Description:TITLE OF THE INVENTION
A system and method of recycling Plastic waste and developing building materials and their composition thereof

FIELD OF THE INVENTION
The field of the present invention relates to recycling of waste plastics and developing them into sustainable and durable building materials such as paver blocks, tiles, and other construction products having enhanced properties.

BACKGROUND OF THE INVENTION
Plastic product’s usage is pervasive in nature despite the robustness, light weight features considered ideal for various commercial utilization. However, upon fulfilment of completion of utilization of such plastic, it is discarded termed technically as plastic waste. It is reported that about 70% of the plastic, used for packaging purposes, ends up as plastic waste in a short span of time. Such, plastic waste is one of the greatest hazards to marineecosystems since 8 million tonnes of the plastic waste get dumped in the oceans, every year. Plasticwaste cannot be dumped into landfills, owing to its slow degradation rate. Further, when the plasticwaste is combusted, it emits dangerous gases that harm the human health. The disposal of plasticwaste in a safe manner remains a huge concern for environmentalists. Though 60% of the plasticwaste gets recycled in India, the country is yet to improve her recycling potential and put theplastic waste to best use. This should be accomplished to support the environmental concern too i.e.,depletion of the natural resources to manufacture the construction materials. So, recycling the plasticwaste into construction materials will be an ideal solution to tackle this problem.

As a final point, the acceptance and demand for these materials from the consumers will not only create more interest among the future researchers, but also will result in the creation of many such alternate materials with zero or less carbon foot print that mutually comforts the human beings as well as the environment.

Several inventions in that line provide a direction to such a thought process.
US6329437B1 titled, “Materials for construction engineering based on recycled or newly made plastic materials, improved building components made for said materials and methods of making same” discuss universal building material for construction engineering that is made from plastic waste material from any and all types of plastics and/or from newly made or fresh plastic materials and is used to make various improved building components, building elements or buildings. The material is environmentally friendly and does not cause any health problems. The material can be combined with other building materials and raw materials. It is also not easily inflammable and has very good heat transfer and thermal insulation properties. In addition, it is waterproof, weatherproof, and it can easily be worked with. The material also has the property that the waste that it produces is always reusable. It has also comparatively small financial and economical expenses during the production and fabrication. The material conserves natural resources and complies with legal requirements in the building industry. The universal building material can contain recycled material from any type of plastic waster materials or fresh or newly made plastic materials, such as PE, PVC, PP, PS and ABS, and can be used for building construction above and below ground, as an additive material in other building materials, as a balance material and for thermal insulation and for sound absorption. The volume and weight ratios or proportions of the different types of plastic materials provided in the recycled material and/or the newly produced plastic materials can be adjusted to fit each particular application.

WO2013057737A2 titled, “Process of recycling plastics, products and applications thereof” relates to a process for recycling of plastic waste comprising: segregating plastic waste collected from various sources followed by cleaning of the segregated plastic waste to obtain segregated cleaned waste; grinding of the segregated cleaned waste to obtain grinded waste; introducing the grinded waste into an extrusion line having a venting extruder component as part of the extrusion line, to obtain molten plastic; and removing the impurities by vacuum venting of the molten plastic to obtained recycled plastic free from impurities. The present disclosure further relates to various articles like Industrial Post Recycled (IPR) plastic tubes, blow moulded bottles, pallates, manufactured from the recycled plastic waste.

US10865143 titled, “Method for recycling waste plastic into concrete” comprise of a method of making a structural lightweight and thermal insulating concrete is described. The concrete has a coarse aggregate partly replaced by recycled plastic pieces. This enables the concrete to maintain a high compressive strength, low thermal conductivity, and low weight, while providing a use for waste plastic. The waste plastic pieces may comprise polyethylene in the form of flakes, fibers, or granules. Due to its low unit weight, adequate compressive strength and high thermal resistance the developed concrete can be used as a structural lightweight and thermal insulating concrete. The use of this concrete leads to economic and environmental benefits.
However, the current research trend manifested in inventions and their patenting suffers from several drawbacks, especially in the field of embodying enhanced properties in the construction properties of the sustainable building material, that is taken care of in the present invention.

SUMMARY OF THE INVENTION
An aspect of the invention is to address environmental concerns by reducing the amount of plastic waste ending up in landfills or polluting the environment.

