a huge percentage of the world’s population.
104% higher in Eastern Europe
54% higher in Latin America
44% higher in Western Europe
and 32% higher in Japan alone

15. Energy Resources & Plastics

16. Basic Questions (A)Why are rubbish dumps thought to be a bad thing?
(B)What does recycling mean?

17. EFFECT OF PLASTICS ON ENVIRONMENT!!!

18. INTRODUCTION
Plastic is the general common term for a wide range of synthetic or semi synthetic organic solid materials suitable for the manufacture of industrial products. Plastics are typically polymers of high molecular weight, and may contain other substances to improve performance and/or reduce costs.
Plastic is one of the few new chemical materials which pose environmental problem. Polyethylene, polyvinyl chloride, polystyrene, PET are largely used in the manufacture of plastics.

19. TYPES OF PLASTIC PRODUCTS
PLASTIC BAGS
PLASTIC COATINGS
PLASTIC FURNITURE
PLASTIC SHEETS
PLASTIC FITTINGS
PLASTIC TANKS
PLASTIC TOYS
PLASTIC BUCKETS
PLASTIC SANITARYWARE
PLASTIC STATIONERY

21. PLASTIC’S ADVERSE EFFECTS ON OUR ENVIRONMENT
Plastics pollute beaches & oceans
Garbage has been discarded into the oceans for as long as humans have sailed the seven seas or lived on seashores or near waterways flowing into the sea. Since the 1940s, plastic use has increased dramatically, resulting in a huge quantity of nearly indestructible, lightweight material floating in the oceans and
eventually deposited on
beaches worldwide.

22. Plastic bags litter the landscape
Once they are used, most plastic bags go into landfill, or rubbish tips. Each year more and more plastic bags are ending up littering the environment. Once they become litter, plastic bags find their way into our waterways, parks, beaches, and streets. And, if they are burnt, they infuse the air with toxic fumes.

23. Plastic bags kill animals
About 100,000 animals such as dolphins, turtles whales, penguins are killed every year due to plastic bags. Many animals ingest plastic bags, mistaking them for food, and therefore die. And worse, the ingested plastic bag remains intact even after the death and decomposition of the animal. Thus, it lies around in the landscape where another victim may ingest it.

24. Plastic bags are non-biodegradable
And one of the worst environmental effects of plastic bags is that they are non-biodegradable. The decomposition of plastic bags takes about 1000 years.

25. PLASTIC’S EFFECT ON HUMAN LIFE
Plastic plays the villain right from the stage of its production. The major chemicals that go into the making of plastic are highly toxic and pose serious threat to living beings of all species on earth.
Some of the constituents of plastic such as benzene are known to cause cancer. Plastic resins themselves are flammable and have contributed considerably to several accidents worldwide.

26. Once plastic is produced, the harm is done once and for all
Once plastic is produced, the harm is done once and for all. Plastic defies any kind of attempt at disposal – be it through recycling, burning, or landfilling.
When you recycle a hazard, you create a hazard.
Recycling of plastic is associated with skin and respiratory problems, resulting from exposure to and inhalation of toxic fumes, especially hydrocarbons and residues released during the process.

27. MEASURES
1.Single-use plastic bags have become such a ubiquitous way of life that it seems as if we simply cannot do without them. However, if we have the will, we can start reducing their use in small ways.
2.A tote bag can make a good substitute for holding the shopping. You can keep the bag with the cashier, and then put your purchases into it instead of the usual plastic bag.

28. MEASURES
3.Recycling the plastic bags you already have is another good idea. These can come into use for various purposes, like holding your garbage, instead of purchasing new ones.
4. While governments may be working out ways to lessen the impact of plastic bags on the environment, however, each of us should shoulder some of the responsibility for this problem, which ultimately harms us.

29. Percentage that can be recycled
About 7% of all household waste is plastic.
Annually, 3 million tonnes of plastic rubbish are produced.
57% of litter found on beaches is plastic.
In 2001 only 7% of all plastic was recycled.

30. Why recycle plastic?
Conservation of non-renewable fossil fuels - Plastic production uses 8% of the world's oil production.
Reduced consumption of energy.
Reduced amounts of solid waste going to landfill.
Reduced emissions of carbon-dioxide (CO2), nitrogen-oxide (NO) and sulphur-dioxide (SO2).

31. How are polymers recycled?
Mechanical recycling of plastics refers to processes which involve the melting, shredding or granulation of waste plastics.
Plastics must be sorted prior to mechanical recycling.
At the moment most sorting for mechanical recycling is done by trained staff who manually sort the plastics into polymer type and/or colour.

32. More
Following sorting, the plastic is either melted down directly and moulded into a new shape, or melted down after being shredded into flakes and than processed into granules called regranulate.

