Industrial Technology Development Institute

Department of Science and Technology

Prepared by:
ARACELI MAGSINO MONSADA, Dr-Engg.
Materials Science Division
ITDI-DOST, Bicutan , Taguig City, MM
Telephone: 02-837-2071 loc. 2201;2233
e-mail: celimonsada@yahoo.com

Yaman Gensan (City’s Business Month) “May Pera sa Basura”

Gaisano Mall Atrium, General Santos City
July 20, 2013
WHAT IS PLASTIC?
The term “plastic” refers to any of
various complex organic compounds
produced by polymerization, capable
of being molded, extruded, cast into
various shapes and films, or drawn
into filaments used as textile fibers.

-- Webster's Dictionary
backgrounder……..

What are Plastics ?

man-made or
synthetic
material
Macromolecule
organic
compounds
“Plaskos”, to
mould
Non-
biodegradable
Plastic resin pellets
Industrial Technology Development Institute
Department of Science and Technology

TYPES OF PLASTICS
 Thermoplastics
Plastics that can be softened by heating but
regain their original properties once cooled
again. e.g.: PE, PS, PP, PMMA, PVC, ABS,
SAN, PC, etc.
 Can be melted
 Soluble
 At RT = soft , hard or brittle
 Thermosets
Plastics that harden through
chemical cross-linking
reactions. Upon heating,
they do not soften but
decompose chemically. E.g.
epoxy, phenolic, urea, alkyd,
etc.
 (x) chemically reactive
sites along chains
 can not be remelted
 does not swell
 insoluble
 hard at room
temperature
DISTINCT CHARACTERISTICS &
ATTRIBUTES OF PLASTICS

 RESISTANT TO CHEMICALS

 GOOD THERMAL AND ELECTRICAL

INSULATORS

 LIGHTWEIGHT

 CAN BE MOLDED IN VARIOUS

PRODUCTS
PET BOTTLES
PLASTIC
PLASTIC PACKAGING
PACKAGING PRODUCTS
PRODUCTS

FOAMED PS PACKAGING
PE PLASTIC PACKAGING PRODUCTS

PE PLASTIC PACKAGING PRODUCTS

PP PLASTIC PACKAGING PRODUCTS
FLEXIBLE PLASTIC FOIL/FILM BAGS
FLEXIBLE PACKAGING LAMINATES
 PIPES AND FITTINGS

Plastics are RECYCLABLE.

 LATEST PLASTIC PACKAGING
TECHNOLOGIES
Biodegradable Plastics
Carry Bags and Trays
- starch based
- bacterial
- polylactic acid
- Oxo- biodegradable plastics
Source : PPIA presentation during the Workshop/Training on Waste Plastics to Fuel, August 2010
MIXED WASTES IN TRANSFER STATION:
Streets
Canals
Bays PLASTICS especially
plastic bags are very
visible in garbage;
blamed for flashfloods,
clogged canals due to
irresponsible disposal.
MIXED WASTES IN DISPOSAL FACILITY :
SOURCES OF RESIDUALS
Sources of Residuals
Market Commercial
Institution 3% 8%
1%

Residential
88%

RESIDUALS : THESE ARE WASTE PLASTICS

MIXED IN THE GARBAGE, SOILED AND
DIRTY…. DESCRIBED AS NON-RECYCLABLES.

SOURCE : WACS CONDUCTED ON MARCH 2009, PAYATAS, QC.

COMPOSITION OF RESIDUALS AT THE
CONTROLLED DISPOSAL FACILITY

Composition of Residuals
Styrofoam
Others 3%
29%

Laminates Sando
6% Bags
62%
 WEIGHT OF RESIDUALS
Weight, kg
Residual Residential Institution Market Commercial Total
Styrofoam 6,011 123 181 649 6,964
Sando Bags 139,482 152 280 9,870 149,784
Laminates 12,880 1,050 4,541 1,189 19,659
Others 64,685 103 259 6,405 71,452
Total 223,057 1,427 5,261 18,113 247,858

