UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ASSIGNMENT (PAIR WORK)
BMFB 2213
MATERIAL ENGINEERING
SEMESTER 1 SESSION 2010/2011
FACULTY OF MANUFACTURING ENGINEERING
ROBOTIC AND AUTOMATION (BMFA)
NAME OF MEMBERS:
NORAIDAH BTE BLAR B050910225
RADIN PUTERI HAZIMAH BINTI RADIN MONAWIR B050910192
NAME OF LECTURER:
EN. JEEFFERIE BIN ABD. RAZAK
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ACKNOWLEDGEMENT
First and foremost, we would like to thank to our lecturer for our Material Engineering subject,
Mr. Jeefferie bin Abd. Razak for his valuable guidance and advice. His willingness to motivate
us contributed tremendously to our project and our study for this subject. We also would like to
thank him for showing us some example that related to the topic of our project.
Besides, we would like to thank the authority of all hostels in Universiti Teknikal Malaysia
Melaka (UTeM) for providing us with a good environment and facilities to complete this project.
Finally, an honorable mention goes to our families and friends for their understandings and
supports on us in completing this project. Without helps of the particular that mentioned above,
we would face many difficulties while doing this project.
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ABSTRACT
Nowadays, the world is facing with the gigantic problems on the wastes from human. Everyday,
people will consume large amount of waste. Therefore, quick action should be taken to overcome
these dangerous problems. One of the effective steps is by recycling the waste according to its
categories. Wastes that can be recycled include glass, paper, metal, plastic, textiles,
and electronics. Among all these recycled waste, we choose plastics as our research. We choose
plastics because to find out types of recycle materials and select a material to be studied, to
appreciate the engineering material for sustainable use by studying the process of plastic recycle,
to recognize the properties of recyclable plastics and the its product of recycled, to investigate
the manufacturing process that involved in the plastic recycling process, and to find out the latest
advanced technology and recycle of plastics. Besides that, we find a lot of information about
plastics as recyclable materials: types, characteristics, symbols etc. Next, we were searching on
the advanced technology on recycling plastics. There are many products that can be produced by
the recycled plastics. In this report, we include two products along with their process of making.
First, we discover that recycled plastic bags can be used as biofuel. Second, the recycled plastic
bottles can be used as mini car. Overall, we found out that there are many products can be
produced by the waste materials and how important recycling in human daily life.
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TABLE OF CONTENT
CHAPTER TOPIC PAGE
ACKNOWLEDGEMENT 2
ABSTRACT 3
1 INTRODUCTION
1.1 Background 5-6
1.2 Objectives 6
1.3 Scope 6
2 PLASTICS RECYCLING 7-17
3 RESULTS AND DISCUSSION 18-25
4 CONCLUSION 26
REFERENCES 27
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CHAPTER 1
INTRODUCTION
1.1 Background
Recycling involves processing used materials (waste) into new products to prevent waste
of potentially useful materials, reduce the consumption of fresh raw materials, reduce energy
usage, reduce air pollution (from incineration) and water pollution (from landfilling) by
reducing the need for "conventional" waste disposal, and lower greenhouse gas emissions as
compared to virgin production. Recycling is a key component of modern waste reduction and
is the third component of the "Reduce, Reuse, Recycle" waste hierarchy.
Recyclable materials include many kinds of glass, paper, metal, plastic, textiles, and
electronics. Although similar in effect, the composting or other reuse of biodegradable waste
– such as food or garden waste – is not typically considered recycling. Materials to be
recycled are either brought to a collection center or picked up from the curbside, then sorted,
cleaned, and reprocessed into new materials bound for manufacturing.
In a strict sense, recycling of a material would produce a fresh supply of the same
material—for example, used office paper would be converted into new office paper, or used
foamed polystyrene into new polystyrene. However, this is often difficult or too expensive
(compared with producing the same product from raw materials or other sources), so
"recycling" of many products or materials involve their reuse in producing different materials
(e.g., paperboard) instead. Another form of recycling is the salvage of certain materials from
complex products, either due to their intrinsic value (e.g., lead from car batteries, or gold
from computer components), or due to their hazardous nature (e.g., removal and reuse of
mercury from various items).
