Journey of Plastic Waste to road asphalting
Types of Plastic
Type of plastic Molecular structure
Characteristics Applications
ThermosetsThermosets are hard and have a very tight-meshed, branched molecular structure.Curing proceeds during shaping, after whichit is no longer possible to shape the materialby heating. Further shaping may then only beperformed by machining
Electricalswitches, Epoxy
ElastomersWhile Elastomers have a cross linkedstructure, they have a looser mesh thanThermosets, giving rise to a degree ofelasticity. Once shaped, heating also cannotreshape Elastomers
Vulcanisedrubber forautomobile tyres
Thermoplastics
Thermoplastics have a linear or branchedmolecular structure, which determines theirstrength and thermal behavior; they areflexible at ordinary temperatures. At approx.120 - 180°C, thermoplastics become apasty/liquid mass. The service temperaturerange for thermoplastics is considerablylower than that for thermosets. Thethermoplastics
Polyethylene(PE), polyvinylchloride (PVC)and polystyrene(PS) are used inpackagingapplications
Do you know!!!Amazing facts about Plastic
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Uses of
plastic
Construction/ Recreational
industries
Automobile/electronic Industries
Health sector
Aviation sector
Food industries
• 45% of plastic used for packing.
• Without plastic..
▫ Alternate packaging - 4x
▫ Emission of GHGs - 2x▫ Energy usage -1.5x
▫ Deforestation - 2x• India generates 1.88 lakh tpd of
garbage of which 12% is plastic
• 60% of plastic waste is recycled in unorganised manner. Rest 40% is landfilled/dumped/burnt.
• Burning of plastic generates 51 types of cancernogenic gases.
• Significantly contributes to climate change.
Cause and Necessity to Use Plastic Waste
Environmental
Hazard Material
Finding a
Meaningful Use
Is Plastic a problem or its
irresponsible disposal???
Say Yes to plastic but no to its
misuse!
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We have a scientific, feasible and
environmental friendly technology
for plastic waste management
Our Company Overview
Our values
• Our Vision is to;
▫ Assist local bodies to build a garbage free cities/towns
▫ Reduce environmental pollution caused by plastic waste
▫ To eliminate the myths about the plastic waste by providing a
scientific technology for permanent disposal of plastic waste.
▫ Promote best usage of plastic waste for road construction thereby
improving its durability, quality and performance.
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We are registered under Companies Act in 2002 and are based in Bangalore –known for -reusing plastics in the construction of roads.
Devised an end-to-end process through which it collects plastic waste with its extended network, sorts this waste and turns it in to flakes. This resulting flake polymer is called “KK Poly Blend”. The KK Poly Blend is then mixed with the bitumen and asphalt used in the construction of roads.
Operates multiple plastic recycling/reuse plants in Bangalore which can process up to 30 metric tonnes of plastics per day.
This technology is backed up by research from the Department of Civil Engineering Bangalore University, the Centre for Transportation Engineering (“CTE”), and the Central Road Research Institute (“CRRI”).
Has patented this technology, and to date is the only company to have successfully commercially implemented.
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Company Overview…
2000 km of plastic waste roads laid in Bangalore by reusing 10,000 tons of plastic waste so far.
MoU has been signed with Bruhat Bangalore Mahanagara Palike for supply of plastic waste blend in all the road projects. They have mandated usage of plastic waste in all its road projects, which is a testimony to the significant benefits arising from the use of the technology.
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…Company Overview
Company has won the following awards and accolades for its efforts.
• CRISIL Award for Excellence in Municipal Initiatives 2004 & 2005
• Government of Karnataka Best Practices Award 2004-05
• Selection for UN-HABITAT Good Practise Award 2004 & 2007
• Green Leaf Award 2009
• Reliance Real Heroes Award 2008
• Manjushree Awards for Innovation and Excellence, 2009
How Plastic waste is collected in
the absence of source
segregation???
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Our collection network
Plastic collection from;
• 80 Dry Waste Collection Centers established by
BBMP. 10 of them are being operated by
KKPWM
• Collection from 20 + apartments
• Direct collection from communities like RWAs,
layouts etc. after frequent awareness under CSR
movement of KKPWM.
• Delhi Public School and Claret school
• Corporate Companies like 3M, Wipro etc.
