Industrial prodaction and sustainable development

-PROJECT-
2014









Lectures: Students:
Prof. Dr. Biolog Camelia Smaranda Caplat Ctlina
Buburuzan Dorin
Plesca Bogdan
Gheorghe Asachi, Technical University of
Iai
Faculty of Chemical Engineering and
Environmental Protection
Domain: Environmental Engineering
Specialization: Environmental
Management and Sustainable Energy
THE EVLUATION OF PLASTIC INDUSTRIAL PROCESS USING
SUSTAINABLE DEVELOPMENT INDICATORS

PET BOTTELS PROCESS
General information on process/industry

The plastics industry is divided into
two broad sectors: raw material suppliers who
produce polymers and resins from intermediates, and
processors who convert these materials into finished
items.
Plastics are synthetic substances produced by
chemical reactions. Almost all plastics are made from
petroleum, except a few experimental resins derived
from corn and other organic substances.
The monomers of petrochemical plastics are
inorganic materials (such as styrene) and are not
biodegradable


Applications
Plastics are versatile materials and are
used to fabricate an enormous array of
products. The development of plastics
has replaced nearly every other traditional
materialincluding wood, stone, leather,
glass, and ceramicsin many applications.
The most common uses for plastic include:
Packaging: bottles, food packaging,
equipment cases
Building materials: pipes and plumbing,
siding
Automobiles: numerous components
Furniture
Toys
PLASTIC BOTTLES
A plastic bottle is a container constructed of plastic, with a neck
that is narrower than its body and an opening at the top. The mouth of the
bottle is normally sealed with a plastic bottle cap. Plastic bottles are typically
used to store liquids such as water, soft drinks, cooking oil, medicine,
shampoo, milk, and ink.

Industrial process description

Before the Bottle is Made
Before a plastic bottle can
be manufactured, the PET must be
made. PET is a polymer that is made
from petroleum hydrocarbons. It
comes from a reaction between
terephthalic acide and ethylene
glycol.
The process to make PET
is called polymerization.


Fig. 1 System Flow Diagram of PET process
Making the Bottle
The process to make PET bottles is called
stretch blow molding. PET pellets are
injection-molded in a thin-walled plastic
tube. The tube is then cooled and cut into
shorter lengths. Each length of tube is
inserted into a mold that is shaped like the
bottle the manufacturer wants to create The
bottle bottom is made from a separate mold
during the process and attached later.



Finishing the Bottle
The mold is then cooled quickly to keep any
of the PET from flowing inside the mold.
The bottle is then removed from the mold
and trimmed to remove and PET that leaked
through cracks in the mold. The bottles are
then packaged and sent to the company that
ordered them.
Process Flow Diagram

Imputs, outputs and consumtion (energy, water, raw materials)

The main output from a plastic bottles process is of course the product, which
represents approximately 70 % of the raw material input.
Process inputs
The Elements: Polyethylene terephthalate (PET) plastics are formed from the combination of
two monomers, ethylene glycol and terephthoyl chloride.
Petrochemical Raw Materials: are petroleum (oil) and natural gas
Additives: Plasticizers, Antioxidants, Lubricants, Foaming agents, Flame retardants,
Colorants, Anti-stats
Energy: According to the plastics manufacturing industry, it takes around 3.4 megajoules of
energy to make a typical one-liter plastic bottle, cap, and packaging.
The production of plastic uses an incredible amount of fossil fuels. Most estimates put the
figure at around 8% of the worlds oil production, 4% of which is actually used in energy
consumption to make the plastic. To give you some idea, it takes about 1/4 of a litre of oil to
produce a 1 litre water bottle







Emissions to air
There are multiple processes occurring at plastic products manufacturing
facilities that give rise to a wide variety of pollutants: making just one tonne of PET
resin produces three tonnes of CO2, as well as arsenic, carbon monoxide,
ethylene glycol, oxides of nitrogen and sulfur dioxide.
Other major emissions from plastic production processes include
sulfur oxides, nitrous oxides, methanol, ethylene oxide, and volatile organic
compounds.
Volatile organic compound (VOC) and hazardous air pollutant (HAP) emissions
resulting from the volatilization of free monomer or solvent in the primary
polymer blend during processing.



