Plastics and the Environment

INDIAN CENTRE FOR PLASTICS IN THE ENVIRONMENT

Growing population and increasing demand for various goods and services have put severe pressure on our natural
resources and fragile eco system. Plastics offer an effective, environment friendly and economical alternative to score of
materials and offer greater protection against environmental pollution. Use of plastics therefore has become not only
desirable but also inevitable for a sustainable development.
 PRODUCTION OF PLASTICS

World
160 Mn Tons +
Per Capita ~ 22 Kgs

India
6 Mn Tons +
Per Capita ~ 6 Kgs
From a meager commercial beginning from the early part of 20th Century, production of synthetic
plastics has reached more than one million tons by the end of that century. In the year 2007, the world
production of plastics has reached about 160 million tons and per capita consumption stood at around 2007
22 Kgs. During the same year India’s production figure stood at around 6 million tons with per capita
consumption at around 6 kgs, much below the world average. Figure
 MAJOR REASONS OF
ENVIRONMENTAL POLLUTION
AIR POLLUTION

WATER POLLUTION

SOIL POLLUTION

GREEN HOUSE EFFECT

&
GLOBAL WARMING

DEPLETION OF OZONE LAYER

If we analyse different reasons for Environmental Pollution, we note that the following are the major ones: Air Pollution, Water
Pollution, Soil Pollution, Global Warming, Depletion of Ozone layer. We will attempt to examine the role of plastics in each of
these environmental issues.
 AIR POLLUTION
MAJOR SOURCE RESPONSIBLE ROLE OF PLASTICS
POLLUTANTS
FUEL BURNING / BOILERS PLASTICS PLAY
SPM DUST STORM / VOLCANIC ERUPTION INSIGNIFICANT ROLE
/ CEMENT / MINING
QUARRYING

FUEL BURNING /H2SO4/ LESS THAN 4% OF

SO2 INCINERATION / CHEM JNDS / REFINERY PRODUCTS
SMELTING / REFINERY ARE USED FOR
PETROCHEMICALS
PETROLEUM OPERATION /
NOX AUTOMOBILES / INDUSTRIAL INSIGNIFICANT
COMBUSTION

INCOMPLETE COMBUSTION OF FUEL CAN BE AVOIDED BY

CO & HC IN INDUSTRIES AND CORRECTIVE METHOD
AUTOMOBILES OF PROCESSING
Air Pollution is considered the most serious concern, mainly in the highly populated/industrial areas. A chart showing the ma jor air pollutants and type of
industries/Source responsible for such pollutions is given. Air pollution due to vehicle emission in some of the metropolita n cities has since come down
after strict implementation of CNG as a fuel in public transport system. Emissions from industries are among the other causes of pollution. The industries
which have been identified under this are :--Thermal Power Plants, Brick Kilns, Potteries, Steel rolling plants and Induction furnaces. Plastics processing
has been kept under non-polluting (Green) category.
 MAJOR CHEMICALS HANDLED DURING
COMMODITY PLASTICS MANUFACTURE
 ETHYLENE
 PROPYLENE
 CHLORINE
 VINYLCHLORIDE MONOMER
 BENZENE
THRESHOLD LIMIT VALUE (TLV) AND
IMMEDIATELY DANGEROUS TO LIFE
OR HEALTH (IDLH)
LIMITS ARE DEFINED AND MAINTAINED
During production of commodity plastics raw materials, mainly four or five major chemicals are involved which attract attention of critics. These are Ethylene, Propylene, Chlorine,
Vinyl Chloride and Benzene. These chemicals, by themselves, are toxic and their presence in the environment would endanger the safety and health of human life. However, the
manufacturers of these commodity plastics, which are essentially in the organized sectors, constantly monitor the TLV of various chemicals and modern technologies enable
these industries to install systems, which ensure that the emissions do not exceed permissible level. Government regulatory b odies also keep a strict vigil and control over the
manufacturing conditions.Once these basic raw materials undergo chemical reactions to form plastics granules / powder, they b ecome completely inert and safe to handle.
Critical characteristics and safety limits, TLV (Threshold Limit Value), IDLH (Immediately Dangerous to Life or Health) limit etc. are maintained.
 EMISSIONS POSSIBLE DURING
PROCESSING / BURNING OF
COMMODITY PLASTICS