Another aspect of the invention is to accomplish the above objective by recycling waste plastics and utilizing them in the production of sustainable building materials, such as paver blocks, tiles and many more product.

A further aspect of the invention is to provide the construction industry with eco-friendly alternatives to traditional materials like asphalt and concrete, which are often associated with significant environmental impacts.

A still further aspect of the invention is developing durable and environmentally friendly paving materials, for contributing to sustainable construction practices and mitigate the industry's carbon footprint.

Another aspect of the invention is to achieve a sustainable supply of raw materials for the production of the eco-friendly construction materials which is achieved by systematically gathering plastic waste from diverse sources including households, institutions, and multinational corporations.

A still further aspect of the invention is to deploy Advanced Sorting and Cleaning Technologies, Integrated Washing Line, Effluent Treatment Plant (ETP) and Innovative Hydraulic Pressing Technology thereby enabling a more comprehensive, efficient, and environmentally sustainable approach to plastic recycling compared to many existing systems.

Another aspect of the invention is to provide for a method of making paver bricks, the method comprising:mixing,treated waste plastic of about 20 wt.%- to about 85 wt.%; fine aggregate of about 0 wt.%- to about 100 wt.%; coarse aggregate of about 0 wt.%- to about 98 wt.%; GGBS of about 0 wt.%- to about 20 wt.%; fly ash of about 0 wt.%- to about 90 wt.% ;sending the combined materials to an extruder and heated at a temperature ranging between 180C to 270C; transferring the extruded lumps generated to the paving machine, transferring the lumps to moulds of predetermined sizes; and washing the moulds with water for 5 minutes before dispatching.

A further aspect of the invention is developing a building construction material comprising treated waste plastic of about 20 wt.%- to about 85 wt.%; and Fine aggregate of about 0 wt.%- to about 100 wt.%; Coarse aggregate of about 0 wt.%- to about 98 wt.%; GGBS of about 0 wt.%- to about 20 wt.%; and Fly ash of about 0 wt.%- to about 90 wt.%.

These and other aspects of the invention will be clear from the description and the appended claims.

DETAILED DESCRIPTION OF THE PREFFERED EMBODIMENTS

This document provides methods and materials for using typically incinerated or landfilled waste as a raw material for compositions that may be used, for example, in sustainable construction materials building materials, such as paver blocks, tiles. In particular, this document provides methods, materials, and systems for using recycled plastics in combination with other aggregates like coarse aggregates, quarry dust, flyash, fine aggregates and Ground Granulated Blast Furnace Slag (GGBS)for generating composites (e.g., structural and non-structural composites), and products containing the composites.

In general, before utilizing the waste plastics from various sources like municipal and industrial waste, the retrieved plastic undergoes treatment which may be summarized as under:
Step 1: COLLECTION
The first step involves a systematic collection of plastic waste from diverse locations, with a primary focus on obtaining post-consumer plastic, especially Multi-Layered Plastics (MLP), from various multinational corporations apart from gathering plastic waste from local areas, by collaborating with different municipalities.

Step 2: SORTING AND DEDUSTING
Sorting of these plastic wastes is done in MRF (Material Recovery Facility) or PRF (Plastic Recovery Facility), primarily involving the following system:

a) Feeding Conveyer: is designed for transporting incoming waste materials and is engineered with several design features to optimize its functionality and efficiency. These design elements include:
i) Inclined Design: It is specifically designed to be positioned at an incline, allowing for gravity-assisted movement of waste materials along the conveyor thereby facilitating continuous flow of materials and reducing the need for additional energy inputs.
ii) Length and Width Specifications: The length of the conveyor ranges between 10 to 15 meters and has a width of 3 feet, thereby providing ample space for transporting waste materials effectively while accommodating varying throughput requirements.
iii) Robust Construction: The conveyor is built using durable materials capable of withstanding the rigors of industrial operations. This ensures longevity and reliability, even during handling heavy or abrasive waste materials.
iv) Conveyor Belt: The conveyor is equipped with a sturdy conveyor belt designed to withstand the weight and abrasion of the materials being transported. The belt's surface texture and material composition are selectedto prevent slippage and facilitate smooth movement of the waste materials along the conveyor.
v) Safety Features: integrated with the design are safety featuresincluding emergency stop buttons, guards, and sensors for preventing accidents and ensuring the well-being of operators.

