Chapter 1

INTRODUCTION

Over the years, plastics have become one of the most commonly used material around
the globe and can be easily considered essential in our everyday lives. However,
associated with the abundant use of plastics, is the problem of ever-increasing
environmental pollution and subsequent deterioration of our eco-system. This is
because plastics are made from non-renewable resources and they are not bio-
degradable. Pakistan, being a third world country is also facing the environmental
issues related to widespread use and disposal of plastics. Conservative estimates made
by Environmental Protection Agency states that around 55 billion plastic bags are
used in Pakistan each year. Most of these bags are not recycled and make their way to
dumps, landfills, water bodies, and streets. The gravity of this issue can be estimated
by reports that suggest that Pakistan has highest percentage of mismanaged plastic in
South Asia.

1.1 Overview
The proposed project presents an effective solution for the recycling of polythene
bags by converting them into pellets. The proposed project is aimed at development of
a setup to recycle polythene bags into pellets for the industrial usage. In this regard,
used plastic bags will be collected and shredder into small flakes. These flakes will
then be melted in an extruder. The melted plastic will be passed through a die (like
spinneret) to produce plastic fibers. These fibers then will be transported to a cutter
where they will be converted into reusable pellets. The proposed project is expected to
process 15-20 kgs of bags in an 8-hour shift.
1.2 Statement of Problem
1.3 Specifications of proposed solution
The specifications of project are;
• The objective of this project is to convert polythene bags into pellets.
• A low-cost system for recycling of polythene bags.
• Recycle polythene bags to overcome the environmental pollution.
• Converting 15 to 20 kg of plastic bag into pellets in 8hrs shift.
1.4 Purpose of the project/research
The proposed project presents an effective solution for the recycling of polythene
bags by converting them into pellets. The proposed project is aimed at development of
a setup to recycle polythene bags into pellets for the industrial usage. In this regard,
used plastic bags will be collected and shredder into small flakes. These flakes will
then be melted in an extruder. The melted plastic will be passed through a die (like
spinneret) to produce plastic fibers. These fibers then will be transported to a cutter
where they will be converted into reusable pellets. The proposed project is expected to
process 15-20 kgs of bags in an 8-hour shift.

For every ton of plastic that is recycled, 7.4 cubic yards of landfill spaced is saved.
Ensuring we recycle as much plastic as possible will extend the lives of our landfill
sites, and stop the process many practice of burning plastics to save space, which
releases toxic irritants and pollutants into the atmosphere.

1.5 Applications of the project/research

Plastic manufacturing companies can re-use these pelletized plastics in a wide variety
of applications, creating a closed-loop recycling process. The pellets of plastic are
used in a wide variety of industries. One of the most common uses is the production
of new plastic bottles. These bottles make up a substantial portion of plastic produced
and are among the most commonly recycled plastic items. The pellets provide the
required uniformity of composition required for the manufacturing process. The
pellets are used in the manufacture of many other products that would otherwise
require new plastic. Items such as plastic bags and industrial plastic wraps are also
commonly produced using pelletized feed stocks.
1.6 Project Plan

1.7 Report Organization

Chapter 2

LITERATURE REVIEW
An estimated one million plastic bags worldwide every minute, and they last
an average of just 12 minutes before being thrown away. Most of these bags are made
from either high-density polyethylene (HDPE), low-density polyethylene (LDPE) or
linear low-density polyethylene (LLDPE).

If plastic bag waste is left untreated and disposed of improperly, it can deeply affect
the environment. Some of the problems may include uncontrolled landfills that may
cause an unhygienic environment, leading to diseases among the people residing
nearby. Landfill is the conventional approach to waste management, but space for
landfills is becoming scarce day by day. It takes 1,000 years for a plastic bag to
degrade in a landfill. Unfortunately, the bags don't break down completely but
instead photo-degrade, becoming micro plastics that absorb toxins and continue to
pollute the environment. There are long-term risks of contamination of soils and
groundwater. Major drawback of landfills from a sustainability aspect is that none of
the material resources used to produce the plastic is recovered the material flow is
linear rather than cyclic. Burning plastic waste (incineration) also releases a range of
toxic gases, heavy metals, and particles into the air. These can be bad for our health.
Dioxins are just one of the many harmful emissions from incinerators. They are
highly toxic and can cause cancer and damage to the immune system.

