MINOR PROJECT REPORT

1. “RECYCLING THE WASTE PLASTIC MATERIAL WITH THE HELP OF
HEAT TREARTMENT”
A MINOR PROJECT REPORT
Submitted in partial fulfillment for degree of Bachelor of Engineering
IN
DEPARTMENT OF MECHANICAL ENGINEERING
SUBMITTED TO
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA
BHOPAL (M.P)
Submittedby Under the guidance of
GAURAV KUMAR 0129ME141005 Mr. YOGESH TEMBHURNE
JAIDEEP KISHANPURI 0129ME141007 ASSOCIATE PROF.OF ME DEPARTMENT
AJEET RAJHBHAR 0129ME141003
ABHISHEK PRAJAPATI 0129ME141002
SHARAD SINGH VAIS 0129ME141020
Department of Mechanical Engineering
BHABHA ENGINEERING RESEARCH INSTITUTE, BHOPAL (M.P.)

2. BHABHA ENGINEERING RESEARCH INSTITUTE, BHOPAL (M.P.)
Department of Mechanical Engineering
CANDIDATE’S DECLARATION
I here by declare that the work, which is being presented in this Minor Project
entitled “RECYCLING THE WASTE PLASTIC MATERIAL WITH THE HELP
OF HEAT TREARTMENT” in particular fulfillment of for the award of the degree
of Bachelor of Engineering in Mechanical Engineering is an authentic record of
work carried out by me.
The matter embodies in this dissertation has not been submitted by me for the
award of any other degree.
GAURAVKUMAR 0129ME141005,
JAIDEEP KISHANPURI 0129ME141007,
AJEET RAJHBHAR 0129ME141003,
ABHISHEKPRAJAPATI 0129ME141002,
SHARAD SINGH VAIS 0129ME141020,

3. TABLE OF CONTENT
1 Introduction ....................................................................................................... 4
2 Plastic identification code.................................................................................7
3 Polymer...................................................................................................9
4 Objective of present work.......................................................................10
5 Scope ......................................................................................................11
6 Methodology...........................................................................................12
7 Method of Plastic Waste Disposal..........................................................14
8 Conclusion ………………………………………………………….…18

4. INTRODUCTION:
Plastic recycling is the process of recovering scrap or waste plastic and
reprocessing the material into useful products. Since the vast majority of plastic is
non-biodegradable, recycling is a part of global efforts to reduce plastic in the waste
stream, especially the approximately eight million metric tonnes of waste plastic
that enter the Earth's ocean every year. This helps to reduce the high rates of plastic
pollution.
Plastic recycling includes taking any type of plastic, sorting it into different
polymers and then chipping it and then melting it down into pellets. After this stage,
it can then be used to make items of any sort such as plastic chairs and tables. Soft
Plastics are also recycled such as polyethylene film and bags. This closed-loop
operation has taken place since the 1970s and has made the production of some
plastic products amongst the most efficient operations today
Compared with lucrative recycling of metal, and similar to the low value of glass,
plastic polymers recycling is often more challenging because of low density and
low value. There are also numerous technical hurdles to overcome when recycling
plastic.
A macro molecule interacts with its environment along its entire length, so total
energy involved in mixing it is largely due to the product side stoichiometry.
Heating alone is not enough to dissolve such a large molecule, so plastics must
often be of nearly identical composition to mix efficiently.

