WO2017037732A1

WO2017037732A1 - Waste plastics impregnated bituminous mix

Info

Publication number: WO2017037732A1
Application number: PCT/IN2016/000214
Authority: WO
Inventors: Venkatasubramaniyan GANAPATHY
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-09-02
Filing date: 2016-08-22
Publication date: 2017-03-09
Anticipated expiration: 2018-03-02

Abstract

About 80 - 150 Kgs of all types of waste plastics are shredded, fine powdered and added to 1000 Kgs of the standard Bitumen of its weight recommended for the road engineering. As a process the plastics are shredded, fine powdered, sieved and heated to 200°C in a specially designed digestor in-builted with a high speed gear box is agitated for one hour. To this 30 Kgs of combined form of Hydrogenated and polymerized Pongamia glabra oil and pyrolysised rubber oil which provide polymer cross link bondage can be used as a catalyst cum stabilizer is added. Further 50 kgs of special binder grade tar pitch is added and the agitator run for 25 minutes at the same temperature and then one MT (1000 kgs) of pre-heated VG 30 or VG 10 grade Bitumen is pumped to the digestor and maintaining the temperature 130°C - 160°C resulting in waste plastic impregnated Bitumen mix.

Description

TITLE: WASTE PLASTICS IMPREGNATED BITUMINOUS MIX

FIELD OF INVENTION The invention relates to a process of preparation of waste plastic impregnated bitumen mix for new generation Road Engineering Technology. Particularly the invention relates to utilization of each and every type of disposed waste plastics like LDPE, PP, PS, FPP, PVC, and PET are Impregnated with standard Bitumen as a Hi-tech engineered polymer Bitumen Matrix. More particularly the invention relates to use of plant based hydrogenated and polymerized oil to act as a stabilizer that provides polymer cross link bonding strength in the aggregate bituminous mix.

ADVANTAGES

By the new matrix of waste plastic impregnated bitumen mix a high quality long-last safer roads with better resistance to rain water stagnation, reduced stripping and potholes, increased compression strength and bending strength can be increased.

We can improve the agriculture sector and reduce the global warming by cultivating the following species like Pongamia trees or Madhuca longifolia or Jatropha curcas, or any other Jatropha species or any other crop species having the properties of fatty acids and bio fuel & can be cultivated in the waste lands, road avenues and dry lands.

Disposing of waste tyres to an extent also will help to balance the health and environmental system for controlling the toxic gases and breeding of mosquitoes from the waste tyres.

The waste plastic impregnated bituminous mix is highly suitable for both Premix carpet and Seal coat. BACK GROUND OF INVENTION

The main constraints and drawbacks in the conventional dry process and tallow used wet process in plastic road constructions are:

The aggregate stones are practically not heated upto the required temperature of 170°C at the field level. The shredded plastics of various sizes, from 3 mm to 6mm are bigger than the aggregates size, sprayed over the heated aggregates wiil not provide uniform coating and not melt properly due to the variation of the softening point and chemical composition of the plastic polymers. Moreover, the aggregates act as the non-conductor, which requires more energy for heating. On the other hand, the dropping temperature, also will result in poor melting and bonding of the plasties sprayed over the aggregates, Then the addition of, Bitumen into the Hot Mix Plant over the aggregates will result in poor homogeneity of the waste plastic, aggregates and bituminous mix.

The disposed waste plastics collected from the Municipal Solid Waste consist of different types of polymers (LDPE, PP, PS, FPP, PVC, PET etc) which has different types of physical and chemical properties. As claimed by CSIR Wet process, Segregation of the plastics under 40 micron is very cumbersome process from the dumped garbage yard. So far the claims are, for the utilization of LDPE, PP and PS only. Practically the vendors will collect all types of plastics inclusive of PVC, FPP, PET and supply in the shredded form. Since the softening point, melting point temperature and the polymer chain varies from plastics to plastics (PVC softening point is ' more than 176°C and PET softening point is more than 240°C -The melting point for PVC and PET is more than 200°C) the conventional dry or wet process results in poor melting and bonding in mixing plant either with the aggregates or with the Bitumen.

Ultimately while paving the road, unmelted plastic particles will not have compatibility with aggregates and poor binding properties will result in uneven surfaces on the roads and the protruded plastics will wither and cause further environmental problem in due course.

It is also well aware that it is difficult to transport the bulk quantity of the plastic shreds to various sites, spillage hazard on transit, monitoring of the aggregate temperature in the mixing plant from time to time, improper mixing ratio of the shreds on the aggregates quantity and to the weight of Bitumen, by the unskilled labourers in the field level has its own practical difficulties resulting in poor quality control.

Moreover, utilizing the hydrogenated Tallow in the process will raise negative support from the animal supporters like Blue Cross society and PETA etc. since it is the source of animal based fatty oil derivative.

