PLASTIC WASTE MANAGEMENT

PROF. BRAJESH KUMAR DUBEY

Department of Civil Engineering
IIT Kharagpur

Topic
Lecture 01:Plastics – What it is Plastic? Types, Uses and Global Statistics
Concepts :

 Plastics – What it is?

Types of plastic

Uses and Global Statistics

Plastics
• Plastics are usually synthetic or semi synthetic
organic Plastics of very high molecular mass
and can be moulded into solid objects of
numerous shapes and sizes.
• Plastics generally include a main chain organic
link; Side linked molecular groups and some
organic and inorganic blends added as
additives, plasticizers, fillers etc.,

Source: https://www.foodnavigator.com/Article/2018/05/29/EU-Commission-unveils-plans-to-tackle-plastic-waste
History of Plastics

PARKESINE

Mr. Alexander Parkes

• A new semi-synthetic plastic was unveiled by Alexander Parkes at
the 1862 Great International Exhibition in London, England.
• PARKESINE, was an organic material consisting of cellulose nitrate
and a solvent.
• Parkesine could be heated, formed while it retained its shape
when cooled and was molded into products such as buttons,
combs, picture frames and knife handles.
History of Plastics

BAKELITE

Dr. Leo H. Baekeland

• The first synthetic plastic was discovered in 1907 when a
Belgian born chemist, Dr. Leo H. Baekeland, reacted phenol
and formaldehyde under pressure using
hexamethylenetetramine as a catalyst for the reaction.
• The result was a thermosetting “phenolic” plastic he named
BAKELITE which was electrically resistant, chemically stable,
heat resistant, rigid, moisture and weather resistant
Plastics production process
Fillers, Plasticizers,
Additives Stabilizers, colorants,
lubricants,
Flame retardants etc.,
Heat, Pressure
Monomers Catalyst Polymers
Polymerization,
Process Condesation or
Addition

For example,
Additives
Catalysts
• These components are added to assist and accelerate the hardening
of resins.
• They are used for quick and complete polymerization.
• For example, Ziegler–Natta catalyst is used in the synthesis of many
alkene chain polymers.
Fillers
• The fillers are inert materials and they impart strength, hardness and
other properties to the plastic.
• The filler may be used as fibrous, laminated or power fillers.
• The minerals commonly used as fillers include calcium carbonate,
talc, silica, clay, calcium sulfate fibers, mica, glass beads, and
alumina trihydrate.
Additives
Plasticizers
• The plasticizers are the organic compounds which are added to improve
the plasticity and to impart softness to the plastic.
• The commonly used plasticizers in plastic are camphor, triacetin, tributyl
phosphate, etc.

Stabilizers
• Polymer stabilizers prolong the lifetime of the polymer by suppressing
degradation that results from UV-light, oxidation, and other
phenomena.
• For example, Tris (2,4-di-tert-butylphenyl) phosphite is a widely used
stabilizer in polymerization.
Additives
Colorants
• The addition of dyes and pigments helps in two ways, namely, they act as
fillers an they impart desired colour to the plastic.
• The commonly used pigments are zinc oxide, barytes, etc.
Lubricants
• The lubricants are applied on the surface of moulds so that the articles of
plastic do not stick to the moulds.
• The application of lubricants on surface of moulds allows easy removal of
articles of plastic from the moulds.
• The commonly used lubricants are graphite, paraffin, wax, etc.
Additives
Flame retardants
• These are added during the process to remove fire-
propagating radicals like H ,OH and others.
• Commonly used flame retardants in plastics are brominated (BRFs) and
other organo-halogen compounds.

Solvents
• These components are added to dissolve the plasticizers.
• For example the alcohol is added in cellulose nitrate plastics to dissolve
camphor.
Manufacturing with plastics
Classification by process rather than product or material is more relevant, because most
processes are suitable for making products from a large variety of plastics.

• Extrusion • Expanded Bead Blowing

• Calendering • Rotational Molding
• Film Blowing • Compression Molding
• Injection Molding • Casting
• Blow Molding • Thermoforming
Extrusion
Description:
• Pellets, granules or powder is placed into a hopper and fed into the extruder barrel.
• As screw in the barrel that turns it blends and moves the material down the barrel.
• Material then forced through a die that is in desired shape. It is cooled by water or air
and cut to length.
Limitations:
Usually limited to sections of uniform cross section.

Source : https://www.researchgate.net/figure/Overview-of-a-plastic-extrusion-machine-with-the-plasticizing-component-in-evidence-The_fig1_321597264
Calendaring
Description:
• Dough-consistent thermoplastic mass is
formed into a sheet of uniform thickness by
passing it through and over a series of heated
or cooled rolls.
• Calendars are also utilized to apply plastic
covering to the backs of other materials.
Limitations:
• Limited to sheet materials and very thin films
are not possible.