b) Trommel: The feeding conveyor delivers the material into the trommel for the separation process which is utilized for separating materials based on size.

c) Sorting Conveyor: is intended for manual sorting operations, requiring manpower for efficient sorting. They are installed parallel to the floor for optimal functionality. The system of the present invention requires two sorting conveyors, each with a length of 10 to 15 meters and a width of 3 feet.

d) The De-duster Machine: optimizes the performance by removing dust from plastic films. This machine ensures that plastic films are cleaned of any particulate contaminants, enhancing the quality and usability of the films. By effectively eliminating dust, the de-duster machine helps maintain the integrity of the plastic films and prepares them for subsequent processing or packaging stages. Its efficient dust removal process is crucial for applications where the cleanliness of plastic films is paramount. the de-duster machineis specifically designed with several key features including:
i) Airflow System: This machine incorporates a robust airflow system creating suction to pull dust particles away from the plastic films, thereby ensuring efficient dust removal while minimizing the risk of recontamination.

ii) Rollers or Brushes: equipped with the de-duster machine are the rollers or brushes whichupon coming in contact with the surface of the plastic films, dislodges the dust particles from the plastic films by agitating the films, and allowing them to be captured by the airflow system.

iii) Adjustable Settings: The machine often includes adjustable settings to accommodate different types of plastic films and varying levels of dust contamination. Operators can adjust parameters such as roller or brush speed, airflow intensity, and contact pressure to optimize cleaning performance.

iv) Dust Collection Chamber: A dedicated dust collection chamber captures the dust particles removed from the plastic films. This chamber is designed for easy access and cleaning, allowing for efficient maintenance of the machine.

v) Safety Features: Safety considerations are integrated into the design, with features such as emergency stop buttons, guards, and sensors for preventing accidents and ensuring operator safety during operation.

vi) Material Compatibility: The design of the de-duster Machine takes into account the compatibility with various types of plastic films commonly used in industrial applications. This ensures that the machine effectively removes dust without causing damage to the films.

Step 3: WASHING AND CLEANING
For a high-quality product, it is recommended to utilize a washing line where the material will undergo grinding, washing, and drying processes. The washing line consists of the following components:

a) Feeding Conveyor: This conveyor is used for feeding the material into the grinder efficiently.

b) Grinder: The grinder processes the material by reducing the size of the plastic material received from the de-dusting machine. The grinder features high-grade cutters with a double-stage cleaner, providing enhanced performance and efficiency. With a cutter thickness of 15 mm and a diameter of 200 mm, it offers a cutting area of 750 mm. It is built with heavy-duty tapered roller bearings and operates via a chain coupling drive system. The helical gearbox allows for speed adjustment ranging from 10 to 60 RPM. Powered by IE2 foot cum flange mount motors totaling 20 + 20 HP (3 Phase Motor - 1440 RPM), it ensures robust operation. Equipped with an auto-reverse system, automatic control panel with VFD systems, and overload alarm indication, it offers ease of operation and enhanced safety features. Additionally, the grinder boasts an easy feeding system and is fabricated with highly prioritized safety aspectswith the help of blades, ensuring it is adequately grinded.

c) Screw Conveyor: A first screw conveyer transports the grounded material from the grinder to the floatation tank.

d) Floatation Tank: The floatation tank, enables the ground material to be thoroughly washed using water and chemicals including detergents and surfactant-based cleaning agents, which are adept at disintegrating and eliminating surface contaminants from plastics.

The cleaning agents may include solvents, such as but not limited to ethanol, isopropyl alcohol, or acetone which exhibit proficiency in dissolving and expelling specific types of contaminants from plastics.

In some embodiments the cleaning agents may be alkaline cleaners, fortified with compounds like sodium hydroxide or potassium hydroxide, which demonstrate efficacy in eradicating oils, greases, and other organic impurities from plastics.

In further embodiments the cleaning agents may be acidic cleaners, comprising solutions such as citric acid or hydrochloric acid, which excel in eliminating mineral deposits or scale from plastics for removing impurities.

e) Screw Conveyor: A second screw conveyor carries the washed material from the floatation tank to the turbo wash.

f) Turbo Wash: provides an additional, more efficient washing stage to ensure the material is thoroughly cleaned.

g) Drier: Finally, the drier is used to dry the washed material, completing the cleaning process.

