Detailed Project Report

STICK
(A composite made of waste plastic and industrial by-products)

Under Guidance- PANKAJ PORWAL

(Principle Techno India NJR Institute of Technolog')

94604A1t75
sachingoyal92 I I @grnail.com
kpr aj ap at87 9 @g mai I. com
[email protected] 9694151808

*4
 Index

S.no. Title Page no.

I Introduction J

l1 Problems J

r.2 Solution 4

2 Objective

3 Technology 6

3.1 Raw materials

).2 Processing 9

J.J Testing 11

4 Planning t2

4.1 Research & Development I-J

5 Time frame t+

5.1 Stage I 15

5.2 Stage 2 16

o Stage 1 -Proposed Products tt

7 Stage 2-Proposed Produets i8

8 Company details 19-20

9 Accoiiiit Detd'ils 2T

10 References 2l
 Introduction
Problems-
WasG plastic, demolition waste, fly ash, arrd malble slurry are among top wastes in the world in td3ms of
annual generation, Annually we generate 200 miiliou tons of tiemoiition waste; I miliion tons o{waste
plastic, 1.63 million tons of fly ash, and 6 million tons of marble slurry. Approx.20,000 plastic bottles
are manufacturing per-second in whole world. Only 1a/o water bottles are recycling in present
scenario.

Some applications have been identified for each of the waste but none of them have been successd.ri
enough to coasirne all the wzistes. Thus large qu{xltities ofthese wa$es still go to tlie laridfills oi dijrilped
in open yards. fhe problem is more severe in developing countries like India where lack on environpental
awareness results ifl most of these wastes being dumped in open dumping yards or by the road sides and
in empty plots,

Our innovative technology combines all these wastes in a synergistic manner to make bricks, paver $locks,
tiles and panels for low cost housing. In these products the molten plastic acts as binder, tlre fly 4sh and
eraishei wrastes act as frl1er lmd the liidfble Slutry aets both AS fi1lef €iiid fife reaidiriit to iiilBfove the fue
resistance properties ofthe final produots.

The preliminary results obtained from tJre prototype brieks me very promising, The performance of these
brick on parameters of strength, soundness, bonding with mortar, drop test, ha.rdness test is comparpble to
first class bricks, which is a huge achievement at this stage. With detailed research and optimizaiion of
mix proportion we are confident that this technology can be commercialized for mass production.

Fig- Marble Slurry Waste tr'ig- Ilemolition Waste

Fig.- Fly Ash Waste

 a{

Our Solution- SLICK

We have developed technology to make low cost & high quality bricks and other related products
misplaced resources-

1. Waste Plastic

2. Marble Slurry

3. FfyAsh
4. Crushed Demolition Waste.

@E r!;nilt

,]
 Objectives

1. Study and select suitable filtering mechanism to minimum environmental impact ofemissions.

2. Explore use of screw compounder for heating and mixing of the waste plastic and other waste
materials.

3 . Study and optimize various processing parameters like pre-heating time and temperature, mixing time
and temperature etc. to minimize emission of gases and optimize the mechanical and physical
properties of various products.

4. Enhaace fire resistance of various products by using suitable admixtures to make them safe for
residentialzmd coiilinorcial 06iistiu0ti6n.

5. Optimize the mix proporiion and compaction pressure for different classes ofbricks for corresponding
strength and other mechanical and physical propedies.

6. Develop and test new products iike tiles and panels for low cost housing using optimized

7. Explore the effect of different plastics on properties ofvarious products.

8. Market research on quantities and prices of different types waste plastics generated.

o Explore other waste materials that can be used as filler and their effect on properties of our products.

10. Market research to identiry quantities and cost of various waste material avaiiable to develop area
specific cost estimate for various products.

11. Obtain qu{ility oefiifioation for v,liioris produets froIi,i acere(lircd laboratories.
 A)

Technology
1. Raw Materials-
ln making siick we used several raw matcrials as fgllows-

a) Marble Slurry

b) Waste Plastic

c) Fly Ash and

d) Crushed Demolition Waste.

a) Marble slurry-
Marble ranks the largest produced naturai stone in the world and it accounts
for 50% ofthe world's natural stone production. Around 9070 ofthe wodd's production ofmarble comes
from India and approx 85% of India's production is received from Rajasthan and almost all mining and
processing activities are concentrated around Udaipur, where the proposed study is planned to undertake.
Rajasthan has around 4000 marble mines and about 1100 marble gang saws (processing plants). The
industry involves Mines, Processing plaats, Cutters for the production oftiles for walls and floors, arlicles,
waste reproduction and other ancillary works.

