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

3

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!

5

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.

8

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.

9

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.

10

…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

13

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.

16

Technology Overview…

Plastic waste is delivered to the plant

17

Waste is segregated Cleaned and shredded

…Technology Overview…

18

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&section=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...