CONTENTS AND SUBJECT INDEX

Chapter 1 Page No. Chapter

-

Page No.
22 22 23 23 23 23 23 24 24 24 24 24 24 25 25 25 25 25 25 25 26 26

Introduction
2

1-2 3-10
3 3 4 4 4 4 4 5 5 5 6 6 6 7 7 7 7 7 7

Details of Polymers
-

Types of Polymers Thermoplastics and Thermosets Polymer Structure Homopolymers and Copolymers Polymer Families Polymer Blends Additives Conversion Engineering Thermoplastics Addition and Condensation Polymerization Aliphatic and Aromatic Polymers Morphology and Properties Copolymerization Additives Classification of Plastics Definition Plastics Classification Thermoplastics Thermosettings

Cellulose Acetate Cellulose Acetate Butyrate Cellulose Propionate Fluorocarbons Nylons Polycarbonate Polyethylene Polyphenylene Oxide (PPO) Polypropolene Polystyrene Polysulfone Polyurethane (Thermoplastics) PVC Thermoplastics Thermosetting Plastics Diallyl Phthalate (DAP) Epoxy Melamine formaldehyde Phenol Formaldehyde Polyesters Silicones Urea Formaldehyde

Recycling of Plastic Waste

Conventional Methods Current Trends Mechancial Recycling Mixed Plastic Waste Feedstock Recycling Hydrogenation Synthetic Gas Production Pyrolysis Solvolysis Energy Recovery A Commonly Used Process for Films Waste - The Commitment - Optimixing Recycling - Source of Plastic Waste

30-37
30 31 31 31 32 32 32 32 32 33 33 34 34 35

Types of Plastics
4

11-11

Identification of Plastics 12-29

Misecellaneous Observations Burning Test Density Determination Heating Test Identification of Plastic Materials Thermoplatics ABS Acetal Acrylic 12 13 14 14 22 22 22 22 22

Chapter
- New Trends - Future

Page No. Chapter

35 36

Page No.
67

Recycling of Thermosets 38-42

7

value added plastics/recycling - Achievable quality- sources of the waste and possibilities to improve the properties - Additives and how they improve processing or quality

68

11

Chemical Recycling

43-50
44 45 46 47 48 49

- Cryogenic Recycling of Bottles - Recycling of Synthetic Carpet Waste - Low-Cost Recycle Sorting - Plastics into Fuel Oil - Mobile System of Recycling - Recycled Engineering Elastomers

Automatic Scrap Recycling

Film Extrusion Sheet Extrusion Injection Moulding Blow Moulding Vacuum Forming Economics

69-75
70 71 71 73 74 74

12

Recycling Commodities Plastics

- Polyolefins - Polystyrene - Polyvinyl Chloride, PVC

51-57
53 55 55

Reclaiming Polyamide Spin Fibres

76-79
77

Recovery of Chemicals from Plastic Waste

-

58-65
59 59 60 61 61 61 61 62 64 64

- Methods of processing PA-spin fibre waste into high quality compounds - Extrusion line for compounding of PA-spin fibre waste to engineering plastic compounds - Performance capabilities of the TSK-N 60 Compounding line

77

78

Plastic Degradation Modes of Polymer Degradation Thermal Degradation Mechanical Degradation Photo Degradation Bio-Degradation Chemical Degradation Solvolysis Results and Discussions ICI, Mitsubishi Rayon Link for Acrylic Recycling Techniques

13

EPS-Recycling from Post-Consumer Expanded Polystyrene

80-85

10

Factors Affecting Recycling Process

- Pre-Conditions for high

66-68
66

- Figure and facts - An Economical way of recycling gives EPS waste a new life - Advantages of this technology - Description of the process and equipment - Advantages of a co-rotaiting twin screw extruder in this terminology

80 80 81 81 81

Chapter
- General information about the TSK-Twin Screw Extruder-Series - Thermoset/Chemical processing machines

Page No. Chapter

82

Page No. 16

84

Recycling Polyester Resins

PET and APET RPET PETG CPET Direct Method Remelting Chemical Reduction Process Route of Michigan Technology University