5. When different types of plastics are melted together, they tend to phase-separate,
like oil and water, and set in these layers. The phase boundaries cause structural
weakness in the resulting material, meaning that polymer blends are useful in only
limited applications. The two most widely manufactured
plastics, polypropylene and polyethylene behave this way, which limits their utility
for recycling. Recently, the use of block copolymers as "molecular stitches “or
"macromolecular welding flux" has been proposed to overcome the difficulties
associated with phase separation during recycling.
The quantity of post-consumer plastics recycled has increased every year since at
least 1990, but rates lag far behind those of other items, such as newspaper (about
80%) and corrugated fiberboard (about 70%).
Plastics are too valuable a resource to send to landfill at their end of life. Industry
wants these materials back to recycle whenever possible. When plastics cannot be
sustainably recycled such non-recyclable plastics provides a valuable energy
resource for advanced thermal process; contributing to energy security and
displacing virgin fossils fuels.
Waste is now a global problem, and one that must be addressed in order to solve the
world's resource and energy challenges. Plastics are made from limited resources
such as petroleum, and huge advances are being made in the development of
technologies to recycle plastic waste among other resources. Mechanical recycling
methods to make plastic products and feedstock recycling methods that use plastic
as a raw material in the chemical industry have been widely adopted, and awareness
has also grown recently of the importance of Thermal recycling as a means of using
plastics as an energy source to conserve petroleum resources. Japan is pursuing
measures to create a recycling-oriented society in order to achieve sustainable
development. Since the Basic Law for Promoting the Creation of a Recycling-
oriented Society was enacted in 2000, a number of recycling-related laws have been
enacted, come into force, been reviewed and amended. Based on this framework,
action to promote the "three Rs" - i.e. reduction and reuse as well as recycling of
waste - has been stepped up to ensure a more effective use of resources. Meanwhile,
the Ministry of the Environment continues to restrict final disposal sites and to
direct incineration plants and similar sites that can emit toxins such as dioxins. Now
that these are recognized as safe, the basic policy stated in the Waste Disposal Law
was amended in May 2005 to say that "first, emission of waste plastic should be
reduced, after which recycling should be promoted; any remaining waste plastic

6. should not go to landfill as it is suitable for use in thermal recovery". This means
that the former two basic categories of burnable and non-burnable waste are now
both classed as "burnable". Later on in May 2004, the Tokyo Metropolitan Waste
Management Council delivered a similar response, and finally as of 2008 Tokyo's
23 city wards have started a new sorted collection which aims to reduce plastic
waste landfill to zero by using plastics as a raw material or for incineration and
Thermal recycling by default. Then in June 2006 the Container and Packaging
Recycling Law was amended to give thermal recycling limited recognition as a
form of recycling plastic containers and packaging. The processing of waste plastics
has seen huge advances, not only becoming less burdensome on the environment
but also socially and economically effective and efficient. In this publication we
consider the question of waste from a number of angles and present the very latest
data on processing of waste plastic and its use as a raw material. Environmental and
waste issues are composed of a great number of factors, which makes a scientific,
multifaceted approach essential to their solution. The reader, we hope, will find that
"An Introduction to Plastic Recycling" throws light on waste problems and in
particular on the issue of plastic waste.
In my dissertation of fuel production through waste polythene and plastic with the
help of zeolite as a catalyst in that first of all i prepare a mild steel closed air tight
vessel having a lid on the top of it along with the hole which is attached by a long
galvanize steel pipe then i filled the container up ¾ of its height with the waste
plastic and polythene then by using external source of heater temperature of closed
chamber is arises up to 300o C-450o C from room temperature on which the
pyrolysis takes place which converts the waste plastic or polythene in useful fuel
whose texture ,odour colour, and all other properties like flash point ,fire point,
cloud point, pour point, viscosity, are almost near to the petrol .After that the
outcome fuel from a waste plastic or polythene is used as a normal fuel in a 100
CC bike and found the fuel gives more millage as compare to petrol about 6-8 km.
Which increases the efficiency of the engine by 15-20%? & by using Taguchi
Technique I optimize the various parameters which affects the production of plastic
fuel .by using advance technique I found the catalyst is most affecting parameter
whose contribution is 75.25 % and second one is time12.93% and the least is time
whose contribution is 9.09%.