NOTE: DAILY GENERATION : ABOUT 248 TONS/DAY

( ONLY 1 MAJOR CITY IN METRO MANILA)
Technology Challenge:
Recycling/conversion of
post consumer waste
plastics into useful
products
 ITDI HAS AN INTEGRATED APPROACH
TO SOLID WASTE MANAGEMENT WHICH
INCLUDES DEVELOPMENT OF
TECHNOLOGIES ON:
Special wastes Clay Lined
Landfill
4%
Non-
biodegradables
Recycling Biodegradables
Technologies 40% 56%
• plastics Bioreactor
Biogas digester
Ecoshops/Buying Centers
Biomass
• Processing/Recycling of Scrap Packaging Laminates
• Plastic Composite Boards
• Recycling of PET Bottles
• Recycling/Processing of Styropor/Styrofoam and
Plastic Sando Bags using the ITDI Densifier
• Waste Plastics in Asphalt Concrete
• Thermal Processing of Plastic Packaging Laminates
ALTERNATIVE PLASTICS RECYCLING

The Technology on processing waste styropor using

the “Styro Oven” or now the Densifier was
developed in cooperation with the Packaging
Council of the Philippines (PPCP) in 2004.

In 2006, the PPIA adopted the same technology

(improved) for processing waste plastic bags (PE,
PP).
“Recycling/Processing of Waste
Styro/Sandobags using the
Styro/Plastic Densifier ”
 Description of the Technology

The technology mainly involves densification of

“waste Styro” or “plastic bags” by melting them
in a vegetable cooking oil at a controlled heating
temperature; converting the waste styro/plastic
bags into rigid functional products.

Simple, affordable, environment-friendly

and able to generate livelihood;
decentralizing plastics recycling (community
level).
POST CONSUMER
WASTE STYROPOR

EXPANDED
POLYSTYRENE (EPS)

Extruded Foamed Polystyrene

(FPS)
POST CONSUMER WASTE PLASTIC BAGS
Plastic Carry/Shopping bags ( supermarkets, malls, stores,
food shops, restaurants, etc.) - Polyethylene (PE)

Poly/Sando Bags ( wet markets, retailers, dry goods shops,

etc.) - Polyethylene (PE)
Flexible Plastic Packaging - consumer products
(Polypropylene (PP), PE)
 PS, PE, PP – Non-Biodegradable;
Thermoplastics (can be remelted)
RECYCLABLE.

1 2 3 4
PETE HDPE V LDPE
(polyethylene terephthalate) (high-density polyethylene) (polyvinyl chloride) (low-density polyethylene)

5 6 7
PP PS Other
(polypropylene) (polystyrene) (including multi-layer packaging)
THE STYRO OVEN/ PLASTIC DENSIFIER

FEATURES :

 Steel casserole with cover, double jacketed body with a

melting capacity of 50 kgs per batch

 A motorized blunger for homogeneous mixing.

 A cylindrical steel downspout - to facilitate the discharge

of melted plastic during casting into
the metal molds.

 The exhaust/chimney is installed with a charcoal stack to

absorb smoke emission during melting.

 The temperature recorder measures the melting

temperature

 LPG fired with three-line burner.

 Portable unit, mobile.

RECYCLING PROCESS

Waste Styro/Plastic Bags

Size Reduction
(Shredding/Grinding)

Melting/Densification

Densified Products
(functional, novelty)
 RAW MATERIALS

Main raw materials include:

] Post Consumer “Waste Styro” (PS)
] Waste plastic bags (PE, PP)
] Cooking oil ( e.g., “used cooking oil”
from fast foods and
restaurants, households )
 BASIC EQUIPMENT
] Grinding Machine – for grinding the
plastics into small particles
(flakes, grind)
] Styro/plastic Densifier – ITDI-DOST
model unit
Auxiliaries:
metal moulds
weighing scale
personnel protective (gloves, dust
mask, eye goggles, etc.)
THE PRODUCT
The resulting molten waste plastic is easily molded
by CASTING INTO THE METAL MOULDS which
displayed potential uses for tabletops, planters,
blocks for pathways, floorings, and other valuable
functional products.
Molding by Casting
Table Tops
COLORED GARDEN POTS
TILES/PAVING BLOCKS
STACKED ON SHELVES
TILES/PAVING BLOCKS
 Styro/Plastic Rigid Paving Blocks
( Product of Payatas Pilot Testing Project)

Sample Modulus of Compressive

Rupture (MOR), Strength (CS),
kg/cm2 kg/cm2

Pure Styro
46.79 99.37

Styro/Plastic Mix
36.35 52.60

Plastic Shredded
metallized 9.63 42.08
wrapper mix
Styro/Plastic with
less oil 38.55 58.57
 Industrial Technology Development Institute
Department of Science and Technology