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Although there are many types of recyclable material, plastics are the most common
waste product that usually polluted the landfill. Just imagine, the amount of solid waste
generated in Peninsular Malaysia was 19,100 tons in 2005, and 24 % of it was plastics
waste. In Europe for example, it is estimated that 100 million tonnes of plastics are produced
each year. As we are believing that this all plastic waste is not a really a waste but a wage, we
decided to do a study on plastic recycling process. In order to complete this assignment, we
gathered the information about the basic chemical and physical properties of plastics, process
to recycle it and the product that able to be produced from it. The most interesting part is the
advanced technology, where the latest research and find of recycled plastics is unearthed.
1.2 Objectives
The main objectives of this assignment are:
i. to find out types of recycle materials and select a material to be studied.
ii. to appreciate the the engineering material for sustainable use by studying the
process of plastic recycle.
iii. to recognize the properties of recyclable plastics and the its product of
recycled.
iv. to investigate the manufacturing process that involved in the plastic recycling
process.
v. to find out the latest advanced technology and recycle of plastics.
1.3 Scopes
In this assignment, we have limited the scope of recycling materials to plastic only. Only
certain characteristic of plastic which is related to its ability to be recycled is discussed;
properties that make the plastic can be recycled and type of plastics that can be recycled. In this
assignment, although we have stated many types of recycle product of plastic, we only highlight
a product which is plastic lumber to be discussed in term of its manufacturing process and used.
For advanced technology, a few example of latest research is stated.
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CHAPTER 2
PLASTIC RECYCLING
2.1 Plastic as a recyclable material
Plastic recycling is the process of recovering scrap or waste plastics and reprocessing the
material into useful products, sometimes completely different in form from their original
state. For instance, this could mean melting down soft drink bottles and then casting them as
plastic chairs and tables. Typically a plastic is not recycled into the same type of plastic, and
products made from recycled plastics are often not recyclable.
2.1.1 Properties of plastic
The term “plastics” is used to describe a wide variety of resins or polymers with different
characteristics and uses. Polymers are long chains of molecules, a group of many units, taking its
name from the Greek “poly” (meaning “many”) and “meros” (meaning “parts” or “units”).
The term “polymer” is often used as a synonym for plastic, but many other types of
molecules — biological and inorganic — are also polymeric. While all plastics are polymers, not
all polymers are plastic. Polymers are rarely useful in themselves and are most often modified or
compounded with additives (including colours) to form useful materials. The compounded
product is generally termed a plastic. Most people have little contact with "polymers" because
most articles that they come across are actually modified and coloured and therefore are actually
plastics. Polymers can be classified in many ways, based on how they are developed and
perform. For this discussion of recycling, an understanding of two basic types of polymers is
helpful:
Thermoplastic polymers can be heated and formed, then heated and formed again and
again. The shapes of the polymer molecules are generally linear or slightly branched.
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This means that the molecules can flow under pressure when heated above their melting
point.
Thermoset polymers undergo a chemical change when they are heated, creating a three-
dimensional network. After they are heated and formed, these molecules cannot be re-
heated and re-formed.
Comparing these types, thermoplastics are much easier to adapt to recycling.
2.1.2 Properties that make plastic hard to be recycled
When compared to other materials like glass and metal materials, plastic polymers
require greater processing to be recycled. Plastics have a low entropy of mixing, which is due to
the high molecular weight of their large polymer chains. A macromolecule interacts with its
environment along its entire length, so its enthalpy of mixing is large compared to that of an
organic molecule with a similar structure. Heating alone is not enough to dissolve such a large
molecule; because of this, plastics must often be of nearly identical composition in order to mix
efficiently.
When different types of plastics are melted together they tend to phase-separate, like oil
and water, and set in these layers. The phase boundaries cause structural weakness in the
resulting material, meaning that polymer blends are only useful in limited applications.
Another barrier to recycling is the widespread use of dyes, fillers, and other additives in
plastics. The polymer is generally too viscous to economically remove fillers, and would be
damaged by many of the processes that could cheaply remove the added dyes. Additives are less
widely used in beverage containers and plastic bags, allowing them to be recycled more
frequently. The use of biodegradable plastics is increasing. If some of these get mixed in the
other plastics for recycling, the reclaimed plastic is not recyclable because the variance in
properties and melt temperatures.