• Directly for BBMP’s primary and secondary
garbage collection vehicles by offering Rs. 4-6/kg
of plastic waste
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Our Products
With extensive research we are manufacturing following products;
1. K K Poly Blend – used for road construction
2. Scarified material recycling for roads
3. Sheets for construction of roads using IIT, Kharagpur technology
4. Road side kerb stones
5. Plastic granules for manufacturing pipes and sheets
6. Green wood made door frames
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K K Poly Blend
Severe climatic conditions with daily and seasonal variation of temperature.
Higher serviceability level of roads with much lower maintenance cost due to longer life.
Increased fatigue resistance of bituminous mixes under repeated loading as well as higher degree of flexibility of roads.
Improved cohesion which assists resistance to weathering and adhesion to reduce risks of binder being stripped by water.
Achieve higher stiffness modulus to minimize thickness of resurfacing in urban areas to avoid milling and raising of kerbs.
Improved grip and performance when used in structural and surface course.
Resistance to cracking, ravelling, deformation and creep failure.
Prevention of environmental degradation/ hazards arising from disposal of plastics.
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Plastic Roads – a Necessity…
The premise of KKP’s offering is the use of waste plastic for road construction.
KKP takes plastic waste and converts it in to plastic flakes “KK Poly Blend” which are usable in the construction of roads. Most of the plastic waste is able to undergo this conversion.
Plastic litter is collected by rag pickers and / or the public at apartment complexes, offices and schools, and is delivered to the KKP plant.
Within the KKP plant, the plastic waste undergoes the following processes:
• Segregation – Any plastic not able to be used in bitumen mix is removed
• Cleaning – Organic waste is cleaned away from the plastic
• Shredding – Plastic is turned in to flakes by passing through shredders
• Packing – Flakes are packaged and made ready for transportation
The plastic flakes are then taken to an asphalt plant where, under KKP supervision, they are added to the bituminous concrete mix. The optimal ratio of recycled plastic to bitumen is 8:100.
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Technology Overview…
Plastic waste is delivered to the plant
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Waste is segregated Cleaned and shredded
…Technology Overview…
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Shredded waste (in flake form) is
packaged up, ready for delivery
KP Poly Blend is added to the
Bituminous Concrete Mix
…Technology Overview
Transported to Hot mix
plant, mixed using
exclusive designed blowers
The tests discussed in this presentation have been carried out at Dayanand SagarCollege, Bangalore under the supervision of Dr. Kiran Kumar B.V. Similar tests have been carried out by several other institutes such as Central Road Research Institute and IIT Chennai.
The Fourier Transform Infrared (FTIR) Spectrometer Scanner was used to establish that the material undergoing testing was KK Poly Blend with bituminous mixes in a ratio of 8:92 (referred to as Waste Plastic Modified Bitumen - WPMB).
The WPMB resulted in a viscosity in poise reading of 1.36 which ensures good flow without becoming difficult to control at high temperatures.
The result of the Thin Oven Film Test (TFOT) was a reading of 0.56% which is well below the limit of 1% indicating a marginal loss in mass of the bituminous mix.
The reading of the original binder (WPMB) under the Dynamic Shear Rheometer (DSR) test was 1.8 kpa at 60˚C and 2.1 kpa at 70˚C which is well above the threshold of 1 kpa. The aged binder (WPMB after heating) has 3.2 kpa at 60˚C and 3.8 kpa at 70˚C which is well above the threshold of 1 kpa.
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Summary of Test Results…
Binder Type
Viscosity in Poise @ 1350C (< 3.0
Poise) on Original Binder
TFOT Loss of Mass in % (<
1.00%)
DSR in Kpa (> 1.00 Kpa for Original
Binder & > 2.20 Kpafor RTFO aged
Binder) @ Temp >
400 C
Remarks
WPMB
1.36-
1.8 (@ 600 C
Temp) Original Binder
-2.1 (@ 700 C
Temp)
-
0.56
3.2 (@ 600 C
Temp)
AgedBinderUsing TFOT -
3.8 (@ 700 C
Temp)
Visco-elasticity Property of Binder
FTIR Scanner for Quality Control of Plastic
Waste Modified Bitumen
FTIR Scanner for Quality Control of Plastic
Waste Modified Bitumen
Test on plane bitumen
FTIR Scanner for Quality Control of Plastic
Waste Modified Bitumen (WPMB)
Test on WPMB
Plastic Waste Mix Laboratory and Field
Studies
Fatigue Test Results of Dense Bituminous Macadam Mix with Nominal
Aggregate Size 26.5 mm and Tire Pressure 7.1 kg/cm2
Temperature in
C0
VG-30 Waste Plastic Mix
Nf εt E Nf εt E
300 415 1705 3337 512 1448 4636
500 154 3359 969 184 2809 1455
700 25 12449 80 61 7674 160
Nf = Number of Repetitions to Fatigue Cracking.