CO2 IN COMMON CASES

CO/ AT FIRE SITUATION
ACROLEIN / (COMMON PHENOMENON
ALDEHYDE IN CASE OF WOOD ALSO).

Processing of plastics is completely safe under normal processing conditions. At burning situations, carbon dioxide, carbon
monoxide, aldehydes etc are evolved. This phenomenon is similar to other organic and natural materials like wood, cotton etc
.Plastics do not create any additional risk to toxic emissions during fire situation.
 Emissions During Processing of P lastics
Polyme r Volatile Organic Compou nds
(processe d (VOCs) and HAPs ( ppm)
at te mp ÞC) VOC as Formic Formald- Hydroch-
per ASTM Acid, Ace tic e hyde (UV loric acid
D-3686 Acid, Spe ctrop- (Calori-
(GC) Acet aldeh yde hotome try) me try)
(HPLC)
LDPE (170-205 ÞC) Nil Nil <1 Nil
Extru sion/Inject ion
Moulding
LLDPE (180-240ÞC) Nil Nil <1 Nil
Extru sion/Inject ion
Moulding
HDPE (210-245ÞC) Nil Nil <1 Nil
Extru sion/Inject ion
Moulding
PP ( 210-270ÞC) <1 Nil <1 Nil
Extru sion/Inject ion
Moulding
PVC ( 150-250ÞC) Nil Nil Nil Nil
Extru sion/Inject ion
Moulding
PS ( 190-270ÞC) <1 Nil <1 Nil
Extru sion/Inject ion
Moulding

Shriram Institute for Industrial Research

 DIOXIN AND PLASTICS

As per the US EPA

report, Dioxin level
in the atmosphere
2,3,7,8- Tetrachlorodibenzo-p-dioxin
in the USA in 2000
was reduced by SOURCE :BOTH NATURAL & MAN MADE
1/3rd as compared
to that in the
1970s. However,  COMMERCIAL/ MUNICIPAL WASTE
production and
consumption of all
 BURNING OF FUEL(COAL , WOOD,OIL)
plastics raw
materials including
 BURNING OF HOUSEHOLD WASTE
PVC has tripled  CHLORINE BLEACHING OF PULP AND PAPER
during this span of
about 30 years.  SOME CHEMICAL MANUFACTURING PROCESS
This clearly proves
that there is no (NOT KNOWN FOR COMMODITY PLASTICS)
direct correlation
between PVC or
 FOREST FIRE
any other plastics
and Dioxin.
 CIGARETTE SMOKE

PLASTICS HAS NOT BEEN SINGLED OUT AS THE

ONE CAUSING DIOXIN GENERATION
 WATER AND SOIL POLLUTION

• PLASTICS DO NOT POLLUTE WATER AND

SOIL
ø IT TRANSPORTS AND STORES POTABLE
WATER AND PRESERVES SOIL FROM
EROSION
ø COMMODITY PLASTICS ARE
COMPLETELY SAFE FOR LAND FILL
Plastics do not pollute water. In fact most plastics materials may be used in contact with food products. Potable water is stored and
delivered through plastics. Plastics processing industries do not generally have scope of releasing any effluent except water itself which is
used as cooling agent. Emission to water during manufacture of plastics is very low compared to that during the production of alternatives
like paper, jute, textile or metals. Regarding safe disposal issue in landfill, plastics by itself are generally inert and pose no problem in land
filling, though it is not a desired practice.
HOWEVER PLASTICS WASTE SHOULD NOT GO TO THE
LAND FILL. IT SHOULD GO FOR RECYCLING /
ENERGY RECOVERY
GREEN HOUSE EFFECT &
GLOBAL WARMING
 GREEN HOUSE GASES