By adopting the conventional dry process, it is highly significant that the waste plastics are stand still everywhere.

To overcome all the above said constrains, the process and method developed by us will dispose all types of plastics to a maximum quantity of 8 - 15% per one MT (1000 kgs.) of VG 30 or VG 10 Bitumen Grade to achieve Zero disposal of waste plastics in the environment. This new genesis technology is to impregnate any type of waste plastic with any . grade of Bitumen and it should be highly suitable for tropical and temperate region.

OBJECTIVES OF THE INVENTION The main objective of invention is to utilize all types of waste plastics and waste tyres for road construction.

Another objective of the invention is to use agro based hydrogenated and polymerized oil to act as a stabilizer to provide polymer cross link bonding strength in the aggregate bituminous mix for long last and safer roads.

Yet another object of the invention is to reduce the Bitumen utilization, which' is a natural resource and higher earning of foreign exchange.

One another objective is to design an improved digestor (004) for waste plastic digestion

SUMMARY OF INVENTION

The present invention provides a method of road laying using waste plastics impregnated modified Bitumen composition comprising of:

(a) Bitumen - 1000 kgs.

(b) Dust free shredded, powdered and sieved all types of plastics - 80 kgs (8%)

(c) Special binder grade Tar Pitch - 50 Kgs. (5%)

(d) Hydrogenated and Polymerized plant based Pongamia glabra oil (Pungam or Karanj Oil) or Madhuca longifolia oil, or Jatropha curcas oil, or all other Jatropha species oilor all other oil of the available crop species having the properties of fatty acids and bio fuel - 30 Kgs. (3%)

(e) Polymerized - Pyrolysised of rubber oil - 30 Kgs. (3%)

The present invention's intention is also to reduce the Bitumen consumption simultaneously to increase the Bitumen :: Aggregates ratio. It is understood that ever .100 kgs. of waste plastic impregnated οΗμηαεη consists of 92 kgs. of bitumen and 8kgs. of all types of waste plastics or impregnated to a homogenous form.

The present invention forms new matrix cross linked polymerized coating on the road will become long last even in the water stagnated condition. .

Ah improved digestor (004) for waste plastic digestion for utilization in the process of preparation of the composition is also disclosed.

BRIEF DESCRIPTION OF THE DRAWING: Figure 1 : Schematic representation of bitumen mix preparation process flow

Figure 2: Enlarged diagram of modified digestor (004)

DEFINITIONS:

LDPE - Low Density Polyethylene

PP - Polypropylene

PS - Polystyrene

FPP - Food packaging Plastics

PVC - Poly Vinyl Chloride

PET - Poly Ethylene Tetra Chloride

MT - Metric Ton

VG30 - Viscosity Grade 30

VG 10 - Viscosity Grade 10

DETAILED DESCRIPTION: Figure 1 displays the various embodiments of the invention described below. In one embodiment of the invention the bitumen is pre heated to 60 - 70°C in the Pre-heating Bitumen Tank (001).

In another embodiment of the invention the binder grade hard Tar pitch is pre-heated in the preheating tar pitch tank (002), pumped to the distillation column (003) and heated to a temperature of 200 - 220°C. In one embodiment of the invention different types of plastic wastes such as LDPE, PP, PS, FPP, PVC, PET are collected, cleaned, shredded, and powdered in a waste plastic powder vessel (006). In one embodiment the distillation column (003) is an interim arrangement to maintain different temperatures such as tar pitch to a temperature in the range of 200-220°C and the VG30 or VG10 Bitumen grade temperatures in the range of 130 - 150°C to maintain the physical and chemical properties of tar pitch and Bitumen. In another embodiment about 80 kgs of powdered waste plastic is transferred through a conveyor (007) to a specially designed digestor (004) held over Concrete Bed (012), heated to 200-220°C by steam inlet* (013) and agitated with a 5000 RPM high speed agitator (009).AU types of waste plastics in the digestor (004) are heated and melted by diesel burner with a cutoff temperature of 300°C by temperature sensor. Then the agitator (009) will be started for running the screw type rollers (010, 011) for smashing the melted plastics to attain greasy condition (Figure 2).

In yet another embodiment about 50 kgs of pre-heated special binder grade tar pitch is added to the digestor (004) and agitated for another 30 minutes maintaining the temperature between 250 - 260°C.

In one embodiment 30 kgs of combined form of hydrogenated and polymerized plant based oil and pyrolysed rubber oil is transferred from the stabilizer tank (005)to the digestor (004) to obtain interlink bondage and homogeneity of the waste plastic and bitumen and continue agitation for half an hour. Hydrogenated and polymerized plant based oil is selected from Pongamia glabra species, Madhuca longifolia, or Jatropha species especially Jatropha curcas or any other available crop species having the properties of fatty acids and bio fuel.