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Figure 1: mixed waste plastic requiring sorting before it can recycled
Hence, in order to recycle plastic, we have to separate the plastic according to
identification code first. The recycling process is easier when different types of plastic are not
mixed together.
2.1.3 Plastic identification code
Plastic Identification code (PIC), PIC was introduced by the Society of the Plastics
Industry, Inc. which provides a uniform system for the identification of different polymer types
and helps recycling companies to separate different plastics for processing.
Figure 2: Plastic Identification Code(PIC) of Polyethylene
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Type number of plastic polymer
Indicate the plastic can be recycled
Abbreviation of plastic name
Consumers can identify the plastic types based on the codes usually found at the base or
at the side of the plastic products, including food/chemical packaging and containers. The PIC is
usually not present on packaging films, as it is not practical to collect and recycle most of this
type of waste.
Plastic
Identification
Code
Type of plastic polymer Properties Common Packaging
Applications
Polyethylene terephthalate
(PET, PETE)Clarity, strength,
toughness, barrier to
gas and moisture.
Soft drink, water and
salad dressing bottles;
peanut butter and jam
jars
High-density polyethylene
(HDPE)Stiffness, strength,
toughness, resistance
to moisture,
permeability to gas
Water pipes, Hula-
Hoop (children's
game) rings, Milk,
juice and water
bottles; the occasional
shampoo / toiletry
bottle
Polyvinyl chloride (PVC) Versatility, clarity,
ease of blending,
strength, toughness
Juice bottles; cling
films; PVC piping
Low-density polyethylene
(LDPE) Ease of processing,
strength,toughness,
flexibility, ease of
sealing, barrier to
moisture.
Frozen food bags;
squeezable bottles,
e.g. honey, mustard;
cling films; flexible
container lids.
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Polypropylene (PP Strength, toughness,
resistance to heat,
chemicals, grease and
oil, versatile, barrier
to moisture.
Reusable
microwaveable ware;
kitchenware; yogurt
containers; margarine
tubs; microwaveable
disposable take-away
containers; disposable
cups
Polystyrene (PS) Versatility, clarity,
easily formed
Egg cartons; packing
peanuts; disposable
cups, plates, trays and
cutlery; disposable
take-away containers;
Other (often polycarbonate
or ABS)
Dependent on
polymers or
combination of
polymers
Beverage bottles;
baby milk bottles;
electronic casing.
Table 1: Plastic Identification Code (PIC) table
2.2 Recycle process of plastic
Industrial waste (or primary waste) can often be obtained from the large plastics
processing, manufacturing and packaging industries. Rejected or waste material usually has good
characteristics for recycling and will be clean. Although the quantity of material available is
sometimes small, the quantities tend to be growing as consumption, and therefore production,
increases. Commercial waste is often available from workshops, craftsmen, shops, supermarkets
and wholesalers. A lot of the plastics available from these sources will be PE, often
contaminated. The following flow chart is plastic reprocessing in low income country.
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Figure 3: Flow chart of a typical plastic reprocessing in a low-income country.
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-Plastic is washed and chopped into flakes.
-mixed plastic sorting into floatation tank,some types of plastic will float, other sink.
-plastic are dired in tumble dryer
-drying flakes fed into ectruder, melt by pressure and heat.
-different plastic melt at different temperature
-molten plastic forced through fine screen,remove any contaminant.
-molten plastic is then formed into strands
-stands is cooled in water and then chopped into uniform pellets.
Figure 4: Plastic manufacturing techniques; extrusion (top), blow molding (middle) and
injection molding (bottom).
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2.3 Common product of recycled plastics
There is an almost limitless range of products that can be produced from plastic.
However, the market for recycled plastic products is limited due to the inconsistency of the raw
material. Many manufacturers will only incorporate small quantities of well-sorted recycled
material in their products whereas others may use a much higher percentage of recycled
polymers. Much depends on the quality required.
In developing countries, where standards are often lower and raw materials very
expensive, there is a wider scope for use of recycled plastic material. The range of products
varies from building materials to shoes, kitchen utensils to office equipment, sewage pipe to
beauty aids. The type of plastic and its product of recycled is shown as in the table below:
Type of plastic Product of recycled
Polyethylene
terephthalate
Cleaning products or other non-food containers, egg
cartons, strapping, surfboards, sailboat hulls, industrial
paints, and fiber products (t-shirts, jackets and carpets).