102-108
102 103 104 105 106 106 106 107

14

New Patented Processes 86-93

- Cryogenic Recycling Technology 86 - Reclaiming vinyl fabric 87 - New ideas for efficiency 88 in Film Recycling - New innovations by Sorema 88 - Another Method for Reprocessing 88 - Most used Scrap Emanating 89 - Patented Process for 89 Recycling Expanded Polystyrene - One Pass Extruder for 90 Reclaiming Film Scrap - Recycling Polymer Alloys 91 - New Technology Eliminates 91 Paint Stripping - Technology from Alida Recycling 91 Ltd. to Reclaim Polyethene Films Label-P.V.C. Adhesive etc. All get separated - Recycling mixed waste 92

17

Polyurethane Waste Recycling

18

109-110

Recycling and Government Policies

Regional Co-Operation Practices abroad-Japan China Malaysia

111-115
113 113 114 115

19

15

Identification of Plastics116-124 94-101

Separation of Laminates Tests for Physical Properties Burning Tests Simplest test for cellulose Griess Test for Nitrogen Prepare Griess Reagent Lie Burmann-s Torch Morawkli Test Burning Tests for Plastic Identification Polyester (Alkyds) Silicones Acrylics Cellulose Acetate CAB 116 116 117 117 118 118 118 119 119 120 120 120 120

Environmental Health and Future Prospects

- Environmental Health and 94 Future Prospects - Hazardous Effects of Plastics 95 - Polluting Substance 95 - Air Pollution 96 - Safety Measures 97 - Product Safety 98 - Future Prospects 99 - Improving working 99 conditions and the environment - Technology transfer 100 and development

Chapter
Cellulose Propionate Cellulose Nitrate Ethyl Cellulose Polystyrene Styrene Acronitrile (SAN) ABS P.V.C. P.V.A. Polyvinylidene Chloride Polypropylene Polycarbonate Nylon Acetals Teflon Poly Phenylene Oxide Poly Sulphone Fibre Glass and Asbestos Filler - Solvent Required for Polymer Identification

Page No. Chapter

120 120 121 121 121 121 121 121 121 122 122 122 122 122 122 122 123 123

Page No.
137 138 138 138 139 139 140

20

- Sink-Folat Technique - Electrostatic Separation Process (ESTA) - Centrifugal System - Froth-Floatation Technique - Recycling -Process Machinery - Physical RecyclingIndian Scenario - Physical Recycling-Techniques Polyethylene Terephthalate (PET) - Polyolefins (PE and PP) - Polyvinyl Chloride (PVC) - Polystyrene (PS) - Industrial and Engineering Plastics - Chemical Recycling - Incineration - Potential Recycled Plastics Products - Indian RecyclingThe Present Status

141 141 141 142 142 144 144 146

Plastics and the Environment

American Scenario Plastics Waste Solutions Source Reduction Recycling Waste-to-Energy Fuel Value Landfills Conclusion Biodegradable Plastics Mechanism of biogradation Problem encountered Applications

125-131
125 125 125 126 126 127 127 127 127 128 129 130

22

Get Virgin Quality from Reprocessed

147-156
147 148 148 149

21

Recycling-An Industrial Approach

- Recycling Routes - Physical Recycling - Physical recyclingSorting Techniques

132-146
132 136 137

- The World of 58 J-Von - Range of TPR Compounds Currently manufctured include - Why TPR? - Products to match Reprocessed Quality with Virgin - The Product - Areas of Application - Advantages - This product has proven its effctiveness in moulded articles like - Test Results - The Product - Areas of Application - Advantages - This product has proven its effectiveness in moulded

149 149 150 151

151 151 152 152 153

Chapter
articles like Test Results The Product Physical Properties The Product Physical Properties