In a recent judgment passed by the Rajasthan High Court, Chief Justice Arun Mishra said:

"There are 250 marble processing units in the Sukher industrial area and they are dumping about
70 tones ofslurry daily as a result of which about 700x500 meters ofthe valley has been ruined.

Properfies - The average chemical composition (in %) of marble of Rajnagar - Kelwa belt near Udaipur
is siven below.

Sample No. 1 (inoh) 2 (in o/o) 3 (in %)

Sioz 7.58 t1.44 0.32

teluS 0.73 0.72 0.64

CaO 30.34 29.40 32.65

Mgo t6.99 12.28 21.29

L,O.I 43.94 44.76 45.06

So3 0.34
 a1

b) Plastic Waste-
About 20,000 bottles being bought every second. More than 480 billion
plastic drinking bottles were sold in 2016 across the world, up from about 300 billion a decade ago. If
placed end to end, they would extend more tlan halfway to the sun.By 2021this wiil increase to 583.3
billion, according to the most up-to-date estimates from Euro monitor Intemational's globai packaging
trends report. Fewer than half of the bottles bought in 2016 were coilected for recycling and just 7% of
those collected were tumed into new bottles. instead most plastic bottles produced end up in landfill or
in the ocean.

Waste plastic Available as

Poly-ethylene terephthalate (PET) Drinkin€ water bottles etc.

Plastic properties-

S. No Property Value
1. Density at 20"C 1.38 g/cc
2. Elastic modulus 2.8 - 3 GPa

J Tensile strength 55 - 75 MPa

4 Elongation at break (%) 50 - 150 Yo

5 Thermal conductivity 0.15 - 0.24 W m-] K-l
6 Ignition temperature 350" C
Note - Results were talan from Chennai central institute of plastic engineering and technologies

c) Fly ash-
Fly ash is thq finely divided residue that {esults from the combusiion of pulverized
coal and is transported from the combustion chamber by exhaust gases. Over 61 million metric tons
(68 million tons) offly ash were produced in 2001.
Fly ash is produced by coal-fted electric and steam generating plants. Typically, coal
is pulverized and blown with air irrto the boiler's combustion chamber where it immediately ignites,
generating heat and producing a molten mineral residue. Boiler fubes extract heat from the boiler,
cooling the flue gas and causing the molten mineral residue to harden and form ash. Coarse ash
particles' refencd to as bottom ash or s1ag, fal1 to the bottom ofthe oombustion chamber; while the
lighter frne ash padicles, termed fly ash, remain suspended in the flue gas. Prior to exhausting the flue
gas, fly ash is removed by particulate emission control devices, such as electrostatic precipitators or
fi lter fabric bashouses.
 Properties-

Components Flv ash class F (7o) Fly ash class C (Yo)

Sioz ff 40
Alz0r 26 17
Fe2O3 7 5

CaO (Lime) ,,, -." ---

a/l

Mgo 2 f,

SO: 1 3

d) Demolition waste.

Demolition waste is waste debris from destruction of buildings, roads, bridges, or other
structffes. Debris varies in composition, but the major components, by weight, in the US
include concrete wood products, asphalt shingles, brick and clay tile, steel, and drywall. There is the
potential to recycle many elements of demolition waste.
Construction and demolition (C&D) activities genei€ite a wide rarige of industrial waste matefi{iIs
including:

o Exoavarted nlateiial sUch as fock arnd s6il.

o Waste asphalt' brioksi sonorete, plastcrboard, timber and vegetation,
o Asbestos and contaminated soil.

Ifnot managed responsibly, these waste streams can pollute the envilonment, pose a public health risk
(particularly asbestos and contaminated soil) and pose amenity issues.

Properties-

S.no. Physical Properties Tcst Results

i maximum size(mm) 20
2 Fineness modulus 7.38
J Speoific gravity 2.64
4 Bulk density kg/rn3 t356-r570
5 Water absorption(%) 0.55
o Moisture Cohten(%) A1
2. Processing-

Most common method in which marble s1urry is usod in various produots is with gemerrt
to make bricks and other related product. But such products exhibit high efflorescence loading to inferior
quality. This happgns because of pre$ence of water 44d hydra!!o11 pXoeesg.

In our pfoduct we have all togexhef ellninated the use of water imd cemenl. Iilstdad we
use molten plastic as binding material and marble slurry + fly ash and demoiition v/aste act as filler
material. Use of marble slurry inffeases tl1e density irnd reduces porosiq/ of the final productt a {d thus
enhances the mechanical properties ofthe final product.