The size of the ground flakes produced will not exceed 30mm.

In some embodiments of the present invention an Effluent Treatment Plant (ETP) can be included for filtering the water discharged from the washing line, thereby, minimizing water wastage and promoting environmental sustainability.

Once the waste plastics obtained from various sources undergoes the treatment of washing and grinding and the final product to be mixed with other materials is obtained, all the materials along with plastics are mixed homogeneously W/W, detailed proportional ratios are enumerated in subsequent paragraphs.

These combined materials are then then sent toan extruder where the temperature ranging from 180C to 270C are applied. The extruded lumps generated by the extruder are sent to the paving machine, where it works on the principle of hydraulic press, as is known in the art. These lumps are transferred to moulds of predetermined sizes and the moulds washed with cold water for 5 minutes.
Raw materials for the building materials
1. Plastics:
The size of plastics should be less than 6mm

2. Fine Aggregate:
Fine aggregate includes sand, from river, sea, and ocean. It is the raw material that is an essential ingredient in concrete. For mixing of concrete, aggregates needs to be clean, hard, strong particles free of absorbed chemical or coating of clay and another fine material that could cause the deterioration of concrete. Typically, fine aggregate generally consists of sand and particles, the particle size being in the range of 4.50- 4.75mm.
Other Properties are as follow:
1. Specific gravity: 2.53
2. Fineness modulus: 3.08
3. Density: 1.63gm/cc
4. Void ratio: 0.55

3. Quarry Dust:
In quarrying activities, the rock is crushed into various sizes; yielding dust, during the process. This dust is called quarry dust and is formed as waste. The quarry dust so obtained, may replace sand completely or partially. Quarry dust is a cost effective good availability product. The quarry dust may be considered as fine aggregate which is basically a by-product of the crushing process which is a concentrated material to be used as aggregates for concreting purposes.
Other Properties are as follow:
1. Specific gravity: 2.57
2. Fineness modulus: 2.41
3. Density: 1.85gm/cc
4. Void ratio: 0.42

4. Coarse Aggregate:
Coarse aggregates are a construction component made of rock quarried from ground deposits. Those particles that are predominantly retained on the 4.75 mm sieve and passes through a 3-inch screen, are termed coarse aggregates wherein, the size of coarse aggregate is less than 4mm.
Properties Coarse aggregate CWR
Crushing strength (%) 22.8 26.8
Impact resistance (%) 17.9 19.5
Bulk density (Kg/m3) 1575 1429
Water absorption (%) 0.3 0.48
Specific gravity 2.6 2.06

5.Ground Granulated Blast Furnace Slag (GGBS) is a by-product of iron and steel industry, produced by quenching molten blast furnace slag with water or steam. Some technical details about GGBS are as under:

1. Chemical Composition: GGBS primarily consists of silicates and alumino-silicates, derived from the composition of blast furnace slag. It typically contains SiO2, Al2O3, CaO, MgO, and other minor elements.

2. Particle Size: GGBS is finely ground to achieve a specific particle size distribution, typically with a Blaine fineness ranging from 350 to 600 m²/kg. This finely ground powder ensures better reactivity and pozzolanic properties.

3. Pozzolanic Reactivity: GGBS exhibits pozzolanic reactivity when mixed with calcium hydroxide (lime) in the presence of water. This reaction produces additional calcium silicate hydrates (C-S-H) and calcium aluminate hydrates (C-A-H), contributing to increased strength and durability of concrete.

4. Sulphate Resistance: The use of GGBS in concrete may enhance sulphate resistance due to its ability to absorb excess calcium hydroxide, thereby reducing the availability of free lime, thus, mitigating the risk of sulphate attack.

6. Alkali-Silica Reaction (ASR) Mitigation: GGBS has been found to be effective in mitigating the risk of alkali-silica reaction (ASR) in concrete by providing a pozzolanic reaction with alkalis, reducing the expansion caused by reactive silica aggregates.

7. Durability Enhancement: Concrete incorporating GGBS typically exhibits improved durability properties, including reduced permeability, increased resistance to chloride ingress, and enhanced resistance to carbonation and corrosion of reinforcement.