Recycling has been an alternative method for management apart from landfill and
incineration. However, recycling quality is affected when all plastics are discarded
into a single recycling bin that increases cross contaminations and operation cost to
the recycling. To be recycled, plastic film must be separated based on density between
high-density polyethylene (HDPE) and low-density polyethylene  and colored
or printed film. Plastic Film that is not separated can greatly affect the value of the
items produced with the recycled plastic. Colored or printed film and clear film go to
different processing streams to avoid contaminating each other’s streams, which
would greatly reduce the value of the end product.

These limitations make recycling harder and accumulation of these scraps are
increasing at alarming rate. Lack of proper recycling and reuse facility to handle the
increasing consumptions resulted in plastic pollution from land to ocean. In 2010,
275 million metric ton of plastic waste was observed among which around
12.7 million metric ton enters into the ocean.
2.1 Related Technologies
2.1.1 Chemical Recycling

Chemical recycling can promote a closed-loop system, known as a circular economy,

where in plastics are reused rather than discarded in landfills or incinerated. There are
three general categories of chemical recycling technologies: conversion,
decomposition, and purification.

Conversion focuses on converting polymers long-chain hydrocarbon molecules built

from smaller repeating units called monomers in mixed plastics into smaller
molecules. This can occur through a variety of techniques, including pyrolysis and
gasification.

 Pyrolysis, sometimes called "plastics to fuel," turns plastic waste into a

synthetic crude oil that can be refined into diesel fuel, gasoline, heating oil, or
waxes. This process involves heating the plastic waste to high temperatures
(300-900°C) in the absence of oxygen. Different forms of pyrolysis use
different temperatures, pressures, and processing times.

 Gasification also heats plastic waste to high temperatures (500- 1300°C) in a

low-oxygen environment to convert plastic waste to synthesis gas, or
"syngas." Syngas a fuel mixture containing mainly hydrogen and carbon
monoxide can be combusted for electric power generation or converted into
other fuels or chemicals, such as ethanol and methanol.

Decomposition breaks down polymers in sorted plastics into monomers to produce

new plastics. This decomposition can be done with heat or chemicals. Chemical
decomposition uses solvents to break the polymers into monomers. Some
decomposition technologies use enzymes to break down polymers at temperatures as
low as room temperature, resulting in less energy consumption.

Purification uses solvents to separate polymers from additives or contaminants.

Unlike other types of chemical recycling, purification does not break or modify the
polymer. Purification may be used with mixed or sorted plastics.

2.2 Related Projects

Projects already done or currently being done related to your work.

2.3 Related Studies/Research

In what direction other researchers from your field are working. What is hot in
research these days and what is not

Researchers are trying to improve the recycling rate with less energy consumed
Recycling of packaging materials has seen rapid expansion over the last decades in a
number of countries. Advances in technologies and systems for the collection, sorting
and reprocessing of recyclable plastics are creating new opportunities for recycling,
and with the combined actions of the public, industry and governments it may be
possible to divert the majority of plastic waste from landfills to recycling over the
next decades

World is now trying to use paper bags instead of plastic bags because paper bags are
100% more biodegradable compared to plastic bags. They are also recyclable and
reusable. And these properties make paper bag more environmentally friendly.
Individual management of waste is the first step to successful non-biodegradable
waste management. Segregation of biodegradable and non-biodegradable waste in
separate bins and following recycling practices whenever possible are some measures
that can be taken at the individual level.

2.4 Their Limitations and Bottlenecks

Non-recyclable materials being put in the recycling stream (such as liquids or plastic
bags) that contaminate recyclable materials and compromise recycling machinery.
There are many kinds of plastics and they are fairly easily recycled as long as they are
a pure stream. That is, not a mix of different plastics in the same stream

Chemical recycling may not be suitable for all types of plastic, particularly when
polymer chains are irreversibly bonded together.

2.5 Summary
It's important to remember that Recycling alone will not save the planet. We have to
focus first on Reducing and Reusing our bags and treat recycling as the last resort it is
intended to be. Better awareness and mindset towards controlling non-biodegradable
waste at an individual level will support the cause. It will further help in protecting
human health as well as the environment.