33. Source Reduction
Refers to a reduction in the amount of material used in any application
The simplest methods to employ source reduction are
To use fewer products that cause waste
To choose size and types of products where- by waste is minimized
To reduce the material requirements of the product (for manufacturer)

34. Source Reduction For example:
The amount of packaging material in 1 litre drink bottle is 40% less than material in 0.5 litre drink bottle (larger size are more efficient in using materials)
Decrease the thickness of materials in application
PE Trash bag (when it was first introduced)- thickness 0.08 mm
LDPE introduced – thickness of trash bag is 0.05 mm
LLDPE (stronger and tougher material) – thickness is mm
HDPE – thickness of mm is available now.

35. Recycling of Plastics
Refers to the reprocessing and refabrication of a material by a consumer or disposal of solid waste.
This type of recycle is called postconsumer recycle (PCR)- different with recycle (generally called regrind) of the scrap from manufacturing process.

36. Recycling of Plastics
Reprocessing and refabrication of PCR involves several steps;
Collection
Handling/sorting
Reclamation/sorting
End-use fabrication

37. Recycling of Plastics

38. Collection
Voluntary recycling by the consumer is the most single factor in improving recycling of all materials
However, consumers do not sort their solid waste but rather mix all materials together
For many plastics, the cost of virgin plastics is about the same as the cost involve in recycling- create problem in recycling process (different case with recycling of aluminium cans)

39. Handling & Sorting
Involves conveying materials from the pickup point (from consumer house) to the reclamation facility.
Sorting of materials is necessary (PET bottle, HDPE waste, aluminium alloy, etc) or in broader material groupings (all metals, all plastics, etc).
For the highest economy benefit, the HDPE and PET and other recyclable plastics must be separated from the plastics that are not to be recycled- thus considerable labour is required to pick up the recyclables by hand.

40. Handling & Sorting
Some sorting can be done by machine, i.e. based on certain characteristics (light absorption), various plastic resins can be distinguished from the others.
Under certain condition, the mixture of several plastic type can be recycled, called as mixed recycled or comingled recycle.
To assist consumers and sorters, Society for plastic Industry (SPI) introduced recycling symbols.

41. Numbering system for plastic recycling
Recycling No.
Abbreviation
Polymer Name
PETE or PET
Polyethylene Terephthalate
HDPE
High-Density Polyethylene
PVC or V
Polyvinyl Chloride
LDPE
Low-Density Polyethylene PP
Polypropylene PS
Polystyrene
OTHER
Other plastics, including acrylic, polycarbonate, polylactic acid , nylon and fiberglass.

42. Uses of Different Polymers
Polymer Name
Uses
Polyethylene Terephthalate
Recycled to produce polyester fibres, thermoformed sheet, strapping, soft drink bottles, reinforcement for concrete.
High-Density Polyethylene
Recycled to become various bottles, grocery bags, recycling bins, agricultural pipe, base cups, car stops, playground equipment, and plastic lumber, flower pot, toys
Polyvinyl Chloride
Recycled to become pipe, fencing, and non-food bottles.
Low-Density Polyethylene
Recycled to become plastic bags, various containers, dispensing bottles, wash bottles, tubing, and various molded laboratory equipment.
Polypropylene
Recycled into auto parts and industrial fibers.
Polystyrene
Recycled into a wide range of products including office accessories, cafeteria trays, toys, video cassettes and cases, insulation board and styrofoam.

43. Reclamation/Cleaning
After sorting, the plastics must be chopped into small flakes or shredded for further processing.
Then the flakes are treated with solvents and washed to remove residual contaminants (original content & paper label).
The flakes are then sent to the fabricators to extrude into pellets.

44. End Uses- Sorted PCR
The recycled material can be used in the same applications or other applications.
However, PCR plastic cannot be used in medical and food-contacting applications due to danger of contamination and disease.
Thermoplastic- can be reheated and reprocessed many times (with minor changes in resin properties).

45. Degradation
Means that the plastic can break down into smaller molecules by natural means, biological agent or by sunlight.
In reality, some materials degrade very slowly.
Some applications require that the material do not degrade, i.e. packaging material.
Some applications need degradable properties, i.e. sutures in medical applications.

46. Waste Tyres
The number of motorcar waste tyres generated annually was estimated to be 8.2 million or approximately 57,391 tonnes.
Landfill- as the easiest way of disposing the waste.
Other industry users collect waste tyres for retreading, rubber reclaim and shredding.

47. Tyre Waste
Examples of use are: Tiles and tile adhesives, mixing with asphalt, sports surfaces, carpet underlay, noise and vibration insulation, playgrounds and matting.

48. Incineration
Incineration or controlled burning is another option for disposing of large percent of solid waste.
The most common purpose of burning is to generate electricity.
Energy content of various solid waste materials and conventional fuels burned to generate electricity.

49. Incineration Method
Incineration can destroy some types of chemicals that other methods can't.
It is also quicker than many other methods.

