A system and method for the production of recycled plastic tiles with steel reinforcement

Abstract

The system comprises a robotic collection device for collecting plastic waste; a separation and cleaning chamber for separating each plastic waste from a bunch of plastic waste and washing the plastic chips to remove glue, paper labels, dirt, and any remnants of the product they once contained; a shredding machine for chopping the plastic waste into smaller pieces; a transporting and operating trailer platform for transferring the chopper plastic waste; a metal drum equipped with a heating device and coupled to the transporting and operating trailer platform receiving for melting the chopped plastic waste and mixing steel fibers along with chemicals with continuous stirring; a hydraulic press device coupled with a mold for pressing the mixture to obtain a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes.

Description

FIELD OF THE INVENTIONThe present disclosure relates to a system and method for the production of recycled plastic tiles with steel reinforcement. In more detail, the system is used to safe guard the environment from waste plastic pollution and use plastic waste in producing tiles for construction works.BACKGROUND OF THE INVENTIONPlastic is a very useful substance in our day-to-day life. Since plastic is cheap, easily available and easy to use, we use it in almost everything. But after the use of plastic, it is discarded as waste in landfills and natural environment. Since plastic is non-biodegradable substance, it becomes harmful for the environment. Approximately 6.3 billion tonnes of plastic have been discarded as waste, of which around 79%has accumulated in landfills or the natural environment, 12% was incinerated and 9 % has been recycled. Incinerators are used to dispose the plastic waste but the gases which evolve in process pollutes air and water. Since plastic is very useful substance it is very hard to be replaced completely. Therefore, plastic waste is used to convert it into plastic tiles which can be used as building materials in construction of structures.In the view of the forgoing discussion, it is clearly portrayed that there is a need to have a system and method for the production of recycled plastic tiles with steel reinforcement.SUMMARY OF THE INVENTIONThe present disclosure seeks to provide a system and method for the production of recycled plastic tiles with steel reinforcement for studying the strength properties of plastic tiles and modifying it as per IS standards.In an embodiment, a system for the production of recycled plastic tiles with steel reinforcement is disclosed. The system includes a processing chamber for separating each plastic waste and chopping into smaller pieces using a Shredding Machine thereby washing the plastic chips. The system further includes a metal drum having fire beneath for melting the chopped plastic waste and mixing steel fibers along with chemicals like Aluminum oxide is added to the same container consisting of melted plastic and the mixture is stirred continuously. The system further includes a mold coated with oil for easy de-molding, before placing the mixture and pressing the mixture using a hydraulic press to get a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes, wherein the mold is cooled and the tile is removed from the mold thereby the de-molded is finished / smoothened in the top to get a good finish.In another embodiment, a method for the production of recycled plastic tiles with steel reinforcement is disclosed. The method includes collecting plastic waste through a robotic collection device. The method further includes separating each plastic waste from a bunch of plastic waste and washing the plastic chips to remove glue, paper labels, dirt, and any remnants of the product they once contained using a separation and cleaning chamber. The method further includes chopping the plastic waste into smaller pieces upon deploying a shredding machine. The method further includes transferring the chopper plastic waste via a transporting and operating trailer platform. The method further includes receiving chopped plastic waste in a metal drum through the transporting and operating trailer platform for melting the chopped plastic waste by a heating device coupled to the metal drum and mixing steel fibers along with chemicals with continuous stirring. The method further includes receiving mixture into a mold for pressing the mixture by a hydraulic press device to obtain a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes, wherein the mold is cooled and the tile is removed from the mold. The method further includes smoothening an upper surface of the de-molded tile to get a smooth and shiny finish using a tile smoothening machine.An object of the present disclosure is to safe guard the environment from waste plastic pollution.Another object of the present disclosure is to use plastic waste in producing tiles for construction works.Another object of the present disclosure is to study the strength properties of plastic tiles and modifying it as per IS standards.Yet another object of the present invention is to deliver an expeditious and cost-effective system for the production of recycled plastic tiles with steel reinforcement.To further clarify advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.BRIEF DESCRIPTION OF FIGURESThese and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:Figure 1 illustrates a block diagram of a system for the production of recycled plastic tiles with steel reinforcement in accordance with an embodiment of the present disclosure;Figure 2 illustrates a flow chart of a method for the production of recycled plastic tiles with steel reinforcement in accordance with an embodiment of the present disclosure;Figure 3 illustrates the plastic waste in accordance with an embodiment of the present disclosure;Figure 4 illustrates the plastic waste generation in India in accordance with an embodiment of the present disclosure;Figure 5 illustrates the smooth finished plastic tile after polish in accordance with an embodiment of the present disclosure;Figure 6 illustrates the recycled plastic tiles in accordance with an embodiment of the present disclosure;Figure 7 illustrates a polythene plastic waste in accordance with an embodiment of the present disclosure;Figure 8 illustrates a shredding machine in accordance with an embodiment of the present disclosure; andFigure 9 illustrates a melting Barrel in accordance with an embodiment of the present disclosure.Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.DETAILED DESCRIPTION:For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.Reference throughout this specification to "an aspect", "another aspect" or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises...a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.Referring to Figure 1, a block diagram of a system for the production of recycled plastic tiles with steel reinforcement is illustrated in accordance with an embodiment of the present disclosure. The system 100 includes a robotic collection device 102 for collecting plastic waste.In an embodiment, a separation and cleaning chamber 104 is used for separating each plastic waste from a bunch of plastic waste and washing the plastic chips 106 to remove glue, paper labels, dirt, and any remnants of the product they once contained.In an embodiment, a shredding machine 108 is used for chopping the plastic waste into smaller pieces.In an embodiment, a transporting and operating trailer platform 110 is used for transferring the chopper plastic waste.In an embodiment, a metal drum 112 is equipped with a heating device 114 and coupled to the transporting and operating trailer platform receiving for melting the chopped plastic waste and mixing steel fibers along with chemicals with continuous stirring.In an embodiment, a hydraulic press device 116 is coupled with a mold 118 for pressing the mixture to obtain a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes, wherein the mold is cooled and the tile is removed from the mold.In an embodiment, a tile smoothening machine 120 is used for smoothening an upper surface of the de-molded tile to get a smooth and shiny finish.In another embodiment, the chemical is preferably selected from Aluminum oxide, which is added to the metal drum and stirring continuously, wherein more metal oxides are added for improve the hardness and brittleness of the tiles.In another embodiment, the mold is coated with oil before placing the mixture for easy demolding of the prepared plastic tiles.In another embodiment, chopped plastic waste are heated at 150°C - 170°C temperature, and once the plastic starts melting the heating is stopped, wherein the chopped plastic waste is heated in absence of oxygen or presence of very less oxygen to avoid damaging of quality of plastic waste.In another embodiment, the Aluminum oxide is added little by little in quantity and stirred for uniform mixing.In another embodiment, the mixture is quickly removed using the spade with the metal shaft 122 and put into the mold with the trowel, wherein the press and work the mixture into the mold so there are no air gaps, wherein once the mold is completely prepared, the mold is cooled either by air cooling or by placing it in water.In another embodiment, the separation and cleaning chamber for separating each plastic waste comprises an infrared LEDs array 124 for projecting infrared light from the plastic waste to one or more detectors 126 to provide a spectral content, with at least two distinct frequency components, through the waste.In one embodiment, a computing device 128 for evaluating the spectral content of the infrared light that is reflected by the plastic waste.In one embodiment, a central processor 130 for comparing the spectral content of the infrared light transmitted through the plastic waste to known spectral content profiles for two or more materials to evaluate which of the two or more materials comprise the plastic waste.In another embodiment, waste plastic is selected from waste elements of plastic bottles, Plastic containers, Reusable water bottles), plastic bags (low-density polyethylene plastic), Shampoo Bottles, a Grocery bags (high-density polyethylene plastic).Figure 2 illustrates a flow chart of a method for the production of recycled plastic tiles with steel reinforcement in accordance with an embodiment of the present disclosure. At step 202, the method 200 includes collecting plastic waste through a robotic collection device.At step 204, the method 200 includes separating each plastic waste from a bunch of plastic waste and washing the plastic chips to remove glue, paper labels, dirt, and any remnants of the product they once contained using a separation and cleaning chamber.At step 206, the method 200 includes chopping the plastic waste into smaller pieces upon deploying a shredding machine.At step 208, the method 200 includes transferring the chopper plastic waste via a transporting and operating trailer platform.At step 210, the method 200 includes receiving chopped plastic waste in a metal drum through the transporting and operating trailer platform for melting the chopped plastic waste by a heating device coupled to the metal drum and mixing steel fibers along with chemicals with continuous stirring.At step 212, the method 200 includes receiving mixture into a mold for pressing the mixture by a hydraulic press device to obtain a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes, wherein the mold is cooled and the tile is removed from the mold.At step 214, the method 200 includes smoothening an upper surface of the de-molded tile to get a smooth and shiny finish using a tile smoothening machine.In another embodiment, the plastic waste is separated upon evaluating the plastic waste, in which analyzing includes projecting infrared light from the plastic waste to one or more detectors to provide a spectral content, with at least two distinct frequency components, through the waste. Then, evaluating the