Source : https://glossary.periodni.com/glossary.php?en=calendering
Film blowing
Description:
• This process continuously extrudes vertically a
ring of semi-molten polymer in an upward
direction, like a fountain.
• A bubble of air is maintained that stretches the
plastic axially and radially into a tube many
times the diameter of the ring.
• The tube is cooled by air and is nipped and
wound continuously as a flattened tube.
Limitations:
• Higher production costs.
• Low efficiency and less accurate process. Source : http://www.appropedia.org/Blown_film_extrusion
Injection molding
Description:
• Similar to die casting metal, pellets are fed into heated cylinder where they are melted.
• The screw rotates much like extrusion molder (it moves back as material in front of it are
melted) then it rams forward pushing the melted material into the die.
Limitations:
High initial tool and die costs; not economically practical for small runs.

Source : http://design-technology.org/injectionmoulding2.htm
Blow Molding
Description:
Extruded tube or preform is expanded by internal pressure
Limitations:
Generally limited to hollow or tubular parts, some versatile mold
shapes, other than bottles and containers.

Source : https://www.quora.com/What-is-a-blow-molding-machine
Expanded bead blowing
Description:
• The process begins with a measured volume of beads
contain a blowing agent or gas, usually pentane, dissolved in
the plastic being placed into a mold.
• The closed mold is heated to soften the plastic and the gas
expands or blowing agent generates gas.
• The result is fused closed cell structure of foamed plastic
that conforms to a shape.
• Limitations:
• Requires process and material precision that creates waste.
• Requires a lot of production methods with limited product
applications. Source : http://jayneks.com/eps-production
Rotational molding
Description:
• A predetermined amount of powdered
thermoplastic material is poured into mould.
• Mould is closed, heated, and rotated in the axis
of two planes until contents have fused to the
inner walls of mould.
• Mould is then opened and part is removed.
Limitations:
• Limited to hollow parts.
• Production rates are usually slow.

Source: http://www.assignmentpoint.com/business/strategic-management-business/rotational-molding.html
Compression molding
Description:
• Thermoset compound, usually preformed, is
positioned in a heated mould cavity.
• The mould is closed (heat and pressure are
applied) and the material flows and fills the
mould cavity.
• Heat completes polymerization and the part is
ejected.
Limitations:
• Extremely intricate parts containing undercuts,
side draws, small holes, delicate inserts, etc.,
• Time consuming process.
Source : https://en.wikipedia.org/wiki/Compression_molding
Casting
Description:
• Liquid plastic is poured into a mould without
pressure, cured, and taken from the mould.
• Cast thermoplastic films are produced against a
highly polished supporting surface.
• This process has the capability to form large
parts with thick cross sections with good
surface finish.
Limitations:
• Limited to relatively simple shapes.
• Except for cast films, method becomes
uneconomical at high volume production rates. Source : http://www.b9robotresource.com/plastic-resin-casting
Thermoforming
Description:
• Heating a thermoplastic sheet and using a vacuum to pull the sheet over perforated mold.
• Heat-softened thermoplastic sheet is positioned over male or female mould;
• Air is evacuated between sheet and mould, forcing sheet to conform to contour of mould.
Limitations:
Limited to parts of simple configuration, high scrap, and limited number of materials
from which to choose.

Source : http://www.euroextrusions.com/the-principle-of-thermoforming/
Characteristics of plastics
Every type of plastic has very distinct characteristics, but most plastics
have the following general attributes.
• Plastics can be very resistant to chemicals and corrosion.
• Plastics can be both thermal and electrical insulators.
• Plastics have very high strength to weight ratio.
• Plastics can be highly durable, resistant to water and have low
toxicity.
• Plastics are materials with a seemingly limitless range of
characteristics and colours and are easy to manufacture.
Classification of Plastics
PLASTICS

