Presentation on Plastic Recycling Technology .ppt

Plastic recycling technology

1. Update on Project No DripUpdate on Project No Drip
Jacqueline Greene Jacqueline Greene
Michelle DufallaMichelle Dufalla
Tania ChanTania Chan
February 22, 2007February 22, 2007

2. Initial Design SchematicInitial Design Schematic
H2O container
Container
wall
Inside
container
cork
Clamp
with
attached
rubber
plug

3. Tap Design ConsiderationsTap Design Considerations

Gravity driven tap- need to ensure water-tight Gravity driven tap- need to ensure water-tight
seal, grit resistant, easily produced, easy to seal, grit resistant, easily produced, easy to
distribute waterdistribute water

2-hole Jerry Can- one removable for water refill, 2-hole Jerry Can- one removable for water refill,
one permanent for water accessone permanent for water access

Can be assembled with cheap, bought materials Can be assembled with cheap, bought materials
(PVC tubing, cork, etc.) or by processing (PVC tubing, cork, etc.) or by processing
recycled plastics (we plan to try and test out recycled plastics (we plan to try and test out
both options)both options)

4. Jerrycans in Kenya
•For use at grade schools
in Kenya
•Durable, can endure many
cycles, up to 1,000,000 a
year
•Suitable for different types
of jerrycans

5. Designs Considered
Pumping System
Pros:
•Basic pumping system
•Does not require water proof sealing
Cons:
•High cost
•Impurities in water may lead to clogging
•Durability?

6. Designs Considered
Gravity Driven System
Pros:
•Water flows from gravity
•Simple design
•Durable
Cons:
•Low water pressure when water is
running low
•Needs sealing around tap

7. Designs Considered
Water Swelling Grommets
Pros:
•Grommet made of water swelling
polymers
•Swelling acts as sealing even when
grommet is not a perfect fit
Cons:
•Polymers lose mechanical properties
after swelling
•Structurally strong swellign polymers
are expensive

8. Materials Costs – Materials Costs –
PVC PipePVC Pipe
http://www.usplastic.com/catalog/product.asp?catalog
%5Fname=USPlastic&category%5Fname=13669&product
%5Fid=16587&gclid=COzC4PfhwIoCFQx1VAoduiiekw&cookie%5Ftest=1
½” - $0.52/foot
¼” - $0.76/foot

9. Materials Costs – Materials Costs –
ClampsClamps
http://www.schoolmasters.com/science4.html
http://www.rjleahy.com/Store/wire/bwi.htm
$1.10
-or-
* 6 Gauge Brass
Wire ~ $1 /foot

10. Materials Costs – Materials Costs –
CorkCork
http://www.corkstore.com
Self-Expanding - $78.26/
1”x36”x24”

11. Materials Costs – Materials Costs –
Bulk RubberBulk Rubber
http://www.rubbercal.com
Pure Gum - $57.64/
1”x36”x12”
Closed Cell
Neoprene Blend-
$183.90/ 1”x70”x
42”

12. Major Materials Costs – Major Materials Costs –
ApproximationsApproximations
PVC Pipe – 2 inches of ½” diameter ~ $0.09
-or- 2 inches of ¼” diameter ~$0.13
Closed Cell Neoprene Blend – 4 sq. in. ~ $0.25
-or- Pure Gum Rubber – 4 sq. in. ~ $0.54
-or- Expanding Cork – 4 sq. in. ~ $0.37
Clamp- 1 - $1.10
TOTAL ~ $1.44-1.77

13. Advantages of Recycling Plastics in Advantages of Recycling Plastics in
Developing CountriesDeveloping Countries

Lower labour costsLower labour costs

existing culture of reuse and recycling, & collection of these existing culture of reuse and recycling, & collection of these
materialsmaterials

Possibilities to create small businesses, opportunities to earn a Possibilities to create small businesses, opportunities to earn a
small income are rarely missed by members of the urban poor. small income are rarely missed by members of the urban poor.