spectral content of the infrared light that is reflected by the plastic waste. Then, comparing the spectral content of the infrared light transmitted through the plastic waste to known spectral content profiles for two or more materials to evaluate which of the two or more materials comprise the plastic waste.Figure 3 illustrates the plastic waste in accordance with an embodiment of the present disclosure.Figure 4 illustrates the plastic waste generation in India in accordance with an embodiment of the present disclosure.Figure 5 illustrates the smooth finished plastic tile after polish in accordance with an embodiment of the present disclosure.Figure 6 illustrates the recycled plastic tiles in accordance with an embodiment of the present disclosure.Figure 7 illustrates a polythene plastic waste in accordance with an embodiment of the present disclosure.Following Methodology is used for the production of recycled plastic tiles with steel reinforcement•Material collection•Manual sorting•Chipping•Washing•Melting of plastic material•Moulding•Demoulding•FinishingMaterial Collection:Materials Used: - Plastic Waste: - Waste plastic generated from waste elements of plastic bottles, Plastic containers, Reusable water bottles), plastic bags (low-density polyethylene plastic), Shampoo Bottles, Grocery bags (high-density polyethylene plastic).Manual sorting:Each plastic waste type is separated from each other and unwanted materials are removed from the waste, like in waste plastic bottles, the plastics normally attached on the skin of bottles and the bottle caps were removed.Figure 8 illustrates a shredding machine in accordance with an embodiment of the present disclosure.Chipping:The various plastic waste which are sorted are then chopped into smaller pieces using Shredding Machine.Washing:The chips are then washed to remove glue, paper labels, dirt and any remnants of the product they once contained.Melting:Light a small fire under the metal drum 104 and gently heat it. The chipped plastic waste is weighed and then added to the drum. As it warms up it will reduce in size. Keep adding plastic gently at the side. Keep heating till the plastic starts melting till (150°C - 170°C). Once the plastic starts melting, stop heating it.Figure 9 illustrates a melting Barrel in accordance with an embodiment of the present disclosure.Mixing of Materials:The Steel fibers along with chemical like Aluminum oxide is added to the same container consisting melted plastic and the mixture is stirred continuously. This is to make the plastic tiles fire resistant. The Aluminum oxide shall be added little by little in quantity and stirred.Moulding:The moulds are coated with oil for easy demoulding, before placing the mixture. Quickly remove the mixture using the spade with the metal shaft and put it into the mould with the trowel. Press and work the mixture into the mould so there are no air gaps. The mixture is then pressed using hydraulic press 108 to get a compact and hard tile 116.Demoulding:Allow the hot mixture in the mould to set for a few minutes. Once the mould is completely prepared, the mould is cooled either by air cooling or by placing it in water. After the mould is cooled, the tile is removed from the mould.Finishing: After the tile is demoulded, the tile is then finished or smoothened in the top to get a good finish.The plastic waste is not being recycled effectively. Approximately 6.3 billion tonnes of plastic have been discarded as waste out of which majority waste is leftover in landfills and natural surroundings which causes land pollution, Water pollution, etc.Since plastic is a nonbiodegradable substance, it remains in the land and natural surroundings emitting toxic chemicals. Since the plastic wastes are not segregated properly it is left over in landfills, etc.Advantages of the invention are:•To protect the environment from the plastic pollution.•Use of plastic waste in manufacturing of tiles which may be used in construction industry.•To safeguard the animals from consumption of plastic waste which may lead to health problems in animals.•To protect the environment from toxic gases like dioxins, mercury etc. liberated due to burning of plastic.Various goals:•To safe guard the environment from waste plastic pollution.•Using plastic waste in producing tiles for construction works.•Studying the strength properties of plastic tiles and modifying it as per IS standards.Advantages of using plastic waste in construction are:•A new type of tiles in market which is cheaper and stronger than standard available tiles.•Use of plastic waste in manufacturing of tiles which may be used in construction industry.•To safeguard the animals from consumption of plastic waste which may lead to health problems.•To protect the environment from toxic gases like dioxins, mercury etc. liberated due to burning of plastic.Disadvantages:•The strength of tiles is less compared to floor tiles.•Finishing of tiles is also lesser than the floor tiles.Recycled plastic tiles with fiber reinforcement will give higher strength tiles which is used in construction industry.•Plastic tiles made out of plastic waste is comparatively equal to normally available tiles, therefore it can be used as a replacement for normally available tiles.•Water absorption of plastic tiles is almost equal to zero.•Compressive strength of plastic tiles is 42N / sqmm, Abrasion resistance of plastic tiles is0.6cm and Impact resistance of plastic tiles is 2mm.•Plastic tiles can be cost effective too as it is made of plastic waste only.• Waste plastic, which is available everywhere, may be put to an effective use in tiles.• Plastic tiles can help to reduce the environmental pollution, thereby making the environment clean and healthy.Industrial applications of the system:i) The recycled plastic tiles are used as flooring tiles in the construction industryii) The recycled plastic tiles are used for aesthetic finishing of buildingsiii) They are used as wall tiles also.The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims.

