Detailed Project Report on plastic recycling unit

PLASTIC RECYCLING UNIT

[CODE NO.4263] 

A plastic is any one of a large and varied group of materials which consists of an essential ingredient combinations of carbon with oxygen, hydrogen, nitrogen and other organic and inorganic elements. While solid in the finished state, at some stage in its manufacture it has been or can be formed into various shapes by flow-usually through the application singly or together of heat and pressure.

Plastic Classification:

Plastics are classified in several ways.  The most accepted division that covers the entire field is by the behaviour pattern.

(1)  Thermoplastic

(2)  Thermosetting plastics

In this report we are only concerned with Thermoplastics.

Thermoplastics are those which soften under heat and again harden when cooled and this process can be repeated a number of times without any appreciable was in the physical properties.

Plastics today have a prominent place in the spectrum of materials frequently used by materials engineers and designers. They have earned this placed on the basis of performance at a price, plus the apparently unlimited ability of the plastics industry to develop new plastics or new grades of older plastics to meet specific needs of modern industry. With this status and the tremendous growth of new uses has come an important need for meaningful data on fundamental plastics behaviour under realistic stresses and strains, couched in engineering terms, in short, engineering properties as contrasted with data sheet properties. Needed are engineering criteria for rigidity, strength, endurance and temperature range, which are common to nearly all plastic applications, as well as more specialized performance characteristics that are important only in certain types of special product (eg. electrical properties).

Among the plastics the various industrial grade plastic waste available, the following are the materials like A.B.S. (Acrylonitrite Butadiene) styrones, polypropylene, HIPS, L.D.P.E., L.I.D.P.E. Polystyrene, Opp. OPS and Acrylic. In this report we have considered Ten Industrial grade plastic waste material and for that plastic granules will be prepared.

Nowadays, PET bottles are the global number one in beverage packaging. More than 400 billion plastic bottles come on the market every year and PET is becoming increasingly valuable as a recyclable raw material used in the production of beverage bottles. Thus, it is important that all of the production steps applied for the manufacture of your PET bottles are made sustainable for the future.

The gentle treatment of resources and economical use of materials are a must when it comes to sustainable production. Valuable raw materials such as PET must be processed as efficiently as possible while still tapping into every way of saving costs. The PET manufacturing and production process allows for the application of a sustainable approach which can optimally combine environmental awareness and cost effectiveness: the bottle-to-bottle recycling concept.

Bottle-to-bottle recycling plant efficiently recycles used PET bottles and the recyclate is then reused in the food and beverage industry as recycled PET (rPET). The complete process comprises the cleaning of the used PET bottles and the treatment of the recyclate so that the end product - which could come in the form of flakes, pellets or preforms - can meet the highest quality requirements after the recycling process. European and American certificates (e.g. FDA), and a number of different corporate approvals, all confirm the high quality of the recyclate for direct use in containers which come into direct contact with foodstuffs.

• Food-grade PET flakes and pellets

Recycling plant produces food-grade PET. With it, returned PET bottles can be reused to make new PET bottles. The use of recyclate has clear economic and ecological benefits. 

• Flakes, pellets or performs

The procedure gives you the freedom to decide which end product you wish to create. The decontamination step required for the material's later contact with foodstuffs is only ever performed with flakes. Afterwards, the flakes are either used directly or are made into pellets. Another extremely energy-efficient use for the decontaminated flakes is the direct feeding of the material into an extrusion process – 

Worldwide, PET-bottles more and more replace glass bottles in the beverage and food sector. The success of PET in comparison to glass is based on several economic (and environmental) advantages.

On the one hand, the production of PET is less expensive and energy consuming than the production of glass. Secondly, the light weight of the PET-bottle makes it easier for merchants and consumers to handle the bottles and crates. It saves energy during transport, particularly on long distance haulage. Finally, PET offers more or less the same material properties as glass regarding hygiene, taste and gas impermeability.

The negative impacts of PET-bottles in recent years result from their use as nonreturnable beverage containers leading to a dramatic increase of beverage container waste. But even here, changes are on the move, particularly in industrialized countries, where PET-bottles enter more and more the existing returning and refilling schemes. Apart from returning and refilling, recycling of used PET-bottles is also possible and will be an interesting option especially for developing countries, where refilling schemes are not in place or economically unfavourable.

COST ESTIMATION

Plant Capacity                                    5 MT/Day

Land & Building (4000 sq.mt.)  Rs. 1.44 Cr

Plant & Machinery                              Rs. 1.72 Cr

Working Capital for 1 Month           Rs. 63.88 Lac

Total Capital Investment                  Rs. 4.03 Cr

Rate of Return                                    30%

Break Even Point                               62%

INTRODUCTION

PLASTIC CLASSIFICATION:

THE MATERIAL

PRINCIPLE OF POLYCONDENSATION

POLYMERIZATION OF PET

RECYCLING OF PET BOTTLES

RECYCLING OF PET-BOTTLES

DEPENDING ON THE TYPE OF RAW MATERIAL THREE TYPES OF RECYCLING ARE POSSIBLE:

TABLE DESCRIBES THE PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES

CLEAR PET FLAKE – BOTTLE SPECIFICATION

PROPERTIES AND ADVANTAGE OF PET

CRYSTAL CLEAR

PURE

SAFE

GOOD BARRIER

LIGHTWEIGHT

NO LEAKAGE

DESIGN FLEXIBILITY

RECYCLABLE

GOOD RESISTANCE

LONG SHELF-LIFE

CSD -- CARBONATED SOFT DRINKS

WATER -- THE CLEAR STORY

JUICE -- HOT FILL QUALITIES

BEER -- A NEW MARKET WITH NEW REQUIREMENTS

RESOURCES OF PLASTIC WASTE

PLASTIC RECYCLING AND ITS IMPORTANCE

THE FOLLOWING ARE THE 6 COMMON TYPES OF PLASTICS

CHALLENGES FOR PLASTIC RECYCLING INDUSTRY

B.I.S. SPECIFICATION

TYPES OF RECYCLABLE PLASTICS

POLYSTYRENE –

POLYPROPYLENE –

LOW-DENSITY POLYETHYLENE –

POLYVINYL CHLORIDE (PVC) –

HIGH-DENSITY POLYETHYLENE (HDPE) –

POLYETHYLENE TEREPHTHALATE (PET) –

NUMBER 1: PETE (OR PET) – POLYETHYLENE TEREPHTHALATE

NUMBER 2: HDPE – HIGH-DENSITY POLYETHYLENE

NUMBER 3: PVC – POLYVINYL CHLORIDE

NUMBER 4: LDPE – LOW-DENSITY POLYETHYLENE

NUMBER 5: PP – POLYPROPYLENE

NUMBER 6: PS – POLYSTYRENE

OVERVIEW OF PLASTIC RECYCLING

STAGES IN PLASTIC RECYCLING PROCESS

1. COLLECTION

2. SORTING

3. WASHING

4. SHREDDING OR RESIZING

5. IDENTIFICATION AND CLASSIFICATION OF PLASTIC

6. COMPOUNDING OR EXTRUDING

SEQUENCES IN PLASTIC RECYCLING

● COLLECTING

● SORTING

● SHREDDING

● WASHING

● MELTING

● PELLETIZING

DETAILS OF PLASTIC RECYCLING PROCESS

THE PLASTIC RECYCLING PROCESS STEPS

1. COLLECTION + DISTRIBUTION

2. SORTING + CATEGORIZING

3. WASHING

4. SHREDDING

5. IDENTIFICATION AND SEPARATION OF PLASTICS

6. EXTRUDING + COMPOUNDING

PROCESS OF MANUFACTURE TO PRODUCE COLORLESS TRANSPARENT PLASTIC GRANULES FROM WASTE

SORTING

SMASHING

WASHING

CONCENTRATION OF BLENDING

SOLVENT ADDITION

REMOVAL OF COLOUR TO OBTAIN TRANSPARENT GRANULES BY ACTIVATED CARBON TREATMENT

FILTERATION

DISTILLATION

COOLING AND DEHUMIDIFYING

GRANULATION

WEIGHING, FILLING AND PACKING

MANUFACTURING PROCESS FLOW SHEET FOR PLASTIC GRANULES FROM PLASTIC SCRAP

PLASTIC RECYCLING PLANT

TECHNICAL SPECIFICATION

A EXTRUDER

GENERAL PROCESS OF MANUFACTURING:-

SORTING:-

SMASHING & WASHING:-

CONCENTRATE & BLENDING:-

SECTION EXTRUDING IST STAGE:-

FILTRATION:-

SECTION EXTRUDING IIND STAGE;-

DRAWING & PELLETIZING:-

COOLING AND DEHUMIDIFYING:-

PACKING & STORAGE:-

MANUFACTURING PROCESS FLOW CHART

RECYCLING POLYETHYLENE TEREPHTHALATE (PET)

RPET IS EMPLOYED FOR NEW PRODUCTS SUCH AS:

PET COLLECTION AND SORTING

PET RECYCLING IN INDIA

STEP 1:  REACHING THE WASTE STREAM, GETTING COLLECTED

STEP 2: SORTING AT THE KABADIWALLAHS

STEP 3: AT THE PET RECYCLERS—SORTING (ONCE AGAIN), CLEANING, FLAKING

PROCESS OF PET RECYCLING UNIT

SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT

PROCESS FLOW DIAGRAM OF PET RECYLING

EXISTING POLICY AND REGULATION FOR PLASTIC RECYCLING INDUSTRY IN INDIA

TABLE: CIRCULARITY IMPLICATIONS OF LEGISLATIVE AND REGULATORY FRAMEWORK FOR PLASTICS IN INDIA

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

IMPLEMENTATION SCHEDULE

EFFLUENT TREATMENT AND DISPOSAL

STANDARDS

TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE

WASTE TREATMENT

PRIMARY TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SOLIDS CONCENTRATION

TYPICAL WASTE SOLIDS CHARACTERISTICS

EQUIPMENT REQUIREMENT

EQUIPMENT REQUIREMENTS

MANPOWER

GENERAL

BASIS OF ESTIMATION

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF PLASTIC RECYCLING PLANT

COMPLETE PLANT SUPPLIERS FOR PLASTIC GRANULES FROM WASTE

SUPPLERS OF PLANT & MACHINERY

SUPPLERS OF REACTION VESSEL

SUPPLERS OF GRANULATORS

SUPPLERS OF MIXER

WASTE RAW MATERIAL SUPPLIERS ADDRESSES

PLASTIC PROCESSING MACHINERY SUPPLIER IN INDIA

MACHINETY AND PROCESS KNOW HOW

PLASTIC TESTING LABS IN INDIA

LIST OF PLSTIC SUTLI MANUFACTURE AND TRADERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)