CO2 > 50%

Water Vapour

NOx

Methane

CFC

The major gases identified as the main causes of Global Warming are CO2, Water Vapour, NOx, Methane and CFC.
Plastics are not making additional contributions. In effect, use of plastics have reduced the emission of CO2 to a great
extent in many applications like in automobiles, packaging, piping and insulation etc...
DEPLETION OF OZONE LAYER
 IDENTIFIED ODS’s

CFC : CHLOROFLUOROCARBON

HALONS : CARBON TETRA CHLORIDE

MCF : METHYL CHLOROFORM

CFC 11& CFC 12 ARE BEING REPLACED BY

CYCLOPENTANE, A NON-ODS.
There are certain chemicals which have been identified as Ozone Depleting Substances (ODS). They cause depletion
of Ozone layer. CFC (Chloro Fluoro Carbon) is one of them. CFC-11 has been used as blowing agent in certain uses of
plastics to give foamy structure. Hydrocarbons, specifically cyclopentane has replaced CFC-11 as blowing agent.
Other ODS substances are Halons and Methyl Chloroform (MCF). These do not find applications in the manufacture of
commodity plastics.
USES OF PLASTICS
 PACKAGING

FOOD & BEVERAGES

– READY TO EAT FOOD
– MILK/ TEA/COFFEE/ BISCUIT / ICECREAME CHOCOLATE
– SOFT DRINK / FRUIT JUICE/ WATER

PHARMACEUTICALS
– TABLETS/ SYRUP/BASIC DRUGS

MEDICAL
– BLOOD / IV SOLN.

COSMETICS / TOILETRIES
 PACKAGING

AGRICULTURAL PRODUCTS
RICE/ WHEAT/ PULSES/SUGAR/ED OIL

INDUSTRIAL PRODUCTS
CEMENT / FERTILISERS

CHEMICALS

WATER BOTTLES
 BUILDING & CONSTRUCTION

• PIPES & FITTINGS

• DOORS / WINDOWS

• PARTITION

• FLOORINGS
 MEDICAL APPLICATIONS

• DISPOSABLE SYRINGES
• I V SETS
• CATHETRES
• HEART VELVE
• TUBE FOR PACEMAKER WIRE
• INSTRUMENT TRAYS
• X-RAY FILMS
 AGRICULTURE

Canal lining Mulch Film

Green House Sprinkler/Drip/Micro irrigation
WATER TRANSPORTATION
ELECTRICALS & ELECTRONICS
AUTOMOBILES
MAJOR BENEFITS OF
PLASTICS
 MILK

Today, 45 Million families daily receive fresh & unadulterated Milk

….. thanks to Pouches
No Polyethylene Pouch ???

Operation Flood will have to be recast, Can we turn the clock back?
ENERGY SAVING – 1 LAC LTRS OF MILK PACKAGING
GLASS VS PLASTIC

• Energy consumption in GJ for

– manufacture of packaging raw material and the
packets and
– transportation of milk
Glass Plastic
2195 291
• Energy saving – 86%
• Energy recovery with plastics - 20
 ENERGY SAVING:1 LAC MT OF ATTA PACKAGING
JUTE VS PLASTIC

• Energy consumption in GJ for

– Manufacturing packaging raw material and
Product and
– Transportation of Atta

Jute Plastic
330 63
• Energy saving – 81%
• Energy recovery with plastics - 35
 EFFICIENT PACKAGING …

Cost of Packaging

Energy Consumption
Without Plastics

Volume of Waste
With Plastics

Weight of Packaging

Source: GVM, Germany-1987 / 91 (APME)

Use of plastics for efficient packaging has resulted in: Reduction in cost of Packaging by 300 %, Reduction in Energy Consumption by 150%,
Reduction in Volume of Waste by 100 %, Reduction in Weight of Packaging by 200 %, in comparison to alternate materials of packaging.