ALTERNATIVE PLASTIC RECYCLING

WASTE PLASTIC BAGS
IN ASPHALT CONCRETE
Consists of aggregates and asphalt with waste
plastic bags
Constructing new road pavements
Resurfacing of road pavements (repair of
potholes)

INDUSTRY COOPERATOR: PPIA

 Asphalt
Shredded waste plastic bags

Blending/Mixing

Asphalt with waste plastic bags

Asphalt with waste plastic bags Aggregates

Mixing

Asphalt concrete with waste plastic bags

Shredding of waste plastic bags
Processing of asphalt with
waste plastic bags
Processing of Asphalt concrete
with waste plastic bags
Pot Hole Scraping & leveling

Filling/Patching Asphalt –plastic mix road

Concrete after compaction
 Pot Hole after patching with
Pot Hole before repair Asphalt-plastic-aggregate mix
PROPERTIES
TESTS

 Marshall Mix Design

 Determines the optimum mix of asphalt and
aggregates suitable for road pavement
 Immersion Compression Strength
 Determines retained strength after immersion in
water for 4 days at 50ºC
 Skid resistance
 Determines durability of asphalt concrete
Marshall stability

Marshall Method Mix Heavy Traffic

Criteria Surface and Base Asphalt concrete with
Min Max waste plastic bags

Compaction, no. of
blows each end of 75 75
specimens

Stability, lb 1800 - 3875

Immersion Compression Strength

Control Asphalt concrete with waste

(Asphalt concrete) plastic bags

Dry Wet Dry Wet

Bulk specific gravity 2.425 2.410 2.403 2.402

Stability,Kpa 2742 1981 2754 2081

Index of retained
strength,%
(minimum = 70) 70.44 75.45
SKID RESISTANCE

 Minimum skid resistance value (SRV)

 55 SRV (Motorways, Trunk, and class 1 and
heavily trafficked road carrying more than 2000
vehicles/day
 Control (asphalt concrete) = 90 SRV
 Asphalt concrete with waste plastic bags = 102
SRV
 ENERGY

Development /
improvement of fuel
production
technologies from
renewable sources

Performance
testing of fuels
 ENERGY

Design / improvement /
development &
performance testing of
energy systems and
efficiency

Energy audit
 WASTE MANAGEMENT

Development /
improvement and
transfer of
technologies &
equipment for
waste processing,
utilization,
recycling
 WASTE MANAGEMENT

Cleaner production
assessments
(recommendations
for proper
management /
reduction of wastes)
 ITDI WASTE PLASTIC TO FUEL TECHNOLOGY

THERMAL PROCESSING OF INDUSTRIAL

WASTES BY PYROLYSIS
Implementing R &D Divisions:
Chemicals and Energy Division (CED)
Materials Science Division(MSD)- Industrial
Technology Development Institute (ITDI)

Industry Cooperator: Unilever Philippines

Objective:
To design and test a thermal processing equipment
that will utilize industrial wastes such as plastic
laminates for heat and oil recovery by pyrolysis.
SCHEMATIC DIAGRAM OF THE
PYROLYSIS SYSTEM
Cooling Tower
Gas Emission

Waste Cold Water

WW Water
Hot water
Scrubber

Gas
Condenser Non-condensable Gas
Pyrolyzer

Afterburner
Ash Oil Condensate

LPG
PROTOTYPE THERMAL PROCESSING
Design of Prototype Pyrolyzer

Dimension of rotating drum: 45 cm diameter *

60 cm length
Volume of rotating drum: 0.175 m3
Bulk density of laminates: 49.74 kg/m3
Amount of laminates at 75% capacity: 6.53
kg/batch
Capacity of prototype : 20 kg/hr @ 3 batches/hr
Furnace temperature: 450°C
WASTE-TO-ENERGY TECHNOLOGIES

 Combustion to produce heat

 Gasification to produce combustible syngas

 Pyrolysis to produce syngas, oil or char

 Biological processes such as anaerobic digestion

or fermentation to produce biogas or alcohol
CEMENT KILN CO-PROCESSING
 AFR IN CO-PROCESSING

Use of waste material in industrial processes

such as cement, lime or steel production and
power stations or any other large combustion
plants

In the process, waste substitutes the primary fuel

and raw material. Such waste materials used
in co-processing are called Alternative Fuel
and Raw Materials (AFR)
 Essentials of Successful Waste Plastics
Recycling Project