Page No. Chapter

153 154 155 155 156 -

Page No.
164 165 165 165 165 165 165

Raw Materials Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point

23

Plastic Granules from Fresh Resin

157-161
157

25

Pet Bottle Recycling

26

166-169 170-179
172 172 173 174 174 174 177 177 177 177 177 178 178

- Manufacturing Process of LDPE Granules from LOPE Resin - Plastic Filler Granules (PP) - PVC Granules - Process of Manufacture - Plant Economics - Land and Building - Plant and Machinery - Fixed Capital - Raw Materials - Total Working Capital/Month - Total Capital Investment - Turn Over/Annum - Profit Sales Ratio - Rate of Return - Break Even Point

Recycling of PVC
158 158 159 159 159 159 160 160 160 160 161 161 161 161

24

Plastic Granules

162-165
162 163 163

- Coding and Aid to Separation - Recycling of Short-LifePVC Products - Bottles - Separation of Hydrocyclones - New Products from Recycled PVC Bottles - Prospects for Chemical Recycling of PVC - Recyclable Vinyl - PVC Bottles, Jars and Containers - Design Consideration - Physical Properties - Marketing Consideration - Safe and Recyclable - Lower Mold Costs

- Process of Manufacture - Concentration of Blending - Removal of Colour to obtain Transparent Granules by Activated Carbon Treatment - Filteration - Distillation - Cooling and Dehumidifying - Granulation - Weighing, Filling and Packing - Plant Economics - Land and Building - Plant and Machinery - Fixed Capital

27

Recycling Techniques- 180-202 The Next Generation

- What is resource Conseration? - Why are plastics used? - Importance of Plastics recycling and waste management for a cleaner environment - MSW (Municipal Solid Waste) Analysis - IDPW (Industrial Packaging Waste) Analysis 181 184

163 163 164 164 164 164 164 164 164

185 185

Chapter
- What does plastic recycling involve? - Plastic waste recycling processes - Challenges in plastic waste recycling - Think Quality: A key to success in plastic recycling - Shredders - Use of a Shredder in the Plastic Industry - Plastic drums and cans - Lumps, purging and sprues - Thermoforming and injection scraps - Our concern for the environment - Characteristics of a typical plastic reprocessing line - Extruder - Forced Feed - The screen changer - Die Face cutter - Conversation of mixed Plastics - Stop Press-A new invention - Dissolving for recycle - Conclusion

Page No. Chapter

186 186 189 192 192 192 193 194 194 194 195 195 195 196 196 196 197 197 201 unde Load Melt Flow Rate Flexural Properties Optical Properties Glass Haze Impact Strength Izod Charpy Tensile Impact Falling Dart Instrumental Impact

Page No.
217 219 219 220 220 221 222 223 223 224 226

29

Plant Economics of 227-228 Phenol Formaldehyde Resin

Rated Plant Capacity Land and Building Plant and Machinery Fixed Capital Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point 227 227 227 228 228 228 228 228 228 228

28

30

Quality Control Tests

- Suggested Equipment for Tests in Quality Control Laboratory - Testing - Anticipating problems - Integrating disciplines - Data disparities - Tapping resources - Automated Stations - Plastic Performance Tests - Tensile Strength - Deflection Temperature

203-226
203

Plant Economics of Poly Amide Resin

-

229-230
229 229 229 229 230 230 230 230 230 230

212 212 212 213 214 214 215 215 216

Rated Plant Capacity Land and Building Plant and Machinery Fixed Capital Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point

Chapter 31

Page No. Chapter 33

Page No.

Plant Economics of Polyester Resins

-

231-232
231 231 231 232 232 232 232 232 232 232

Rated Plant Capacity Land and Building Plant and Machinery Fixed Capital Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point

Plant Economics of Urea Formaldehyde Resin

-

235-236

32

Rated Plant Capacity Land and Building Plant and Machinery Fixed Capital Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point

235 235 235 235 236 236 236 236 236 236

Plant Economics of Polycarbonate Resin (All Fig. in Lacs)

-

233-234

34

Rated Plant Capacity Land and Building Plant and Machinery Fixed Capital Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point

233 233 233 234 234 234 234 234 234 234

Plant Economics of Acrylic Copolymer Emulsion

-

237-238

Rated Plant Capacity Land and Building Plant and Machinery Fixed Capital Total Working Capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point