εt = Tensile Strain at Critical Location.
E = Stiffness of the Material
Plastic Waste Mix Laboratory and Field
Studies
Fatigue Test Results of Bituminous Concrete Mix with Nominal Aggregate Size 19.0 mm and Tire Pressure 7.1 kg/cm2
Temperature in C0
VG-30 Waste Plastic Mix
Nf εt E Nf εt E
300 474 1538 3687 473 1656 3063
500 305 3038 610 270 3339 532
700 92 9192 53 66 10618 49
Nf = Number of Repetitions to Fatigue Cracking.εt = Tensile Strain at Critical Location.E = Stiffness of the Material
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Plastic Waste Mix Laboratory and Field
Studies
Moisture Sensitivity Test Results of Dense Bituminous Macadam Mix with Nominal Aggregate Size 26.5 mm as per AASHTO T-283
Type of Compaction
VG-30 WPMB
IDT*
IDT**
TSRIDT
*IDT**
TSR
SGC 13.73 15.51 88.50 19.83 21.22 93.46
RCRA 14.85 15.59 95.24 21.43 22.07 97.09
MH 13.78 15.30 90.09 17.60 19.01 92.58
IDT*- Indirect Tensile Strength of Conditioned Sample in kg/cm2
IDT**- Indirect Tensile Strength of Unconditioned Sample in kg/cm2
SGC – Specimen compaction using Super Gyratory CompactorRCRA – Specimen compaction using Rolling Compactor cum Rut AnalyzerMH – Specimen compaction using Marshall HammerTSR – Tensile Strength Ratio in %
Plastic Waste Mix Laboratory and Field
Studies
The following advantages can be attained by using WPMB over VG-30 grade binder
in DBM layer:
1. The cost of using anti stripping agent in case of VG-30 grade
binder can be cut by using WPMB as alternative. Since WPMB
exhibits better resistance to stripping when compared to VG-30
binder.
2. Using WPMB in DBM layer the fatigue life of the layer increases by
2.0 (two) times to that of VG-30 grade binder. Table-1 above indicates
the fatigue life of DBM mix cast using VG-30 and WPMB, when tested
at 3 test temperatures 30, 50 and 70 deg C respectively.
Plastic Waste Mix Laboratory and Field
Studies
The performance study has been conducted for Waste Plastic Modified Bitumen
at following Research Centers :
• Central Road Research Institute, Delhi.
• Indian Institute of Technology, Madras has conducted field study on NH-207
using WPMB.
• Center for Transportation Engineering, Bangalore University.
• Dayananda Sagar College of Engineering, Bangalore.
• Government. Engineering College, Hassan.
• Government SKSJIT College, Bangalore.
Plastic Waste Mix Laboratory and Field
Studies
• Bruhat Bengaluru Mahanagara Palike (BBMP), Bangalore has taken an initiative
in March 2001, in laying “Plastic Roads” as a technology demonstration for the
Chief Minister, showed superior smoothness and uniformity and less rutting as
compared to a plastics-free road laid at the same time.
• The process was also approved in 2003 by the CRRI (Central Road Research
Institute) Delhi, and has thereafter been included in the Govt of Karnataka’s PWD
Schedule of Rates.
• The existing road structure is evaluated through Benkelman Beam Deflection
(BBD) Survey. The BBD Study Conducted on this Plastic Roads from
Nayandahalli to Silk Board Jn, Bangalore. The study has shown higher
characteristic deflection, which indicates fair condition of pavement.
SL
No.