7. Plastic identification code
Seven groups of plastic polymers each with specific properties, are used worldwide
for packaging applications (see table below). Each group of plastic polymer can be
identified by its plastic identification code (PIC), usually a number or a letter
abbreviation. For instance, low-density polyethylene can be identified by the
number "4" or the letters "LDPE". The PIC appears inside a three-chasing-arrow
recycling symbol. The symbol is used to indicate whether the plastic can be
recycled into new products.
The PIC was introduced by the Society of the Plastics Industry, Inc., to provide a
uniform system for the identification of various polymer types and to help recycling
companies separate various plastics for reprocessing. Manufacturers of plastic
products are required to use PIC labels in some countries/regions and can
voluntarily mark their products with the PIC where there are no
requirements Consumers can identify the plastic types based on the codes usually
found at the base or at the side of the plastic products, including food/chemical
packaging and containers. The PIC is usually not present on packaging films, since
it is not practical to collect and recycle most of this type of waste.
Plastic
identificati
on code
Type of plastic
polymer
Properties
Common packaging
applications
Melting(°C)
and
transition
temperatur
e
Young's
modulus
(GPa)
Polyethylene
terephthalate(PET,
PETE)
Clarity,
strength,
toughness,
barrier to gas
and moisture.
Soft drink, water and salad
dressing bottles; peanut butter
and jam jars; small consumer
electronics
Tm =
250;]
Tg =
76
2–2.7
High-density
polyethylene(HDPE)
Stiffness,
strength,
toughness,
resistance to
moisture,
permeability
to gas
Water pipes, hula
hoop rings, five gallon buckets,
milk, juice and water bottles;
grocery bags, some
shampoo/toiletry bottles
Tm =
130; Tg = -
125
0.8

8. Polyvinyl
chloride(PVC)
Versatility,
ease of
blending,
strength,
toughness.
Blister packaging for non-food
items; cling films for non-food
use. May be used for food
packaging with the addition of
the plasticisers needed to make
natively rigid PVC flexible. Non-
packaging uses are electrical
cable insulation; rigid piping;
vinyl records.
Tm =
240; Tg =
85
2.4-4.1
Low-density
polyethylene(LDPE)
Ease of
processing,
strength,
toughness,
flexibility,
ease of
sealing,
barrier to
moisture
Frozen food bags; squeezable
bottles, e.g. honey, mustard;
cling films; flexible container lids
Tm =
120;]
Tg = -
125
0.17–0.28
Polypropylene(PP)
Strength,
toughness,
resistance to
heat,
chemicals,
grease and
oil, versatile,
barrier to
moisture.
Reusable microwaveable ware;
kitchenware; yogurt containers;
margarine tubs;
microwaveable disposable take-
away containers; disposable
cups; soft drink bottle caps;
plates.
Tm =
173; Tg = -
10]
1.5-2
Polystyrene(PS)
Versatility,
clarity, easily
formed
Egg cartons; packing peanuts;
disposable cups, plates, trays
and cutlery; disposable take-
away containers
Tm = 240
(only
isotactic);
Tg = 100
(atactic and
isotactic)
3-3.5
Other
(often polycarbonate
or ABS)
Dependent
on polymers
or
combination
of polymers
Beverage bottles; baby milk
bottles. Non-packaging uses for
polycarbonate: compact discs;
"unbreakable" glazing; electronic
apparatus housings; lenses
including sunglasses,
prescription glasses, automotive
headlamps, riot shields,
instrument panels.
Polycarbon
ate: Tg =
145; Tm =
225
Polycarbonat
e: 2.6;]
ABS
plastics: 2.3

9. Polymer
Polymer are the natural or synthetic molecules that are composed of a large number
of smaller monomers, which have reacted to form long chain. The most basic
polymers are made from the same monomers – the name of this substance is made by
adding prefix ‘Poly’ to the name of monomer.
Polymers can be classified into a number of ways which are described below.
Figure 1
Plastic materials are cannot be decomposed easily in a short period of time. These
plastic wastes can be classified as industrial and municipal according to their origins;
these groups have different qualities and properties. The level of waste plastic
continuous increase it is generating environmental problems worldwide.
classification of plastics includes high-density poly-ethylene, (High-Density
Polyethylene Milk, detergent & oil bottles, toys, containers used outside, parts and
plastic bags). low-density polyethylene (LDPE, Many plastic bags, shrink-wraps,
garment bags or containers)., polypropylene and polystyrene. Also, plastics are
classified by their chemical structure of the polymer's backbone and side chains.
Some important groups in these classifications are the acrylics, polyesters, silicones,
polyurethanes, and halogenated plastics. Poly Propylene. Refrigerated containers,
some bags, most bottle tops, some carpets, and some food wraps. There are two main
types of plastics: thermoplastics and thermosetting polymers. These waste plastic
convert to useful oil and reduces the many problems increasing in world.