Fewer laws to control the standards of recycled materials. (i.e. in Fewer laws to control the standards of recycled materials. (i.e. in
the US recycled plastics can not be used to package food- must the US recycled plastics can not be used to package food- must
be virgin plastic) be virgin plastic)

Lower transportation costs, hand or ox carts often being used. Lower transportation costs, hand or ox carts often being used.

Innovative use of scrap machinery often leads to low entry costs Innovative use of scrap machinery often leads to low entry costs
for processing or manufacture. for processing or manufacture.
http://practicalaction.org/practicalanswers/product_info.php?products_id=190http://practicalaction.org/practicalanswers/product_info.php?products_id=190

14. Disadvantages of RecyclingDisadvantages of Recycling

Cost: “May not be economical to recycle small quantities of Cost: “May not be economical to recycle small quantities of
plastics. plastics.

Training of waste generators will be required, so they can separate Training of waste generators will be required, so they can separate
the wastes properly. the wastes properly.

Market prices for recycled plastic are currently $200 to $1000/ton Market prices for recycled plastic are currently $200 to $1000/ton
from local recycling centers based on recent surveys in selected from local recycling centers based on recent surveys in selected
regions. As presented below, a recycling program, dedicated only regions. As presented below, a recycling program, dedicated only
to plastic container recycling, is not likely to be cost effective to plastic container recycling, is not likely to be cost effective
unless large quantities of plastic containers are collected and sold. unless large quantities of plastic containers are collected and sold.
This is primarily a function of the market price for plastic. It will This is primarily a function of the market price for plastic. It will
however be cost effective if incorporated into an existing however be cost effective if incorporated into an existing
program that includes glass and aluminum recycling. program that includes glass and aluminum recycling.
Joint Service Pollution Prevention Opportunity handbook, US NavyJoint Service Pollution Prevention Opportunity handbook, US Navy
http://p2library.nfesc.navy.mil/P2_Opportunity_Handbook/7_I_A_7.htmlhttp://p2library.nfesc.navy.mil/P2_Opportunity_Handbook/7_I_A_7.html

15. Recycling vs. Disposal costsRecycling vs. Disposal costs

According to the Institute for Lifecycle According to the Institute for Lifecycle
Environmental Assessment (Environmental Assessment (
http://www.ilea.org/lcas/Tellus.htmlhttp://www.ilea.org/lcas/Tellus.html),),
““Though there is no decisive research on the Though there is no decisive research on the
environmental impacts of recycling plastic, environmental impacts of recycling plastic,
relating the economic cost of disposal to relating the economic cost of disposal to
recycling shows that the cost to recycle plastic is recycling shows that the cost to recycle plastic is
$360 per ton while normal disposal cost is $250 $360 per ton while normal disposal cost is $250
per ton. “per ton. “

16. How Plastics are RecycledHow Plastics are Recycled
http://www.eia.doe.gov/kids/energyfacts/saving/recycling/solidwaste/plastics.htmlhttp://www.eia.doe.gov/kids/energyfacts/saving/recycling/solidwaste/plastics.html

                
1. Inspection
 

Workers inspect the plastic trash for contaminants like rock and glass, and for plastics that the plant
cannot recycle.
 

                
2. Chopping and Washing
 

The plastic is washed and chopped into flakes.

                
3. Flotation Tank
 

If mixed plastics are being recycled, they are sorted in a flotation tank, where some types of
plastic sink and others float.

                
4. Drying
 

The plastic flakes are dried in a tumble dryer.

17. How Plastics are Recycled cont’dHow Plastics are Recycled cont’d
http://www.eia.doe.gov/kids/energyfacts/saving/recycling/solidwaste/plastics.htmlhttp://www.eia.doe.gov/kids/energyfacts/saving/recycling/solidwaste/plastics.html

                
5. Melting
 

The dried flakes are fed into an extruder, where heat and pressure melt the plastic.
Different types of plastics melt at different temperatures.