Trail Type
Average Characteristic Deflection in mm
Annual Rainfall in
mm
Soil Type
Nayandahalli to Silk
Board
Silk Board to
Nayandahalli
For Bangalore Region Both Sections
1
Cycle-1
09-12-2010 1.12 1.08 930
Clayey sand
(SC)
2
Cycle-2
06-06-2011 1.27 1.19 930
Clayey sand
(SC)
Bangalore Roads using WPMB
Road Recycling
Introduction
• Conservation of non renewable natural resources
Conserve 80% of virgin aggregate
Reduces 2% of bitumen usage
• Preserves significant extent of land which otherwise used for disposal of;
Scarified materials
Plastic mix garbage
• Reduces 60 % of energy by preventing;
Transportation of scarified materials
Mining and transportation of virgin aggregates
Manufacture and transportation of Bitumen
Reduced machinery usage for road asphalting
Transportation of plastic mix garbage to landfill site
Calculations show that it requires roughly 500,000 BTU’s to produce a tonne of new asphalt. To recycle a ton of asphalt in place requires roughly 200,000 BTU’s only.
Cont…
• Reduce Green House Gas emission significantly byReduced emissions from mining and manufacturing activities
Reduced emissions from landfill sites due to indiscriminate dumping of plastic mix garbage
Avoid transportation of raw materials to site
Less drilling of fossil fuel
Lowers greenhouse gas emissions by 27 ton/kilometre when compared to conventional paving methods. Eligible to earn carbon Credits!!
• Two folds of added life to roads due to usage of plastic waste will cut down frequent relay of roads
• Plastic free garbage eases segregation, treatment and disposal in a scientific and environmental friendly manner
Cause and Necessity to Use Reclaimed
Asphalt Mix
• Increasingly aggressive traffic conditions.
• Severe climatic conditions with daily and seasonal variation of temperature.
• Need to maintain roads at higher serviceability level.
• Increased fatigue resistance of bituminous mixes under repeated loading and higher degree of flexibility.
• Improved cohesion which assists resistance to weathering and adhesion to reduce risks of binder being stripped by water.
• Achieve higher stiffness modulus to minimize thickness of resurfacing in urban areas to avoid milling and raising of kerbs.
Cause and Necessity to Use Reclaimed
Asphalt Mix
• Improved performance when used in structural and surface course.
• Resistance to cracking, ravelling, deformation and creep failure.
• Prevention of environmental hazard near disposal sites.
• Better grabby roads with improved performance.
• Saving in maintenance cost.
Methodology Adopted
Test Section of the Pavement (Road from WEP-1 Ch.14+500 m to
15+100 m Chikkanahalli) considered for study
Reclamation
Milling & Re-use of MaterialShallow Depth Cutting
& Grinding
Methodology Adopted
hivanapur to chitamani, road feeder road to NH 4, 38 km
from Bangalore, a trial run stretch of 500 mt is
completed and performance evaluation is under process.
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What are we looking at...
• Tie up with every municipal corporation in India to set up network of
plastic collection
• Facilitate a minimum of 2 acres of land on lease for a minimum of
15 years period to establish mechanised plastic processing plant
• Have an agreement for supply of K K Poly Blend at a cost of Rs.
27/kg + transportation which can be used in laying of roads
• Have an agreement to scarify the worn out roads and supply the
recycled scarified material for laying new roads on contract basis
Annexures
New York Times - Plastic Roads Offer Greener Way to Travel in India -http://www.nytimes.com/2009/11/14/business/global/14plastic.html
BBC World News Horizons explores sustainable ways of dealing with global waste - http://www.bbc.co.uk/mediacentre/worldnews/horizons-ep13.html
Reuters - Plastic paving for eco-friendly Indian roads http://www.reuters.com/article/2010/01/14/us-india-plastic-roads-idUSTRE60D07F20100114
Khaleej Times - Plastic paving for eco-friendly Indian roads http://www.khaleejtimes.com/DisplayArticle08.asp?xfile=data/environment/2010/January/environment_January9.xml§ion=environment
CNN IBN - Bangalore: Paving greener ways through plastichttp://ibnlive.in.com/news/bangalore-paving-greener-ways-through-plastic/294744-62-132.html
Outlook India - Roads Of Plastic Waste http://m.outlookindia.com/story.aspx?sid=4&aid=224669
The Hindu - Plastic waste to be used for asphalting roadshttp://www.hindu.com/2005/09/21/stories/2005092117280300.htm
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Annexure 1 – Select Media Coverage
Annexure 1 – Awards
Reliance Real Heroes Award 2009
(CNN-IBN and Dhirubhai AmbaniFoundation)
Reliance Real Heroes Award 2009
(CNN-IBN and Dhirubhai AmbaniFoundation)
Thank you
We hope that we can build a cleaner and healthier cities/town together, whilst creating better and longer-
lasting roads...