10. Objective of present work
The overall objective of the project is to study the thermal and catalytic pyrolysis of
three types of waste plastics i.e. low density polyethylene, polypropylene, and
polystyrene in a closed container with an objective to optimize the liquid product
yield by changing different parameters such as temperature, catalyst and catalyst to
plastic ratio. The specific objectives of this study are:
• To study the effect of sulphuric acid treatment on the physicochemical
characteristics of Zeolite and its catalytic behavior in the waste polypropylene.
• To optimize the process experimentally for production of liquid fuel from
different waste plastics.
• To characterize the liquid fuel for its composition and fuel properties for its
suitability as fossil fuel substitute.
• To study the engine performance and emission analysis of waste plastic oil
obtained by the catalytic pyrolysis.
• To optimize the process variables of catalytic degradation of waste
polypropylene by Taguchi method.

11. SCOPE:
The work focused on the thermal and catalytic pyrolysis of waste plastics
[Polypropylene (PP), Low Density Polyethylene (LDPE), and Polystyrene(PS)] to
liquid fuel/chemicals using kaolin activated kaolin catalyst. The main objective was
to screen the catalyst and optimize the process to obtain suitable liquid fuel from
different waste plastics. Characterization of liquid fuel for its composition and fuel
properties for its Waste plastic to fuel-A sustainable approach to energy recovery
suitability as fossil fuel substitute and study the engine performance and emission
analysis was other aspects of the work.
The aim of this dissertation is mainly to carry out study regarding to minimize the
plastic waste in the world. The world construction industry should implement several
methods to minimize the plastic waste material such as provide proper management
for the material, reuse and recycle method and so on. Therefore, all the solution
should be implementing in world in order to achieve the aims of this study. This
research is mainly focusing on the plastic wastes or polythene convert to the fuel and
also help in Swachha Baharat mission started by prime minister.

12. Methodology
Pyrolysis process for conversion of waste plastic into fuel
Pyrolysis is the chemical decomposition of organic substances by heating the
word is originally coined from the Greek-derived elements pyro "fire" and lysys
"decomposition". Pyrolysis is usually the first chemical reaction that occurs in the
burning of many solid organic fuels, cloth, like wood, and paper, and also of some
kinds of plastic. Anhydrous Pyrolysis process can also be used to produce liquid
fuel similar to diesel from plastic waste. Pyrolysis technology is thermal
degradation process in the absence of oxygen. Plastic waste is treated in a
cylindrical reactor at temperature of 200ºC – 350ºC.Now a days plastics waste is
very harmful to our nature also fo human beings .plastic is not easily decomposable
its affect in fertilization ,atmosphere ,mainly affect on ozone layer so it is necessary
to recycle these waste plastic into useful things .so we recycle this waste plastic into
a useful fuel.
Taguchi Method - The method presented in this study is an experimental design
process called the Taguchi design method. Taguchi design, developed by Dr.Genichi
Taguchi, is a set of methodologies by which the inherent variability of materials and
manufacturing processes has been taken into account at the design stage. Although
similar to design of experiment (DOE), the Taguchi design only conducts the
balanced (orthogonal) experimental combinations, which makes the Taguchi design
even more effective than a fractional factorial design. By using the Taguchi
techniques, industries are able to greatly reduce product development cycle time for
both design and production, therefore reducing costs and increasing profit.
The objective of the parameter design is to optimize the settings of the process
parameter values for improving performance characteristics and to identify the

13. product parameter values under the optimal process parameter values. The parameter
design is the key step in the Taguchi method to achieving high quality without
increasing cost. The steps included in the Taguchi parameter design are: selecting the
proper orthogonal array (OA) according to the numbers of controllable factors
(parameters); running experiments based on the OA; analysing data; identifying the
optimum condition; and conducting confirmation runs with the optimal levels of all
the parameters.
Taguchi method the experimental procedure included experimental design by
Taguchi method, welding materials, welding equipment and welding procedure.
Taguchi method can study data with minimum experimental runs. In this paper, the
design of experiment work can be decided by this method.
Steps of Taguchi method are as follows:
1. Identification of main function, side effects and failure mode.
2. Identification of noise factor, testing condition and quality characteristics.
3. Identification of the main function to be optimized.
4. Identification the control factor and their levels.
5. Selection of orthogonal array and matrix experiment.
6. Conducting the matrix experiment.
7. Analysing the data, prediction of the optimum level and performance.
8. Performing the verification experiment and planning the future action.