In an embodiment 1 MT (1000 kgs.) of either VG30 or VG10 grade Bitumen is pre-heated to a temperature ofl00°C in the distillation column (003) and is pumped to the digestor (004) through the distillation column (003).

In another embodiment the pre-heated bitumen is pumped to the digestor(004) from the distillation column (003) under constant agitation by hood and screw type rollers (010, 01 1) for one hour to obtain homogenously blended waste plastic impregnated bituminous mix wherein the temperature of the digestor (004) is reduced .and maintained in the range of 130 - 150°C. After thorough mix the waste plastic impregnated bitumen collected in the collection outlet (008) is packed in 200 litre newly designed horizontal tar drums and end product used for road construction.

Examples Example 1:

Table 1: Aggregate, Bitumen and waste plastic ratio

The Table 1 presents the ratio of aggregate:bitumen:waste plastic used to prepare the waste plastic impregnated bitumen mix for laying premix carpet and the seal coat.

Example 2:

Table 2: Characteristics of the waste plastic impregnated bitumen mix

HINCOL (*)

SI. BITPLAST

TEST Polymer Modified

No. (NIT(**) report)

Bitumen - (PMB 120)

1 Viscosity @ 150°C Poises 1-3 4.33

2 Flash point ° C 220 221

3 Softening point ° C 50 51

4 Penetration @ 25° C 90-150 148 5 Ductility 50 24

6 Specific Gravity 1.04

(*) HINCOL - HINDUSTAN COAL LIMITED, MUMBAI, INDIA

HINCOL - PMB 120 conforming to Indian Road Congress (IRC) SP 53:2002 (**) NIT - NATIONAL INSTUTE OF TECHNOLOGY, TRICHY, TAMILNADU

(Government Nodal Officer for Pradhan Mantry Gram Satak Yojana - PMGSY

Road projects-India)

HINCOL is producing polymer modified bitumen where the polymer (determined physical and chemical characters) is the derivative of the petroleum by-products having the characters after the modification in the bitumen as given in Table (2)

BITPLAST- 8% all types of waste plastics impregnated modified bitumen where the waste plastics used for the production are unknown and has different physical and chemical characters after modification in the Bitumen as given in the Table (2)

Eventhough BITPLAST is using all kind of waste plastics collected from garbage for producing modified bitumen for road construction, the comparative characters of the PMB70 and BITPLAST is not having much significant difference in the characters of the end product used for road construction.

INDUSTRIAL APPLICABILITY

The composition plastic impregnated bitumen mix can be used for construction of high quality long-last safer roads and in building sector with better resistance towards rain water stagnation, reduce stripping and potholes, increase the compression strength and bending strength.

Claims

I Claim:

1. A process for preparation of waste plastic in

consisting of:

1 MT (1000 kgs) VG 30 or VG 10 grade bitumen;

80 kgs waste plastic polymers;

50 kgs tar pitch; and

combined form of 30 kgs. of hydrogenated and Polymerized plant based oil and pyrolysized rubber oil;

the process comprising of steps:

Collecting, cleaning, shredding and powdering waste plastic polymers in a waste plastic powder vessel (006);

^' Digesting of powdered waste plastic in a digestor(004) at 200-250°C under constant agitation of the screw type rollers (010, 011) in an agitator (009);

Adding pre-heated special binder grade tar pitch from pre-heating bitumen tank (001) after one hour and agitate for 30 minutes;

Adding combined form of Hydrogenated and Polymerized plant based oil and pyrolysized rubber oil;

Adding VG 30 or VG 10 grade Bitumen to digestor (004) with temperature maintained at 130 - 150°C under constant agitation with high speed 5000 RPMagitator (009) for one hour.

2. The process for preparation of waste plastic impregnated bitumen mix for road laying as claimed in claim 1, wherein the plant based hydrogenated and polymerized oil is derived from plant species Ponsamia glabra, Madhuca lonzifolia, Jatropha species, preferably Jatropha curcas, and plant species having the properties of fatty acids and bio fuel.

3. The process for preparation of waste plastic impregnated bitumen mix for road laying as claimed in claim 1, wherein the waste plastic polymers are selected from LDPE, PP, PS, FPP, PVC, PET used separately or combination thereof.

4. An improved digestor (004) for waste plastic digestion for use in the process for preparation of waste plastic impregnated bitumen mix consisting of :

Four agitators (009), oriented opposite to each other in pairs enclosed in a gear box and said pairs fitted top and bottom; separated at a distance of 45cm; lower blades.(Ol l) are mounted with self weighted 2" screw type rod with bush arrangements touching the bottom plate in the opposite direction for proper blending of the molten plastic and stabilizers;

upper blades (010) connected with 45 degree angled inclined hood plates fixed on opposite side for creating turbulence in digestor(004)vessel to obtain homogenous plastic impregnated bitumen.

5. The utilization of the waste plastic impregnated bituminous mix is preferable for premix carpet or seal coat.