                
6. Filtering
 

The molten plastic is forced through a fine screen to remove any contaminants that
slipped through the washing process. The molten plastic is then formed into strands.

           
7. Pelletizing
 

The strands are cooled in water, then chopped into uniform pellets. Manufacturing
companies buy the plastic pellets from recyclers to make new products. Recycled
plastics also can be made into flowerpots, lumber, and carpeting.
 

18. Manufacturing Techniques for Manufacturing Techniques for
Recycled PlasticsRecycled Plastics

Extrusion: the product is usually in the form of a continuous 'tube' of plastic such as piping or Extrusion: the product is usually in the form of a continuous 'tube' of plastic such as piping or
hose. The reclaimed plastic is forced along the heated tube by an archimedes screw and the plastic hose. The reclaimed plastic is forced along the heated tube by an archimedes screw and the plastic
polymer is shaped around a die. The die is designed to give the required dimensions to the product polymer is shaped around a die. The die is designed to give the required dimensions to the product
and can be interchanged. and can be interchanged.

Injection moulding. The first stage of this manufacturing process is identical to that of extrusion, Injection moulding. The first stage of this manufacturing process is identical to that of extrusion,
but then the plastic polymer emerges through a nozzle into a split mould. The quantity of polymer but then the plastic polymer emerges through a nozzle into a split mould. The quantity of polymer
being forced out is carefully controlled, usually by moving the screw forward in the heated barrel. A being forced out is carefully controlled, usually by moving the screw forward in the heated barrel. A
series of moulds would be used to allow continual production while cooling takes place. This type series of moulds would be used to allow continual production while cooling takes place. This type
of production technique is used to produce moulded products such as plates, bowls, buckets, etc. of production technique is used to produce moulded products such as plates, bowls, buckets, etc.

Blow moulding. Again the spiral screw forces the plasticised polymer through a die. A short piece Blow moulding. Again the spiral screw forces the plasticised polymer through a die. A short piece
of tube, or 'parison' is then enclosed between a split die - which is the final shape of the product - of tube, or 'parison' is then enclosed between a split die - which is the final shape of the product -
and compressed air is used to expand the parison until it fills the mould and achieves its required and compressed air is used to expand the parison until it fills the mould and achieves its required
shape. This manufacturing technique is used for manufacturing closed vessels such as bottles and shape. This manufacturing technique is used for manufacturing closed vessels such as bottles and
other containers. other containers.

Film blowing. Film blowing is a process used to manufacture such items as garbage bags. It is a Film blowing. Film blowing is a process used to manufacture such items as garbage bags. It is a
technically more complex process than the others described in this brief and requires high quality technically more complex process than the others described in this brief and requires high quality
raw material input. The process involves blowing compressed air into a thin tube of polymer to raw material input. The process involves blowing compressed air into a thin tube of polymer to
expand it to the point where it becomes a thin film tube. One end can then be sealed and the bag expand it to the point where it becomes a thin film tube. One end can then be sealed and the bag
or sack is formed. Sheet plastic can also be manufactured using a variation of the process or sack is formed. Sheet plastic can also be manufactured using a variation of the process
described. described.

19. 2/6/07 2/16/07 2/26/07 3/8/07 3/18/07 3/28/07 4/7/07 4/17/07 4/27/07 5/7/07 5/17/07
Background Research
Recycling
Processing Cost
Mat erial Cost
Targ et User
Design of Tap on SolidWorks
Mat erials Economic Analysis
Mat erials Testings
Mat erials in Chlorinated Water
Prod uct ion of Prot otype #1
Testing of Prop osed Desig ns
Leak Test
Mechanical Test
Recycling and Processing of Plastic Bag s
Troubleshoot Prob lems of Prototyp e #1
Overall Evaluation of Prototype after Improvements
Prod uct ion of Final Prod uct
Increase Efficiency and Decrease Cost of Prod uct ion
Troubleshoot Defects in Final Product
Prep aration for Final Presentat ion
Completed Remaining
Gantt Chart