High-density polyethylene
Plastic lumber, base cups for soft drink bottles, flower
pots, plastic toys, traffic barrier cones, bottle carriers,
trash cans, detergent bottles, garbage bags and grocery
bags.
polyvinyl chloride
drainage piping, fencing, handrails and house siding
polypropylene auto parts, batteries, bird feeders, furniture, pails, water
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meter boxes, bag dispensers, golf equipment, carpets,
recycling containers, and industrial fibers.
polystyrene or
polystyrene foam
polystyrene products as well as insulation, plastic
lumber, license plate frames, cafeteria trays, and hard
plastic pens.
Table 2: Type of plastic and recycled product
2.3.1 Lumber plastic as a product of recycled plastic
Plastic lumber (PL) is a 100% recyclable material lumber or timber made
of recycled plastic. It is composed of virgin or waste plastics
including HDPE, PVC, PP, ABS, PS and PLA. The powder or pellets are mixed to a dough-
like consistency at roughly 400 degrees F and then extruded or molded to the desired shape.
Additives such as colorants, coupling agents, stabilizers, blowing agents, reinforcing agents,
foaming agents, lubricants help tailor the end product to the target area of application. The
material is formed into both solid and hollow profiles or into injection molded parts and
products.
Resin, regrind, and most of the additives are combined and processed in a pelletizing
extruder. The new material pellets are formed in mold and cooled. Pre-distribution testing
can help determine the optimal combination of chemical agents, design, agitation and other
flow aid strategies for the specific material in use. Modern testing facilities are available to
evaluate materials and determine the optimal combination of equipment components to
assure the highest level of accuracy and reliability. Computerized performance test reports
document equipment performance.
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Figure 5: Various colour of plastic lumber
Figure 6: Table that make of plastic lumber
Plastic Lumber is still a very new material relative to the long history of natural lumber as
a building material but can be substituted in many instances. Besides being 100% resistant
to rot, the major advantage of this category of building materials is its ability to add another
stage of reusability. Unlike wood-plastic composite lumber, plastic lumber is 100%
recyclable after its original intended use.
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A major advantage over wood is the ability of the material to be molded to meet almost
any desired spatial conditions. It can also be bent and fixed to form strong arching curves.
Plastic lumber behaves like wood and can be shaped using conventional woodworking
tools. At the same time, it is water proof and resists all types of rot and mold, although they
are not as rigid as wood and may slightly deform in extremely hot weather. The material is
not sensitive to staining from a variety of agents. A major selling point of this material is its
lack of need of paint as it is manufactured in a variety of colors, but are widely available in
grays and earth tones.
Plastic lumber is more environmentally friendly and requires less maintenance than the
alternatives of wood/plastic composites or solid wood of rot-resistant species. Impervious to
cracking and splitting (with correct installation), these materials can be molded with or
without simulated wood grain details. Even with the wood grain design these materials are
still visually easy to distinguish from natural timber as the grains are the same uniform color
as the rest of the material. Well-known trade names include MAXiTUF and Bear Board.
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CHAPTER 3
DISCUSSION AND RESULTS
3.0 Advanced Technology of Plastics
3.1 Definition
The terms chemical recycling and feedstock recycling of plastics, sometimes collectively
referred to as advanced recycling technologies, describe a family of plastics recycling processes
that convert solid plastic materials into smaller molecules (chemical intermediates). These
chemical intermediates, which can be liquids or gases or solids, are suitable for use as feedstocks
for the production of new petrochemicals and plastics. The process can be likened to separating a
long freight train into its individual railroad cars in a freight yard, and then putting the train back
together, perhaps in a slightly different form, at a later time. These technologies can complement
conventional mechanical recycling, a process that directly recovers clean plastics for reuse as
high molecular weight plastics in the manufacture of new plastic products. The intention of
advanced recycling technologies continues to be the processing of materials not suitable for
successful mechanical recycling into useful chemicals. The challenge has been to find robust
technologies and satisfactory business models.
Like all plastics recycling processes, technical and economic feasibility and overall commercial
viability of advanced recycling methods must be considered at each step of the recycling chain.