Emissions to water
Emissions from the moulding compound are released
into the air during the process. Oil leaks from the hydraulic
systems may contaminate stormwater.
The use of solvents to clean dispensing equipment
may generate liquid wastes that need special handling

Solid waste
The most obvious form of pollution associated with
plastic packaging is wasted plastic sent to landfills. Plastics
are very stable and therefore stay in the environment a long
time after they are discarded, especially if they are shielded
from direct sunlight by being buried in landfills.
Decomposition rates are further decreased by anti-oxidants
that manufacturers commonly add to enhance a containers
resistance to attack by acidic contents.


Hazardous and toxic substances

Manufacturing PET resin generates more toxic emissions (nickel, ethylbenzene,
ethylene oxide, benzene) than manufacturing glass. Producing a 16 oz. PET bottle
generates more than 100 times the toxic emissions to air and water than making the same
size bottle out of glass.
Producing plastics can be hazardous to workers, too. Serious accidents have included
explosions, chemical fires, chemical spills, and clouds of toxic vapor. These kinds of
occurrences have caused deaths, injuries, evacuations and major property damage.
Significant releases of toxic chemicals include:
trichloroethane
acetone
methylene chloride
methyl ethyl ketone
styrene
toluene
benzene
1,1,1 trichloroethane

Identification of pollution prevention
option

EMISSIONS REDUCTION
The reduction of emissions from
plastics processing operations is best achieved
through carefully designed programs to
optimize all aspects of the manufacturing
process, particularly with respect to the use of
raw materials including energy and water.
Continuous improvement is best achieved
through the implementation of an effective
environmental management system..

AIR RESIDUALS GASES AND DUST
Greenhouse gas emissions,
principally CO2, can be reduced by ongoing
improvements in energy efficiency.




Volatile Organic Compounds Reduction
The industry will proceed on two
parallel fronts. First, the industry will secure
the acceptance and funding to pursue
research into an alternative-blowing agent.
Second, the industry will further
investigate possible methods to reduce the
percentage of butane used in production.
Dust Reduction
Fugitive dust levels may also be
reduced through the use of collection systems
located close to key locations within facilities,
such as material handling areas and locations
dedicated to blending and grinding operations.

WASTEWATER AND LIQUID WASTES
Typical preventive measures include
the following:
oil interceptors for plant discharges;
blocking building drains in areas where spills
are likely; and
secondary containment for storage tanks.
Whenever possible, floor drains
within the plant should be capped or sealed to
contain minor spills
SOLID WASTE
Many companies
already recycle packaging
materials. Used gaylords are in
demand by many industries for
use as storage containers.
Substitution of critical raw materials

Taking into consideration that plastic is a petroleum-
based product, recycling plastics reduces dependency on
oil. Making plastic bottels from recycled materials, use
only 40% of the energy needed to produce PET from crude
oil

Waste management recycle/reuse/recovery

Plastic wastes - Reduce, Reuse and Recycle of plastics are essential to make environment
greener and safer. It has been observed, to reduce bad effects of waste plastics, it is better to
recycle and re-utilize waste plastics in environment-friendly manners. As per statistics, about
80% of post-consumer plastic waste is sent to landfill, 8% is incinerated and only 7% is
recycled. In addition to reducing the amount of plastics waste requiring disposal, recycling and
reuse of plastic can have several advantages, such as:
Conservation of non-renewable fossil fuels Plastic production uses 8% of the worlds oil
production, 4% as feedstock and 4% during manufacture.
Reduced consumption of energy.
Reduced amounts of solid waste going to landfill.
Reduced emissions of carbon-dioxide (CO2), nitrogen-oxides (NOx) and sulfur-dioxide
(SO2).
Conclusions
Sustainable industrial production of plastic industry has great advantages
because it uses resources and energy more efficiently and reduce emissions
of greenhouse gases. Therefore, the production of plastic and its use affects
less the environment.
Plastics can be more sustainable if they are made from recycled or bio-
based plastics and are made with lower CO2 emissions and less solid waste.
Sustainable green packaging can be certified with an audit process that
calculates the life cycle assessment of the manufacturing process.
Thank you for your attention!