237 237 237 238 238 238 238 238 238 238

PLASTIC WASTE RECYCLING TECHNOLOGY

PLASTIC WASTE RECYCLING TECHNOLOGY

Written By :

EIRI Consultants and Engineers

4449, Nai Sarak, Main Road, Delhi-110 006 (India) Ph. : 91-11-23918117, 23916431, 23840361 Fax : 91-11-23916431, 23918117 E-Mail : eirisidi@bol.net.in Website : www.eiriindia.org
Sole Distributor : EIRI PROJECT CONSULTANTS & PUBLISHERS 4/54, Roop Nagar, Delhi-110007

Printed and Published by :

4449, Nai Sarak, Main Road, Delhi-110 006 (India) Ph. : 91-11-23918117, 23916431, 23840361 Fax : 91-11-23916431, 23918117 E-Mail : eirisidi@bol.net.in Website : www.eiriindia.org

Distributed by :

EIRI PROJECT CONSULTANTS & PUBLISHERS

4/54, Roop Nagar, Delhi-110007

Copy Reserved by Sudhir Gupta, Delhi

ISBN : 978-81-89765-30-9
Printed in New Delhi (India)

The book is sold subject to the condition that it shall not, by way or trade or otherwise, be lent, resold, hired out, or otherwise circulated without the publisher's prior written consent, in any form of binding or cover other than in which it is published/compiled and without a similar consent including this condition being imposed on the subsequent purchaser and without limiting the rights under copy rights reserved above, no part of this publication may be reproduced, stored inor introduced into a retrieval system, of transmitted in any form or by any means (electronic, mechanical, photocopying or otherwise), without the written prior permission of both the copyright owner and above mentioned publisher of this book. While the book has been prepared carefully, yet the publisher's printer and compiler do not hold any responsibility on the subject of the book. All disputes regarding this book are Subject to Delhi Jurisdiction only

Rs. 750
Printed and Published by Sudhir Gupta for "Engineers India Research Institute", 4449, Nai Sarak, Main Road, New Delhi-110 006 and Printed at Swastik Offset, Delhi

Preface
The recycling industry will provide employment to thousands all over the country in organised waste collection, encourage the municipal corporation to upgrade their garbage collection systems for the ease of separation, encourage new investments and also help the machinery suppliers to utilise their installed facilities to manufacture sophisticated recycling lines. With consumption of plastics in the country rising manifold during recent years, plastics waste management is emerging as a parallel industry with materials valued at around Rs. 2,500 crore recycled annually. Having invaded practically every other application such as packaging, consumer durables and disposables, industrial, electronics and telecommunications, medical and health care, building and construction, plastics as a group of materials have emerged as an unavoidable component of modern life. The book 'Plastic Waste Recycling Technology' covers various methods including Introduction, Details of Polymers, Types of Plastics, Identification of Plastics, Recycling of Plastic Waste, Recycling of Thermosets, Chemical Recycling, Recycling Commodities, Recovery of Chemicals from Plastic Waste, Factors affecting recycling Process, Automatic Scrap Recycling, Reclaiming Polyamide Spin Fibres, EPS-Recycling from PostConsumer Expanded Polystyrene, New Palented Processes, Environmental Health and Future Prospects, Recycling Polyester Resins, Polyurethan Waste Recycling, Recycling and Government Policies, Identification of Plastics, Plastics and the Environment, Recycling-An Industrial Approach, Get Virgin Quality from Reprocessed, Plastic Granules from Fresh Resin, Plastic Granules, Pet Bottle Recycling, Recycling of PVC, Recycling TechniquesThe Next Generation, Quality Control Tests, Plant Economics of Phenol Formaldehyde Resin, Plant Economics of Poly Amide Resin, Plant Economics of Polyester Resins, Plant Economics of Polycarbonte Resin (All Fig. in Lacs), Plant Economics of Urea Formaldehyde Resin, Plant Economics of Acrylic Copolymer Emulsion. The book has been written for the benefit and to prove an asset and a handy reference guide in the hands of new entrepreneurs and well established industrialists.

Nai Sarak, Main Road, Delhi-110 006 (India) E-mail : eirisidi@bol.net.in