Collection, processing, and marketing are each critical to the success of chemical and feedstock
recycling. Today, with few exceptions, these technologies remain developmental and have not
yet proven themselves sustainable in a competitive market. Nevertheless, they remain of
considerable interest for their longer term potential.
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3.2 Plastic Bags to Power
Entrepreneurs have been trying for years to turn low-value wastes into high-value products.
Waste plastic is among the lowest in value, and gasoline or diesel fuel the highest, but machines
that carry out that conversion usually consume a lot of energy and get gummed-up by leftover
material that they cannot convert.
Rather than languishing in landfills or littering roadsides, plastic bags could make their way into
useful products like toner, lubricants, or rechargeable cell phone or laptop batteries, if new
research becomes commercialized. Plastic recycling is limited by the fact that different types of
plastic cannot be mixed. The quality of the resulting recycled plastic may also be poor. That is
why recycling is not very successful. If the plastics bags degraded, we can take the different
kinds of plastics together.
Figure 7: Plastic to Fuel Plant
In a process that is as simple as throwing bits of plastic in a chamber and heating it up, we can
turn the plastic into tiny spheres of pure carbon just a few microns across. These spheres, which
conduct heat and electricity, could be useful in a long list of applications from tires to batteries to
lubricants. Adding the spheres to tires, for instance, could dissipate the heat generated from
friction against the road, protecting the rubber from melting.
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It is also working very well as an anode for a lithium ion rechargeable battery. These are the
types of batteries used in mobile phones and laptops, for instance. Carbon nanotubes made from
plastic bags via a similar process for several applications including rechargeable batteries.
Carbon microspheres are also useful in lubricants, toner, paint and filters.
Rather than just melting the waste plastic and re-extruding it, the process continues to heat
plastic bags or other plastic waste past the point of melting. He holds the material in a sealed
container that builds up pressure as the material gets hotter and hotter and becomes a gas.
At high temperatures and pressures in the chamber, the plastic decomposes into its elements. If
the chamber is filled with inert gas instead of air, the hydrogen in the plastic becomes hydrogen
gas, which can be collected and used as hydrogen fuel.
The carbon in the plastic forms spheres or egg-shapes depends on the type of waste plastic used
in the reactor. The uniform size and shape make the spheres particularly useful for certain
applications, like filtration, where packing tightly together is useful. Microspheres are expensive
to make using the current technology.
Now a company in Washington, D.C., is trying out a new way — heating the plastic to a very
carefully controlled temperature range, with infrared energy.
The company, Envion, is expected to cut the ribbon on Wednesday morning on a $5 million
plant that it says will annually convert 6,000 tons of plastic into nearly a million barrels of
something resembling oil. The product can be blended with other components and sold as
gasoline or diesel.
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Figure 8: Process of Plastic to Fuel
The company is the world’s largest oil consumer and the world’s biggest producer of waste. The
chairman and chief executive of the company is Michael Han.
Montgomery County, just north of Washington, D.C., apparently agrees, at least to the extent
that it is giving Mr. Han a free supply of plastic and a spot at its waste transfer station to set up
shop.
Mr. Han pointed out bales of plastics waiting to be shredded and fed into his machine, including
planters, McDonald’s large-sized beverage cups, margarine containers and other materials
typical of what suburban residents put out in blue bins once a week for pick-up. His machine can
digest the blue bins too.
Indeed, the machine will take everything except PET (the bottle with the “1’’ on the bottom)
because those have a higher value on the recycling market. He will process the caps, though.
The finished product looks like a slightly murky lemonade and smells somewhere between
gasoline and diesel fuel. One company has already agreed to buy the material for blending into
motor fuel, and Mr. Han said he is in discussion with others. Envion would like to license its
technology for use around the world.
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Mr. Han and other company officials were a little vague on some details, which they said were
proprietary, but the plant essentially consists of a two-story-high chemical reactor with an
internal agitator (for mixing up the soup) and heating elements that give off infrared energy.
Another trick is to limit the amount of oxygen.
Because the process is driven by electricity and not with an open flame, the temperature can be
tightly controlled, so most of the material — about 82 percent, according to the company —
becomes liquid fuel.
Company executives predicted that they would have to shut down to clean out leftover sludge
two to four times a year (conventional processes get clogged much faster). The sludge can be
burned for energy too, but it has much lower value.