Plastics - The best packaging medium

 WOOD CONSERVATION : A MUST
Wooden Crates are Simply not
available anymore !!

Yearly consumption -
50 million Plastic Chairs &
15 million Crates

Savings over
10 yrs. ~
Close to 20
million trees
Source: Economic Times Polymer Bureau
PLASTIC CARRY BAGS A
SOME FACTS

• Plastic Carry Bags Generate 60 – 79% Less Green

House Gases than Paper Bags

• Plastic grocery bags consume 40% less energy

during production and generate 80% less solid waste
after use than paper bags.

• Paper sacks generate 70% more air pollutants and

50 times more water pollutants than plastic bags do.

• It takes 91% less energy to recycle a kilogram of

plastic than a kilogram of paper.
 ….PLASTIC CARRY BAGS
A

• 150,000 Plastic Bags of 20 cm

x 30 cm x 40 micron weighs
~ 600 kgs and needs 1 small
Tempo for transportation
while Paper Bags of same size
& number weighs ~ 1500 kgs
and needs > 10 such Tempos
for transportation - due to
higher volume.
 AIR & WATER POLLUTION BY
POLYETHYLENE & PAPER
Environmental Burden Polyethylene Paper
Energy in GJ for Manufacture 29 67
SO2 9.9 28.1
NOx 6.8 10.8
CH4 1.5 3.8
CO 1 6.4
Dust 0.5 6.8
COD 0.5 107.8
BOD 0.02 43.1

Fabbri, A in Scott, G and Gilead, D., editors, Degradable Polymers, Principles and Application, Chapman & hall,
1995, Chapt
 PLASTIC AND JUTE BAGS

Energy Saving during Manufacture of Raw

Materials, Production and Transportation of
Plastic Bags compared to Jute Bags is 81%.
 ENVIRONMENTAL BURDEN DURING
PRODUCTION OF RAW MATERIAL & BAGS
Environmental Burden Jute Bag Plastic Bag

Air Pollution
CO kg 54.3 0.6
CO2 kg 6610.2 760
SOx kg 134.8 5.2
Nox kg 68.1 4.8
CH4 kg 39.5 3.2
HCL kg 5.3 0
Dust kg 67.6 1.4
Water Pollution
Suspended Solids kg 352.3 0.2
Chlorides kg 4535.5 0.1

The values are for packaging of one lac MTs of Atta. Source – Report by Centre for Polymer Science and
Engineering, IIT - Delhi
 THE ENVIRONMENTAL BURDEN DURING
TRANSPORTATION OF THE FINISHED BAGS

Emission Gm/km Excess Emission for Plastic Bags

jute Bags
CO2 781 11107.3 Taken as Basis

CO 4.5 64.0 Taken as Basis

HC 1.1 15.6 Taken as Basis

NOx 8 113.8 Taken as Basis

Particulates 0.36 5.1 Taken as Basis

Total Regulated 13.96 198.5 Taken as Basis

Tailpipe
Emission
The values are for packaging of one lac MTs of Atta. Source – Report by Centre for Polymer
Science and Engineering, IIT - Delhi
 PLASTIC AND TEXTILE BAGS

Plastics manufacturing consumes 400 kwh/mt while

composite textile mills consume 1310 kwh/mt

Textile contributes 30% SOx (Second Highest by

Any Sector) and 23% NOx (Highest by Any Sector)

Consider the enormous environmental burden

generated by Jute & Textile bags, which are not
visible to naked eyes though, in comparison to
Plastic Bags!
Source : Warmer Bulletin, July 01
 ENERGY REQUIREMENTS OF
VARIOUS MATERIALS
10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

0
Al-DIE CAST

PVC
PA-6

PA-66

HDPE
Zn-DIE CAST

ABS
PP
PC

PS

LDPE
ACETAL

PMMA
MOD.PPO

PET
Mg-DIECAST

STEEL

Plastics consume least energy for conversion into product.