Composition Of Slick-

Plastic @ET) Fine Aggregate Coarse Aggregate

Materials Marble
Fly Ash Crusher Sand Demolition Waste
Slurry
ltratio 1 0.67(Combifled) L67(Comblned)
Density I .3 8 g/cm3 1.5 g/cm3 2,80 glcm3 1.52-1..68 glcm' 1.17 -2,67 glcms
Particle 20nm- 0.5 pm-
25-7 5pm 1smrn 40-6Omm
siz6 1 000rrricroris 300 rm
Melting 2500c
Point
Boiling
3500c
Point

Processing Steps of slick-

a) To make the bricks with marble slurq/, waste plastic and demolition wastet the waste plastio was
heated in oven up to 2500 C,

b) The Demolition waste + Fly ash and marble slurry were added to molten plastic and this mixture
was poured into a mould iind eomptessed by applying lkN load and allowed td cdoi dowil

c) For preliminary study a block of size 70 mm x 70 mm x 65 mm was cast where *Ie waste
plastic, marble qlurry + Fly ash, and Demolitiqr wa$tq we:e used in 1:0,67:1.67 ratio by wqighl'
d) The Fly ash was well graded and the particle size of s1urry was less than 600 micron. The block
was tested for oompressive strengli in UdiVerSdl Testing Maihine.

e) 'Lhe compressive strength of the speoimen was 6 NlPa his is very close to the compressive sffength
of second class bricks.
 Fif,i Typical moiildirig itioaCas

Raw material processing

Plastic nrelting

Compressing Moulding Pouring

3. Preliminary Test -
13I
a) Compressive Test-
112
l0
Coihitrcssivo Strongth- 6 MPa t.?5
,5
14,'
x
5F

$.r
2.S

r.2t

20 a0 80 !0 18 n0 rao rao {l
Iamo S€c

b) Pult Out Test-

Bond strength - 0.14 Mpa

e) Hardress test- Not ssrateh from nails,

d) Soundness test= Good metallic sound.

e) Water Absorption Test- Almost no water absorption.

11
 Planning
18 Month Plan-

4r..."r)\
Target

t""y 4,, ;
Delivr !ry

Ar"")\
Testing/
6*\
' Analysis & \

q-*-17 q*-iil
Product

Timeline
(month)

3 12 15 8

Optimal Consumer
Product Design Feedback
Finalizc
Initial Order J,

Sample
Delivery
for l}iai

L2
 rt@

Research & development

1. Optimal product design- To get Optimum Product Design we will cast several nuniber of
samples with different proportion of all constituents. As the maximum strength obtained out of diifferent
ratios, is finaiized for further development ofmarket available oroduct.

2. Trial Batch testing Specification - In slick, we decided to test our product thoroughly before
sending it to the main stream market because we think quality is important over quantity. For this purpose
we decided to make some ftial samples of each product and to perform various test on it. In testing we
have plan to test sample timely and will note down the results and will study this resuits and try to improve
our product.

3. Product to Target Customers We decided to make our products oustomer friendly. Our all
-
products are exactly like normal one with more eco-friendly material. The price of our product will pe low
as compare to the similar product in market. We are keep trying to reduce our product cost.

4. Sample Delivery for Trial- Review is very essential in any industry so we are planriing to
distribute our test samples to retailer. whole seller. customer to use it and evaluate it.

5. ConsUrnei Feedback- Feedback reflects response of any product and we believe it is true.
Delivering our products for trial, we will record all the reviews and suggestions tluough online portal,
social media aad verbally.

6. Result Analysis & Product Optimization- Timely analysis of product shows it pro and cons.
we will analyse the feedback which was recorded in earlier trial period from customers. We will sep what
is customers demand and where we failed in our earlier trial stage. We will work on this requiremelnt and
try to optimize our product accordingly.

7. Finalize Inifial Orders- Amlyse and improving the product thoroughly now our product i$ ready
to launch. We will starl accepting orders from customers. Our plan is to received order offline aqd then
will think to expand our business tlrougb online according to market response.

8. Initial Order Delivery - Accepting the orders from customer we will try to deliver products
tlrough our distribution channei i.e. factory to diskibutor then to whole sel1eq from whole seller to
and finally to customer.