Production depends on the plastic used as feedstock, but each ton of waste will produce 3 to 5
barrels of product, according to Envion. Producing a barrel consumes between 59 and 98
kilowatt-hours — two or three days’ worth of electricity for a typical house. The price of
electricity per gallon comes to 7 to 12 cents, the company says.
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3.3 Plastic Bottles to Mini Car
Figure 9: T25 Supermini Car
Gordon Murray, designer of the McLaren F1 Supercar, has designed a microcar concept that is
here to boast its green credentials. Dubbed the “T25 Supermini Car,” this futuristic vehicle is
easy to park thanks to its 4-foot width. What makes the car stand out is the fact that it is made
entirely of recycled plastic bottles.
The plastic material used for the car keep the car’s weight down to 600 kg. The reduced weight
of the car also results in excellent fuel efficiency. The small size lets three T25 cars park legally
in a standard, single car-parking bay. Apart from being aesthetically appealing, it will also save
the planet by diverting plastic bottles from landfills
The man behind one of the world's fastest production cars, the McLaren F1 (capable of 240
mph), has redesigned the manufacturing process for cars, calling it the iStream process. He
suggests that his new process could be "the biggest revolution in high-volume manufacture"
since Ford’s Model T from a hundred years ago.
The iStream process is based on the concept of using a separate chassis frame and a composite
body (in the case of the company's T.25, made from 720 upcycled plastic bottles), which
eliminates the need for pressed steel panels, cutting the tooling costs and simplifying the
carbuilding process. Different models can be built onto the same chassis, allowing cars, trucks,
or vans to go down the same assembly line, saving money, factory space, and energy.
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iSream Process
The process centres on a separate body chassis assembly process.
The assembly process is separate. During the first part, the powertrain, wiring harnesses, brakes,
suspension and all major components can be fitted directly onto the chassis prior to the body
panels being fitted.
The body panels are delivered to the line pre-painted.
The body panels are ‘married’ to the completed chassis near the end of the assembly process,
helping to reduce paint damage normally associated with a standard assembly line. All external
panels can be mechanically fixed to the chassis.
Figure 10: T25 Car can save space
Imagine a car so narrow that two can drive next to each other in one lane; a car so small and
short that three can park in one parking space.
Now imagine that the car is built in a shed from glass fibre, recycled plastic bottles and steel
tubes, using just a fifth of the material required to build a conventional car.
Such a vehicle would have the potential to prevent gridlock on the world's roads as the number
of cars quadruples to 2.5 billion by 2020.
It could also help hundreds of millions of people achieve their dream of owning a car, without
depleting scarce resources such as water, energy or steel.
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Figure 11: Characteristics of T25 Car
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CHAPTER 4
CONCLUSION
With the advanced technology, we don't have to invest new petroleum gases to make carbon
spheres or nanotubes. Because it's cost effective and it is reproducible. And, for now, it's a
product made from something many people want to get rid of. Not only are the resulting spheres
cheaper than today's sources, it also take care of plastic waste. It is helpful that the potential
applications for the spheres have huge markets to match the huge amount of plastic waste. It
makes sense to replace a mass level of waste with something that has a mass level of usage.
Using fewer and cheaper parts to build cars provides manufacturers with tremendous cost
savings, but perhaps more importantly it reduces investment risk as less money is required
upfront to get a project started, according to Prof Murray.
In the future, car factories could be smaller, cheaper and less polluting than they are today. The
actual factory that builds an iStream car - no matter what shape it is, no matter what size it is - is
about 20% of the capital investment and 20% of the size of a conventional car manufacturing
plant - and about half the energy. Such arguments are slowly winning over both conventional
carmakers and companies that have never sold cars before, so Prof Murray is hoping a number of
them will soon be manufacturing cars using his team's know-how.
In conclusion, nowadays our consumption levels have increased and our lives have become
better. The plastic waste problem has become worse. We should use a solution to solve this
problem. Recycling plastic is our best choice because it can reduce the waste of our resources
such as nonrenewable resource oil; it won’t generate any toxic substances and it can reduce the
amounts in landfills. In addition, it is good for the earth’s ecosystem; we can sustain the balance
of nature. It is a really good solution to dispose of the plastic waste. Due to the fact that our life
depends on the environment, we should regard this solution as an international issue; everyone
has the responsibility to join this plastic recycling program.
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