14. Methods of Plastic Waste Disposal (and possible complications)
Today’s post aim to give a broad overview on the 4 main method of plastic
disposal. They are: Landfilling, Incineration, Recycling and Biodeg
radiation.

15. 1. Landfilling
To be frank, all plastics can be disposed in landfills. However, landfilling is
considered highly wasteful as it requires a vast amount of space and the chemical
constituents and energy contained in plastic is lost (wasted) in this disposal
route. In 2008, 29.2 million tons of plastic was disposed in landfills in the United
States. In countries where landfills are poorly managed, plastic wastes can be
easily blown into waterways or carried out to sea by flood water. In addition,
when plastics decompose in landfills, they may leak pollutants (phthalates and
bisphenol A) into the soil and surrounding environment.
2. Incineration
Plastics are derived from petroleum or natural gas, giving them a stored energy
value higher than any other material commonly found in the waste stream.
Incineration return some of the energy from plastic production. In fact, one
pound of plastic can generate as much energy as Wyoming coal and almost as
much energy as fuel oil.
However, plastic incineration tends to cause negative environment and health
effects as hazardous substances may be released into the atmosphere in the
process. For example, PVC and halogenated additives are mixed into plastic
waste and their incineration leads to release of dioxins and polychlorinated-
biphenyls into the environment.

16. 3. Recycling
Many plastics can be recycled. and the materials recovered can be given a
second-life. However, this method is not fully utilized, due to difficulties with
the collection and sorting of plastic waste. Many developing (and even some
developed countries) have poor waste management facilities which often result
in plastics (and other waste) being recklessly disposed into rivers and
waterbodies. Even though recycling is the most effective way to deal with plastic
waste, its effectiveness is highly depended on public awareness, economic

17. viability, and the implementation of public infrastructures to make recycling
more efficient (recycling bins, specialized waste collecting trucks).
4. Biodegradable Plastics
Biodegradable plastics are plastics that decompose by the action of living
organisms. Biodegradable plastics have the potential to solve a number of waste-
management issues, especially for disposable packaging that cannot be easily
separated from organic waste. However, biodegradable plastics are not without
controversy. Even though biodegradable plastics can be completely metabolizing
by organisms into carbon dioxide and water, there are allegations that Oxo-
Biodegradable plastics may release metals into the environment.

18. Conclusion:
There is so much information about recycling. But high quality education is a must
if the amount of recycling is to be increased. We must communicate one message if
people are to understand the seriousness of the problem. Everyone should
understand the subject thoroughly so that the only excuse can be a lack of interest.
The problem of contamination of recycling bins must be overcome.
Research is of vital importance and must continue. For example, the recycling of
films which are laminates of different plastics must continue to be investigated.
Together we must reduce, reuse and recycle. We can reduce by purchasing items
with the least amount of packaging and buying in bulk when appropriate. We can
reuse by avoiding disposable items. Finally we can recycle by using community
recycling programs and purchasing products made form recycled materials.
Never before has there been a time when environmental issues such as recycling
have been more relevant. We must stop refusing to look past today.

19. By using this fuel oil in 100 cc bike it increases efficiency of bike by 15 to 20% as
compared to petrol used in the bike. Engine fuel with waste plastic oil exhibits higher
thermal efficiency. By comparing the density of HDPE oil with petrol its gives
approximately same value. Also comparing the density of LDPE oil WITH diesel oil
its gives approximately same value. It could be concluded, that thermal pyrolysis of
plastic waste leads to the production of fuel oil, valuable resource recovery and
reduction of waste problem. Thermal pyrolysis of waste plastic waste has also
several advantages over other alternative recycling methods. It has been shown that
the conversion at lower temperature in the presence of catalyst into liquid is a
feasible process. Parameters with respect to percentage calibration is Catalyst,
temperature, time contribution indicates the relative power of a factor to reduce
variation. For a factor with a higher percent contribution, a small variation will have
a great influence on the performance. The percent contributions of the plastic fuel
parameters on the percentage calibration According to ANOVA this, catalyst was
found to be the major factor (75.24) affecting the percentage calibration, whereas
time was found to be the second factor (12.93 %), least one is temperature 9.09%.