Hence,wherever plastic products are replacing alternate
materials like metal, glass or even paper, we save energy and
save the environment to that extent.
 DESPITE ALL THESE BENEFITS
PLASTICS ARE UNDER THE SCANNER

• ISSUES:

• SAFETY
• TOXICITY
• BIODEGRADABILITY
• DISPOSAL
 SAFETY

PLASTICS ARE APPROVED SAFE MATERIAL

FOR USE …

• IN CONTACT WITH FOOD,

PHARMACEUTICALS AND DRINKING
WATER

• AS IMPLANTS WITHIN HUMAN BODY

 TOXICITY

ISSUE:
PLASTICS ARE TERMED AS TOXIC AND
INJURIOUS TO HEALTH

REALITY:
• PLASTICS ARE INERT MATERIALS AND HENCE DO NOT POSE
ANY DANGER OF TOXICITY

• ADDITIVES USED IN PLASTICS ARE APPROVED AS PER BIS /

FDA STANDARDS

• EMISSIONS AT FIRE SITUATION HAVE SIMILAR OR LESSER

IMPLICATIONS IN COMPARISON TO SITUATION INVOLVING
NATURAL ORGANIC MATERIALS LIKE WOOD & COTTON
 BIODEGRADABILITY
• PLASTICS ARE USEFUL FOR ITS LONG LIFE CHARACTERISTICS

• BIODEGRADABLE PLASTICS ARE REQUIRED FOR SPECIFIC

APPLICATIONS LIKE NURSERY BAGS, MULCH FILM, ONE – TIME USE
CUTLERY / CUPS ETC TO BE CARRIED IN SHIPS

• THE INDUSTRY IS IN ITS NASCENT STAGE

• BIS HAS RECENTLY ADOPTED ISO 17088:2008 ON COMPOSTABLE

PLASTICS IN ITS INDIAN STANDARD

• BIODEGRADABLE PLASTICS ARE NOT RECOMMENDED FOR MASS

APPLICATIONS AS COMPOSTING CREATES GREENHOUSE GAS
EMISSION – CO2 AND CH4. ITS USE IS LIMITED TO SPECIAL
APPICATIONS

INDUSTRY RECOMMENDS RECYCLING OVER BIODEGRADATION

 DISPOSAL

ISSUE:
PLASTICS ARE BLAMED AS THE MAJOR CAUSE OF SOLID
WASTE PROBLEM

REALITY:
• ACCORDING TO INDIAN STUDIES PLASTICS FORM ABOUT
5% OF TOTAL MSW

WHILE ALL SOLID / THICK PLASTICS WASTE ARE

SYSTEMATICALLY PICKED UP BY THE WASTE
COLLECTORS FOR RECYCLING, DISPOSAL OF
THIN PLASTIC CARRY BAGS, SINGLE-USE PLASTIC
WASTE AND MULTI-LAYER PACKETS HAVE
CREATED SOLID WASTE PROBLEM
 SOLUTION TO DISPOSAL PROBLEM

• SEGREGATION AT SOURCE

• PROPER SYSTEM FOR COLLECTION OF

SEGREGATED WASTES FOR FORWARDING TO
RECYCLERS

• INCENTIVES / ENCOURAGEMENT FOR RECYCLING

• UPGRADATION OF THE EXISTING MECHANICAL

RECYCLING TECHNOLOGY

• ENCOURAGEMENT FOR ALTERNATE METHODS OF

RECYCLING / RECOVERY OF ENERGY
WASTE MANAGEMENT
SEGREGATION OF WASTE AT SOURCE

Rag pickers with van Loading of dry waste

in Municipality van

Dry waste being

carried for loading into
Municipality van

Dry waste at housing Municipality van with

colonies dry waste on way to
segregation area
SEGREGATION OF WASTE AT SOURCE

Segregation of dry Storing of segregation dry

waste waste in secured place

Packing of segregated Segregation of dry waste being

dry waste weighed and sold to recyclers /
traders
 RECYCLING

Waste fertliser, cement and other bulk packaging bags are recycled in to Newar Patti for making cots and to Box Strapping
for use in packaging industry.
 RECYCLING