_15
 Time frame

lehaserl-E

Phase 1: Design, settlement, develop components of solution

Phase 2: Fabrication and development ofprototype

Phase 3: Testing, validation and fine tuning

Budget- 15,00,000

St.nge 1- for 12 month

^ Machinqs & Equipments I,90,000

b Matild$,Itaw q?terials 44,300
Stipend & overhead '7,70,000
d Lab testing & Labour charge 1,22,000
Total 11.26.295

Stage 2- for 6 month

Stipend & overhead

Lab & Laboure
Total
 Stage 1- 12 month plan

Quantity of Raw materials.,

s.
no. Ratio sample fiue cq4r!9 total
Product (Plastic : F.A. plastic aggreg4te(kg) aggregate(lrg) No. of quantity
Quantity (kc)
: C.A.) (kc) marble fly demolition crusher samples for samples
slurry ash wasfe sand (kc)
I Planter I 0,67 1.67 J.l I l.)J 0.51 100
0.51 1.28 1.28 il1,00
2 Louvers 0,67 L67 6,89 2.06 0,69 0,69 t,72 1,72 100 689,00
3 Paver 100--
0.67 1.67 2.59 0.78 0.26 0.26 0.65 0.65 259.00
blocks
Total 436.83 146,34 146.34 364.75 364,75 300 1459.00

Detailed Estimate-
s.no. Activity Qxandft unit Rate nlt Afioiin {
I Raw material
ll Matble slurry 146.34 kg per kg
3 439.1 2
1.2 Plastic 436.83 kg 30 per kg 13,10, .9
I.J Fly ash t 46.34 kg 4 per kg )d).1 6
1.4 Demolition waste 364.75 kg 2 per kg 729.
I,J erusher sand 354.75 kg 1.23 per kg 436,3425
2 Mould
2.'l Paver Blocks 2 no. 7500 15,0010
z.J Plzrntef I no. 10000 per piece i0,0( c
2.4 Louvers 1 no. 4000 per plece +,9'01
J Machine & Equipnnenis
J.l Extruder I no, 100000 per plece 10,00 r0

Sbredder I no. 40000 pe! plese 40,0( l

3.3 hydraulic press 1 no. 50000 per piece s0,0c

4 Lab testiiig 1 no. 50000 50,00

5 Iabour charge I no. 72000 per person 72,04

6 overhea{ charges 1 no. 50000 per persojr 50,00

Total 4,06,295. lttl
7 Stipend (15,000 rs) 4 180000 1200( l
Grand total 11,26,29! .123
 Stage 2- for 6 month

Fine total
s, Ratio Sample aggregate(kg) Coarse aggregate(kg) No,
no Product Plastic quantity
(Plastic : F.A. Quantity of
: C.A.) (kg) Marble Flv Denolifio Crusher Sam.
for
(ke)
slurry ash n waste Samples
sand ples
Garden
1
pots 1 0.67 1.67 i3 3.89 t.30 1.30 3.25 3.25 30 390.00
2 Bricks 1 0.67 t-o I 2.65 0.79 0.27 0.27 0.66 0.66 30 79.50
3 Urinals 1 0.67 r.o/ 14.5 4.34 1,45 1.45 3.63 J.OJ 30 435.00
Tree
/l
guard 1 0.67 1.67 66 19.76 6.62 6.62 16.50 tr- 30 i980.00
Total 863.62 289.31 289,31 721.13 72r.13 120 2884.50

Detailed Estimate-
s.no. Activity unit Quantity Rate unit Amoull r
1 RaiV niAteiiel
1.1 Marble sluny kg 289.3r per kg 867.93
1.2 Plastic kg 863.62 30 per kg 25908.(
Fly ash kg 289.31 4 per kg 1151,24
t.4 Demolition waste kg 721.13 2 per kg 1AtJ )n
l.) crusher sand kg 721.13 1.23 per kg 886.9899
2 Moulds
2.1 Garden pot no. 2 10000 Der Dlece 20000
2.2 Brick no. 2 3000 per piece 5000
Urinals 1lO. 7500 per piece 7500
2.4 Tree guard no. I 12500 per piece 12500

J Lab testing no. 1 50000 50000

n
labour charge no, I 36000 pef pefson 36000

5 O-,v-erhelC,charges no. 10000

1
.....p.!f person 10000
__--:__.---.-
-------___.-----
I
----T
Total 1122$,qtl 9

Stipend (10,000 rs.) |

I 240000
( ;rand total 472263.01! I
 Stage l.Proposed Products

Fig.- lduvers Fig.- Paver blocks

Fig.- Planters
 Stage 2-Proposed Products

ll
'lt:tl
i

Fig.-Urinals Fig.- Tree Guards

Fig.- Bricks Fig.- Pots

L8
 o

Company Details

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Colsdtodon of Bu5lress Propriao'rship

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20