6. Fly-Ash: Fly ash is a fine powder consisting of spherical glassy particles generated as a by-product from the combustion of pulverized coal in power plants. It is widely used as a supplementary cementitious material in concrete production due to its pozzolanic and cementitious properties. Here are some technical details about fly ash:

1. Chemical Composition: Fly ash primarily comprises silicon dioxide (SiO2), aluminum oxide (Al2O3), iron oxide (Fe2O3), and calcium oxide (CaO), along with other minor elements such as magnesium oxide (MgO) and sulfur trioxide (SO3). The chemical composition varies depending on the source of coal and combustion conditions.

2. Particle Size Distribution: Fly ash particles range in size from fine powder to larger spherical particles, typically with a median particle size ranging from 5 to 50 micrometers. The particle size distribution influences the reactivity and pozzolanic properties of fly ash in concrete.

3. Pozzolanic Reactivity: Fly ash exhibits pozzolanic reactivity when mixed with calcium hydroxide (lime) in the presence of water. This reaction produces additional calcium silicate hydrates (C-S-H) and calcium aluminate hydrates (C-A-H), which contribute to the strength and durability of concrete.

4. Fineness: The fineness of fly ash, measured by its specific surface area (Blaine fineness), typically ranges from 300 to 600 m²/kg. Finer particles result in better pozzolanic activity and improved concrete performance.

5. Hydraulic Properties: In addition to its pozzolanic reactivity, certain types of fly ash, known as Class C fly ash, also exhibit hydraulic properties. This means they can partially replace Portland cement in concrete mixes and contribute to strength development through hydration reactions.

7. Strength Enhancement: Concrete incorporating fly ash typically exhibits improved compressive strength, flexural strength, and durability compared to plain Portland cement concrete. The pozzolanic reaction and filler effect of fly ash contribute to denser microstructure and reduced permeability.

8. Sulfate Resistance: The use of fly ash in concrete can enhance sulfate resistance by reducing the permeability of concrete and mitigating the risk of sulfate attack on concrete structures.

9. Environmental Benefits: Fly ash utilization in concrete production helps reduce greenhouse gas emissions and conserves natural resources by replacing a portion of Portland cement. It also facilitates the disposal of large quantities of waste material generated by coal combustion, promoting sustainable waste management practices.

Enumerated below are some example mixtures comprising fine aggregates, coarse aggregates, GGBS and fly ash (together referred hereto as premixes) of the present invention in probable ratios to be mixed with the plastics obtained by undergoing the above mentioned treatment. The plastic composition ratio with the premixes are also provided in subsequent paragraphs.

The various composite mixtures that may be utilized for developing the construction materials are enumerated below:

PREMIX- Example 1
Sl.no Mat. Quantity
1 Fine Aggregate 40.3
2 Coarse Aggregate 40.3
3 GGBS 16.12
4 Silica Fumes 3.22
TABLE 1
In this example composition, the treated plastic is taken as 80% by wt. of materials and mixed with 20% by wt. of the premix of Table 1 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.
PREMIX- Example 2
Sl.no Mat. Quantity
1 Fine Aggregate 30
2 Coarse Aggregate 60
3 GGBS 5
4 Fly-ash 5
TABLE: 2
In this example composition, the treated plastic is taken as 70% by wt. of materials and mixed with 30% by wt. of the premix of Table 2 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.
PREMIX- Example 3
Sl.no Mat. Quantity
1 Fine Aggregate 20
2 Coarse Aggregate 40
3 GGBS 20
4 Fly-ash 20
TABLE: 3
In this example composition, the treated plastic is taken as 80% by wt. of materials and mixed with 20% by wt. of the premix of Table 3 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 4
Sl.no Mat. Quantity
1 Fine Aggregate 20
2 Coarse Aggregate 40
3 GGBS 20
4 Fly-ash 20
TABLE: 4
In this example composition, the treated plastic is taken as 85% by wt. of materials and mixed with 15% by wt. of the premix of Table 4 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 5
Sl.no Mat. Quantity
1 Fine Aggregate 5
2 Coarse Aggregate 80
3 GGBS 0
4 Fly-ash 15
TABLE: 5
In this example composition, the treated plastic is taken as 70% by wt. of materials and mixed with 30% by wt. of the premix of Table 5 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 6
Sl.no Mat. Quantity
1 Fine Aggregate 5
2 Coarse Aggregate 95
3 GGBS 0
4 Fly-ash 0
TABLE: 6
In this example composition, the treated plastic is taken as 50% by wt. of materials and mixed with 50% by wt. of the premix of Table 6 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 7
Sl.no Mat. Quantity
1 Fine Aggregate 5
2 Coarse Aggregate 90
3 GGBS 0
4 Fly-ash 5
TABLE: 7
In this example composition, the treated plastic is taken as 60% by wt. of materials and mixed with 40% by wt. of the premix of Table 7 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 8
Sl.no Mat. Quantity
1 Fine Aggregate 0
2 Coarse Aggregate 90
3 GGBS 0
4 Fly-ash 10
TABLE: 8
In this example composition, the treated plastic is taken as 45% by wt. of materials and mixed with 55% by wt. of the premix of Table 8 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 9
Sl.no Mat. Quantity
1 Fine Aggregate 90
2 Coarse Aggregate 5
3 GGBS 0
4 Fly-ash 5
TABLE: 9
In this example composition, the treated plastic is taken as 40% by wt. of materials and mixed with 60% by wt. of the premix of Table 9 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 10
Sl.no Mat. Quantity
1 Fine Aggregate 80
2 Coarse Aggregate 5
3 GGBS 0
4 Fly-ash 15
TABLE: 10
In this example composition, the treated plastic is taken as 45% by wt. of materials and mixed with 55% by wt. of the premix of Table 10 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 11
Sl.no Mat. Quantity
1 Fine Aggregate 70
2 Coarse Aggregate 10
3 GGBS 0
4 Fly-ash 20
TABLE: 11
In this example composition, the treated plastic is taken as 60% by wt. of materials and mixed with 40% by wt. of the premix of Table 11 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 12
Sl.no Mat. Quantity
1 Fine Aggregate 60
2 Coarse Aggregate 10
3 GGBS 0
4 Fly-ash 30
TABLE: 12
In this example composition, the treated plastic is taken as 60% by wt. of materials and mixed with 40% by wt. of the premix of Table 12 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 13
Sl.no Mat. Quantity
1 Fine Aggregate 100
2 Coarse Aggregate 0
3 GGBS 0
4 Fly-ash 0
TABLE: 13
In this example composition, the treated plastic is taken as 30% by wt. of materials and mixed with 70% by wt. of the premix of Table 13 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 14
Sl.no Mat. Quantity
1 Fine Aggregate 0
2 Coarse Aggregate 98
3 GGBS 0
4 Fly-ash 2
TABLE: 14
In this example composition, the treated plastic is taken as 20% by wt. of materials and mixed with 80% by wt. of the premix of Table 14 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX- Example 15
Sl.no Mat. Quantity
1 Fine Aggregate 5
2 Coarse Aggregate 5
3 GGBS 0
4 Fly-ash 90
TABLE: 15
In this example composition, the treated plastic is taken as 40% by wt. of materials and mixed with 60% by wt. of the premix of Table 15 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

PREMIX-Example 16
Sl.no Mat. Quantity
1 Fine Aggregate 20
2 Coarse Aggregate 10
3 GGBS 0
4 Fly-ash 70
TABLE: 16
In this example composition, the treated plastic is taken as 35% by wt. of materials and mixed with 65% by wt. of the premix of Table 16 and the combined homogenous materials is sent to an extruder and heated at a temperature ranging between 180C to 270C, the extruded material is then sent to the paving machine.

The process of production of recycled of waste plastics and developing them into sustainable and durable building materials such as paver blocks, tiles, and other construction products with other aggregates as mentioned above may be summarised as under:
a) Collecting the plastic waste from various sources;
b) Transporting the waste plastics of step (a) by means of feeding conveyer to a trommel for separation of the materials based on size;
c) Transporting the separated size-based materials for manual sorting into a first and second sorting conveyer;
d) Removing dust from the sorted materials by means of de-duster machine;
e) Washing, cleaning and grinding of the dusted materials in a washing line;
f) Drying of the washed material of step (e);
g) Mixing the cleaned and dried material of step (f) with other materials homogenously w/w ratios and the mixture sent to an extruder and heated; and
h) Transferring the extruded lumps to specific sized moulds and then washing the prepared moulds with water for shipping.