Behavior with respect Structure Type of Resin

to heating Physical & Chemical
properties

Homogenous PET LDPE

Thermoplastics
Soft Rigid

Heterogeneous HDPE PP
Thermosetting Elastomers Semi rigid

PVC PS

Others
Classification based on their Thermal
behavior
PLASTICS

THERMOPLASTICS THERMOSETS

Thermoplastics variety Thermosetting plastics can

softens by heat and hardens not be reused. This variety
when cooled down. It can be requires a great pressure
used by remoulding as many and momentary heat
times as required. during moulding which
Source : Source: https://www.polyplastics.com/en/pavilion/beginners/02-01.html hardens on cooling.
Thermoplastics
Properties
• It may melt before passing to a gaseous state.
• Allow plastic deformation when it is heated.
• Chemical composition do not change on heating.
• They are brittle and glossy.
• They are soluble in certain solvents.
• Swell in the presence of certain solvents.
• Good resistance to creep.
Thermoplastics
Pros
• Highly recyclable
• Aesthetically-superior finishes
• High-impact resistance
• Remoulding/reshaping capabilities
• Chemical resistant
• Hard crystalline or rubbery surface options
• Eco-friendly manufacturing
Cons
• Generally more expensive than thermoset
• Can melt if heated
Thermoplastics
Examples
• Polyethylene
• Polypropylene
• Polystyrene
• Acrylics
• Teflon
Source: http://www.meadex.co.uk/thermoplastic

• Polycarbonate
• Nylon
• Acrylonitrile butadiene styrene (ABS)
Thermosets
Properties
• These are soluble in alcohol and certain organic solvents, when they are in thermo-
plastic stage. This property is utilized for making paints and varnishes from these
plastics.
• They undergo irreversible chemical process.
• These are durable, strong and hard.
• They are available in a variety of beautiful colours.
• They are mainly used in engineering application of plastics.
Thermosets
Pros
• More resistant to high temperatures than thermoplastics
• Highly flexible design
• Thick to thin wall capabilities
• Excellent aesthetic appearance
• High levels of dimensional stability
• Cost-effective

Cons
• Cannot be recycled
• More difficult to surface finish
• Cannot be remoulded or reshaped
Thermosets
• Epoxies
• Polyurethane
• Unsaturated polyesters
• Phenolics
• Silicones
Source: https://www.osborneindustries.com/news/thermosetting-plastic-uses-applications/
Classification based on their Structure

PLASTICS

These plastics are composed of the

These plastics are chain containing carbon, hydrogen,
composed only of Homogenous Heterogeneous oxygen, nitrogen and other elements
hydrocarbon atoms and plastics plastics and they exhibit a heterogeneous
they exhibit a structure.
homogeneous structure.
Examples Examples
• Polyethylene • Polytetrafluoroethylene
• Polypropylene • Polyamides or nylons
• Polystyrene • Polyvinylchloride
• Acrylonitrile butadiene
styrene
Classification based on their physical and
chemical properties
PLASTICS

Rigid Semi rigid Soft

Elastomers
plastics plastics plastics
Examples Examples Examples Examples
• HDPE tubs • LDPE films • Children’s toys • Polyisoprene
• PP cups • Flexible ducts • Rattles • Polybutadiene
• PET pallets • PVC sheets • Fishing baits • Polyisobutylene
Rigid and Semi rigid plastics
Rigid plastics
These plastics have a high modulus of elasticity and
they retain their shape under exterior stresses applied
at normal or moderately increased temperatures.

Semi rigid plastics

These plastics have a medium modulus of elasticity
and the elongation under pressure completely
disappears, when pressure is removed.

Source : http://www.mpact.com/our-products/plastics-business/plastic-fmcg-containers
Source: https://www.alibaba.com/product-detail/Semi-rigid-plastic-pvc-sheet-rolls_60660138827.html
Soft plastics and Elastomers
Soft plastics
These plastics have a low modulus of elasticity and
the elongation under pressure disappears slowly,
when the pressure is removed.
Source : https://www.wired2fish.com/fishing-tips/a-guide-to-bass-fishing-soft-plastics/
Elastomers
These plastics are soft and elastic materials with a low
modulus of elasticity. They deform considerably under
load at room temperature and return to their original
shape, when the load is released. The extensions can
range up to ten times their original dimensions. Source : https://in.pinterest.com/pin/475552041896217612/
Classification based Resin identification code

Source: tupperware.com
Polyethylene terephthalate(PET)
 Introduced by J. Rex Whinfield and James T. Dickson
in 1940, this plastic is one of the most commonly
used on the planet. Interestingly enough, it took
another 30 years before it was used for crystal-clear
beverage bottles, such as the ones produced by
Coca-Cola and Pepsi.
 PET plastics make up 96% of all plastic bottles and
containers in the United States, yet only 25% of these
products are recycled. By being mindful and making
sure to recycle code 1 plastics, you’re helping to
ensure a cleaner environment and less landfill
pollution
Monomer of PET

 PET is an excellent moisture and water barrier material

 oxygen permeability
 light weight
 semi rigid
 robust and impact-resistant
 hygroscopic in nature
Application of PET