50. Obstacles of Recycling
Usage of various copolymer blends (i.e. PET) from different manufacturers do not dissolve into one another when heated. Instead, they tend to phase-separate, like oil and water.
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 frequently.

51. Rubber and tyres
Good maintenance reduces waste:  To reduce waste and save money, good advice is to treat your tyres properly for maximum tyre life.  Simple maintenance and correct inflation pressures mean you don't need to replace them prematurely.  A worn tyre is not only dangerous, but uses more fuel.  When the time comes to change your tyres, considering the environmental aspects of their replacements may save money.  Why not consider a retreaded tyre?
Re-treads : Re-treading doubles the life of a tyre, reducing the numbers of new tyres needed and minimising waste.  The UK has a well-established re-tread industry (there can be shortages of those used tyres suitable for re-treading) and many old tyres are exported. 

52. New uses
As tyres cannot go to landfill, and incineration is undesirable, what else can be done?  Alternative ideas for re-using scrap tyres are increasing, but the number of outlets remains less than that which would meet potential demand.  Small numbers are used as boat fenders, playground equipment and by farmers.
Material recovery from tyres and other rubber products is increasing.  The main technique is to shred and reduce the rubber to crumb, and use this as a moulding material or filler.  Applications include brake linings, carpet underlay, equestrian, sports and safety surfaces, including playgrounds, as well as surfacing for, paths, and low grade use as landscape mulch or waste oil absorbent.  Finer grades of crumb are used in rubbers for vehicles.  Small amounts are also being used for stationery and office items

53. What is the effect of recycling plastics?
Recycling plastic uses less water and energy resources than in producing new plastics, and produces fewer greenhouse gases.
One problem with recycling, however, is that is reduces the strength and versatility of the plastic over time.
This is because the polymer chains become damaged or contaminated with food or other types of plastic.

54. What are biodegradable plastics?
One of the problems with traditional plastics is that they do not break down when thrown away.
Biodegradable plastics are plastics that can be broken down. They are converted into carbon dioxide, water and minerals by micro-organisms.
Biodegradable plastics are increasingly being used in carrier bags, bin bags and food packaging.
Biodegradable plastics, such as polylactide, are plant-based polymers. They are often made from starch that has been modified to become more stable.

56. Commodity Plastic: Current Scenario in India
Share of commodity plastics (> 80 % of over 5 million tons) mainly used in the making of low-value household articles, pipes, extruded sheets, packaging film, etc.
Polymer consumption is growing faster than any other material. Growth is 14% p.a. (double of GDP).
Development of plastic production technologies based on renewable, sustainable, agricultural wastes (sugarcane bagasse, wheat/rice straw, etc.
Government of India sponsored research projects on environment – friendly plastics from renewable resources (PLA, cellulose acetate from sugarcane bagasse, sugarcane juice, etc.) on-going briskly.

57. Current Scenario of Plastic Waste
India has a high rate of plastics recycling: +60% (World average is 15-20%).
Recycling is a thriving business in India.
India has per capita consumption of ~5 kg (2005) (greater for urban areas; set to grow rapidly; world average 18 kg).
Plastic in solid waste stream is lowest at 0.5-4% because of recycling (World average is 7-8%).

58. Synthetic Plastics: Environmental Issues
The area of greatest concern is plastics used in packaging :
In total production of plastics packaging accounts for ~52% in India (total consumption 4.3 mt in 2002, +5.0 mt in 2005, 8.0 mt in 2007).
Growth of plastics consumption is 14% per annum.
Urban folks spend about 88% more than their country cousins on food, education, entertainment, fuel and lighting, clothing and durables, according to latest estimates of the National Sample Survey Organisation (NSSO) (Economic Times, Nov.24, 2005).
Therefore in larger cities, the consumption of plastics is larger; expected to continue to grow at 14%; should reach world average in a few years Therefore in larger cities, the consumption of pl larger; nm to gmroat 14%. Should reach world

59. Applications of Waste Plastics

61. CURRENT STATUS IN INDIA: Value and Employment (upto 2010-11)
Major Raw Material Producers
Processing Units
Turnover (Processing Industry)
Capital Asset (Polymer Industry)
Raw Material Produced approx
Raw Material Consumed approx
Employed Direct/Indirect
Export Value approx
Revenue to Government approx.
15 Nos. 25,000 Nos. Rs.85,000 Crores Rs.55,000 Crores 5.3 MMT 5.1 MMT 3.3 Million US $ 1.9 Billion Rupees 7300 Crores Contd…

62. By 2011 - 12 Demand Potential Additional Employment
Investment Potential
12.5 MMT
4.0 Million
Rs.84,000 Crores

63. VISION 2015 – Indian Plastics Industry
Consumption of 15% CARG
Turnover of plastics Industries
Additional Employment Generation
Requirement of Additional Plastics Processing Machines
Additional Capital Investment In Machines ( )
18.9 Million tonnes Rs.1,33,245 crores 7 Million Nos Rs.45,000 crores