The bricks obtained by the above process ha properties as described in the below mentioned table 17, which elaborates the differences in properties of the present invention in comparison to the existing products.

TABLE 17

It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.

, Claims:WE CLAIM:

1. A system of preparing paver bricks from waste plastics comprising the steps of:
i) Collecting the plastic waste from various sources;
j) Transporting the waste plastics of step (a) by means of feeding conveyer to a trommel for separation of the materials based on size;
k) Transporting the separated size-based materials for manual sorting into a first and second sorting conveyer;
l) Removing dust from the sorted materials by means of de-duster machine;
m) Washing, cleaning and grinding of the dusted materials in a washing line;
n) Drying of the washed material of step (e);
o) Mixing the cleaned and dried material of step (f) with other materials homogenously w/w ratios and the mixture sent to an extruder and heated; and
p) Transferring the extruded lumps to specific sized moulds and then washing the prepared moulds with water for shipping;
wherein,
the said paver bricks thus formed possess:
compressive strength ranging from 25MPa-70MPa;
load bearing capacity of 100-150MT;
tensile strength ranging between 20MPa-65MPa;
weight of 1.0-2.9kg;
having water absorption capacity less than 1%;
abrasion resistance(mm3/5000mm2) of 529; and
product life of 10-15 years.

2. The system as claimed in claim 1, wherein the said de-duster machine is equipped with a robust air flow system for creating suction for pulling dust particles away from the plastic films.

3. The system as claimed in claim 1, wherein the said washing line comprises a feeding conveyer, grinder, at least one screw conveyer, floatation tank and a drier.

4. The system as claimed in claim 1, wherein the said feeding conveyer has an inclined design.

5. The system as claimed in claim 1, wherein the said mixture is heated at a temperature ranging between 180C to 270C.

6. The system as claimed in claim 1, wherein the said feeding and sorting conveyer has a length ranging between 10 to 15 meters and a width of 3 feet.

7. The system as claimed in claim 1, wherein the sources for collection of plastic waste is industrial and municipal waste.

8. The system as claimed in claim 1 and 10, wherein the said cleaning agents are any one ethanol, isopropyl alcohol, or acetone.

9. The system as claimed in claim 1 and 10, wherein the said cleaning agents are alkaline fortified with sodium hydroxide or potassium hydroxide.

10. The system as claimed in claim 1 and 10, wherein the said cleaning agents are acidic fortified with citric acid or hydrochloric acid.

11. A plastic waste composite construction material comprising:
treated waste plastic of about 20 wt.%- to about 85 wt.%; and
Fine aggregate of about 0 wt.%- to about 100 wt.%;
Coarse aggregate of about 0 wt.%- to about 98 wt.%;
GGBS of about 0 wt.%- to about 20 wt.%; and
Fly ash of about 0 wt.%- to about 90 wt.%.

12. The plastic waste composite construction material as claimed in claim 11, wherein the size of the plastic is less than 6mm and the particle size of fine aggregates ranges between 4.50- 4.75mm.
13. A method of making paver bricks, the method comprising:
mixing,
treated waste plastic of about 20 wt.%- to about 85 wt.%;
fine aggregate of about 0 wt.%- to about 100 wt.%;
coarse aggregate of about 0 wt.%- to about 98 wt.%;
GGBS of about 0 wt.%- to about 20 wt.%;
fly ash of about 0 wt.%- to about 90 wt.%;
sending the combined materials to an extruder and heated at a temperature ranging between 180C to 270C;
transferring the extruded lumps generated to the paving machine,
transferring the lumps to moulds of predetermined sizes; and
washing the moulds with water for 5 minutes before dispatching.
wherein,
the said paver bricks thus formed possess:
compressive strength ranging from 25MPa-70MPa;
load bearing capacity of 100-150MT;
tensile strength ranging between 20MPa-65MPa;
weight of 1.0-2.9kg;
having water absorption capacity less than 1%;
abrasion resistance(mm3/5000mm2) of 529; and
product life of 10-15 years.

Dated this 16th day of September of 2024
DIGITALLY SIGNED

(Lipika Pain)