Source: plastichistories.blogspot
High-density polyethylene (HDPE)
 In 1953, Karl Ziegler and Erhard Holzkamp used
catalysts and low pressure to create high-density
polyethylene. It was first used for pipes in storm
sewers, drains, and culverts. Today, this plastic is used
for a wide variety of products.
 HDPE is the most commonly recycled plastic because
it will not break under exposure to extreme heat or
cold. According to the EPA, 12% of all HDPE products
created are recycled in a year. This is a very small
dent in the planet’s carbon footprint.
Monomer of HDPE

 High strength-to-density ratio

 density of HDPE can range from 930 to 970 kg/m3
 it is harder and can withstand somewhat higher temperatures (120 °C/
248 °F for short periods).
 the physical properties of HDPE can vary depending on the
molding process that is used to manufacture a specific sample
 strong and a dimensionally stable material
Application of HDPE

Source : fosimpe.com
 Polyvinyl chloride (PVC)
 PVC is one of the oldest synthetic materials in industrial
production. It was actually discovered on accident twice;
once in 1838 by French physicist Henri Victor Regnault and
again in 1872 by German chemist Eugen Baumann. On
both occasions, these men found it inside vinyl chloride
flasks left exposed to sunlight.
 PVC is one of the least recycled materials; generally less
than 1% of PVC plastic is recycled each year. It has been
called the "poison plastic" because it contains
numerous toxins and is harmful to our health and the
environment.
Monomer of HDPE

 Light
 strong
 fire resistant with excellent insulating properties
 low permeability
 easily processed
 Good weathering resistance
 Application of PVC

Source: British plastic federation

Low-Density Polyethylene (LDPE)
 LDPE was the first polyethylene to be produced,
making it the godfather of the material. It has less
mass than HDPE, which is why it’s considered a
separate material for recycling.

 Packaging and containers made from LDPE make

up about 56% of all plastic waste, 75% of which
comes from residential households. Fortunately,
many recycling programs are evolving to handle
these products. This means less LDPE will end up
in landfills and negatively affect the environment!
Monomer of LDPE

 LDPE is defined by a density range of 0.917–0.930 g/cm3

 It can withstand temperatures of 80 °C continuously
and 90 °C (194 °F) for a short time
 It is not reactive at room temperatures , except by strong
oxidizing agents, and some solvent cause swelling.
 strong and a dimensionally stable material
 high resilience
Application of LDPE

Source: pinterest.co.uk
Polypropylene (PP)
 J. Paul Hogan and Robert L. Banks of Phillips Petroleum
Company discovered polypropylene in 1951. At the
time, they were simply trying to convert propylene into
gasoline, but instead discovered a new catalytic
process for making plastic.
 Only about 3% of polypropylene products are
recycled in the US, but interestingly enough, 325
million pounds of non-bottle plastics were collected
for recycling over a year. In other words, a lot of this
plastic is created, but only a small fraction is actually
recycled.
Monomer of PP

 Rigid
 opaque
 Flexible
 low density
 electrical and abrasion resistance
 good dimensional stability at high-temperature and humidity
tough and lightweight
 excellent chemical resistance
 Weathering resistance
Application of PP

Source: Petroquim
Polystyrene or Styrofoam (PS)
 In 1839, German apothecary Eduard Simon accidentally
came across polystyrene while preparing medication. He
isolated a substance from natural resin and didn’t realize
what he had discovered. It took German chemist Hermann
Staudinger to research this polymer and expand on its uses

 Since polystyrene is lightweight and easy to form into

plastic materials, it also breaks effortlessly, making it more
harmful to the environment. Beaches all over the world
are littered with pieces of polystyrene, endangering the
health of marine animals. Polystyrene accounts for about
35% of US landfill materials.
Monomer of PS

 Rigid or foamed
 Clear, and hard
 inexpensive resin
 easily processed
 good strain &abrasion resistance
 transparent, or can be colored with colorants.
Application of PS

Source : polystyrene-recycling.org
 Other/Miscellaneous Plastics
 The remaining plastics include: polycarbonate, polylactide,
acrylic, acrylonitrile butadiene, styrene, fiberglass, and nylon.
Of course, there are many differences in the plastics
classified as miscellaneous by recycling programs.