Waste Automobile battery cases are recycled into cheaper

luggage and Brief cases for use by common mass.
 RECYCLING

Waste PET bottles are converted into Floor Carpets, Fibre filling for pillows, mattresses and other fibre products.
 FUEL FROM WASTE PLASTICS
Invention by Indian Scientist

Waste generated out of mixed plastics, co-mingled plastics

and plastics materials made out of a combination of different
plastic materials are generally difficult for normal recycling
and hence creates waste management problem. Success has
already been achieved in converting such plastics waste in to
industrial fuel in an environmental friendly technology in the
country (Nagpur, Chennai). Technologies are available from
developed / other countries also. This option has the benefit
of using mixture of different types of plastics waste, mixed
together, without segregation. Elaborate cleaning / washing is
also not required. Encouragement is required for popularizing
this technology among the entrepreneurs for its commercial
utilization.
ENERGY RECOVERY IN
CEMENT KILN

ACC PLANT AT KYMORE, MP

 RECOVERY OF CALORIFIC ENERGY
FROM PLASTICS
• CALORIFIC VALUES OF DIFFERENT PLASTICS
• MJ/Kg
– POLYETHYLENE 46
– POLYPROPYLENE 44
– POLYAMIDE 32
– PET 22
– CALORIFIC VALUE OF COAL : 29 MJ/Kg
One of the most effective methods of recycling of plastics waste for recovery of energy is its use as an alternative fuel
in cement kilns. The high temperature used in the cement kilns gives a scope for use of even some type of plastics
waste contaminated with toxic chemicals like pesticides and some other hazardous materials. No segregation or
cleaning is required for such type of disposal. Low-end plastics waste, which creates a waste management problem,
may provide the vital energy to the cement industry. There are about 170 cement kilns in the country, in different
zones. Even at the rate of 30 MTD of plastics waste, the total requirement of plastics waste by theses cement kilns
could be as high as close to 2.0 million tons, much higher than the total plastics waste generation in the MSW stream.
Plastics Waste are also used as Reducing Agent in Blast Furnace Successful examples are available for use of waste
plastics as a reducing agent in the blast furnace for the manufacture of iron from its ore. Use of coke in the blast
furnace provides only one type of reducing agent – Carbon Monoxide. In contrast, use of plastics waste provides one
additional type of reducing agent – Hydrogen. The process also reduces generation of ‘ash’. A steel manufacturing
facility having production capacity of 3 million tons per anum, can consume 600, 000 Mts of plastics waste.
 ADVANTAGES

• ALL TYPES OF MIXED PLASTICS WASTE CAN BE

USED TOGETHER – NEEDS NO SEGREGATION

• NO MAJOR CLEANING REQUIRED

• NO TOXIC EMISSION – OPERATIONAL

TEMPERATURE ≈ 2000 ° C
 PLASTICS WASTE IN ROAD CONSTRUCTION

Prof. V S Aghase Road – Dadar,

Mumbai

Plastics Waste has been successfully used in the construction of asphalt roads. Plastics waste is converted in
to powdery form or is shredded in to small pieces and is added with the hot bitumen or hot aggregates, partly
substituting bitumen to the tune of 10 – 15 % by weight. This results in better quality of road with higher life at
lesser cost and providing a scientific solution to the disposal of low-end plastics waste.
Bidhya Sagar Road- Kalyani- West Bengal
Segregate waste at source.
Adopt and popularize the concept of Two – Bin
Culture