 Many BPA products fall into this category, which means

it’s best to avoid this plastic for food products. It is not
very easy to break down these plastics once they are
created, unless they are exposed to high temperatures.
This makes these plastics nearly impossible to recycle.
POLYCARBONATES

 High-temperature resistance
 Flame retardant
 Excellent clarity
 self-lubricating
 UV Resistant with use of UV stabilizers
 Glass like visibility and transparency
POLYACRYLATES

 Optical clarity
 Excellent outdoor material
 Very good tensile strength, flexural strength,
transparency, polish ability, and UV
 easy handling and processing, and low cost
 Good impact resistance
TEFLON(PTFE)

 Chemically inert
 low friction coefficient
 high-temperature resistant
 excellent lubricant excellent dielectric properties
 high bulk resistivity
POLYAMIDES

 High mechanical strength

 Stiffness & Thermal stability
 Tough at low temperatures
 Excellent resistance to chemicals
 Low friction; Easy processing
 Durability.
ABS

 flexible design
 excellent surface quality
 brilliant and profound colors
 dimensional stability
 chemical and impact resistance
 Brilliant gloss retention
URETHANES

 Easily foamed
 Good bearing surfaces
 excellent cushioning properties
 Good insulation
PLASTIC WASTE MANAGEMENT
PROF. BRAJESH KUMAR DUBEY
Department of Civil Engineering
IIT Kharagpur

Topic
Lecture 04:Plastics – Uses and Global Statistics
Concepts : during this week

 Plastics – What it is?

Types of plastic

Uses and Global Statistics

Major fields of application
• Automotive
• Industrial machinery
• Medical devices
• Building construction
• Electrical and electronics
• Consumer Goods
Global plastic compounding market volume
• Packaging by application, 2016 (%)
as per Plastic Compounding Market Size &
• Optical media Share, Industry Report, 2018
Source : https://www.grandviewresearch.com/industry-analysis/plastic-compounding-market
Automotive industry applications

Source : https://blog.americanchemistry.com/2014/11/plastics-and-composites-are-reshaping-car-design-ihs-report-shows
Industrial machinery applications

Source : http://www.reliable-machinery.com
Medical applications
• IV and respiratory fittings
• Filters of the laboratories and filter casings
• Diagnosis devices and blood collection tubes
• Separation equipment and dialysis components
• Catheters, Plastic pill casings
• Surgical & examination gloves
• Inflatable splints, inhalation masks
• Disposable gowns, wipes and droppers
• Urine continence and ostomy products Source : blog.americanchemistry.com
Construction industry applications

Source : https://https://www.plastics.ca/PlasticTopics/IntelligentPlasticsInOurLives/PlasticsConserve/GreenBuildings/
Electrical & Electronics applications
ABS - telephone handsets, keyboards, monitors.
Amino resins - lighting fixtures
Epoxy resins - electrical components
Ethylene vinyl acetate - freezer door strips, vacuum lean hoses
Phenol formaldehyde - fuse boxes, knobs, switches, handles
Polyamide - food processor bearings, adaptors
Polycarbonate - telephones
Polyesters - business machine parts, coffee machines
Polyethylene - cable & wire insulation
Polypropylene - kettles
Polystyrene - refrigerator trays/linings, TV cabinets Source :
americanchemistry.com

Polytetrafluoroethene - electrical applications

Polyvinyl chloride - cable and wire insulation, cable trunking
Consumer goods applications

Source : https://inhabitat.com/proctor-gamble-shuns-greenwashing-and-vows-to-go-truly-green/
Packaging industry applications

Source : https://dailyindustryreports.com/plastic-packaging-market-revenue-opportunities-with-region-wise/382570/
Optical media applications

Source : https://www.leoni-fiber-optics.com/en/products-and-services/fibers/pof/
PLASTIC WASTE MANAGEMENT
PROF. BRAJESH KUMAR DUBEY
Department of Civil Engineering
IIT Kharagpur

Topic
Lecture 05:Plastics – Global Statistics
Concepts : during this week

 Plastics – What it is?

Types of plastic

Uses and Global Statistics

Distribution of global plastic material production

China is the largest producer of plastic material,

followed by Europe and NAFTA

Source: plastic euprope,2017

Plastic converter demand main market sector

Source: Plastic Europe market research group(PEMRG) and conversion market and strategy GmbH
Plastic conversion demand by resin type 2016

Source: Plastic Europe market research group(PEMRG) and conversion market and strategy GmbH
European plastic conversion segment demand by segments and
polymer types in 2016

Source: Plastic Europe market research group(PEMRG) and conversion market and strategy GmbH
Per capita plastic products consumption kg/person

2014 2017

Polymer utilization by application global and India,2013

(Source: FICCI 2014,2017)

Demand breakup of plastic Region wise plastic
in India by types,2013 Consumption, India 2013

Source: Chemicals & Petrochemical Statistics, Analysis by Tata Strategic, IOCL, Industry reports, Research by Tata Strategic