Claims

1. A system for the production of recycled plastic tiles with steel reinforcement, the system comprises: a robotic collection device for collecting plastic waste; a separation and cleaning chamber for separating each plastic waste from a bunch of plastic waste and washing the plastic chips to remove glue, paper labels, dirt, and any remnants of the product they once contained; a shredding machine for chopping the plastic waste into smaller pieces; a transporting and operating trailer platform for transferring the chopper plastic waste; a metal drum equipped with a heating device and coupled to the transporting and operating trailer platform receiving for melting the chopped plastic waste and mixing steel fibers along with chemicals with continuous stirring; a hydraulic press device coupled with a mold for pressing the mixture to obtain a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes, wherein the mold is cooled and the tile is removed from the mold; and a tile smoothening machine for smoothening an upper surface of the de-molded tile to get a smooth and shiny finish.

2. The system as claimed in claim 1, wherein the chemical is preferably selected from Aluminum oxide, which is added to the metal drum and stirring continuously, wherein more metal oxides are added for improve the hardness and brittleness of the tiles.

3. The system as claimed in claim 1, wherein the mold is coated with oil before placing the mixture for easy de-molding of the prepared plastic tiles.

4. The system as claimed in claim 1, wherein chopped plastic waste are heated at 150°C -170°C temperature, and once the plastic starts melting the heating is stopped, wherein the chopped plastic waste are heated in absence of oxygen or presence of very less oxygen to avoid damaging of quality of plastic waste.

5. The system as claimed in claim 1, wherein the Aluminium oxide is added little by little in quantity and stirred for uniform mixing.

6. The system as claimed in claim 1, wherein the mixture is quickly removed using the spade with the metal shaft and put into the mold with the trowel, wherein the press and work the mixture into the mold so there are no air gaps, wherein once the mold is completely prepared, the mold is cooled either by air cooling or by placing it in water.

7. The system as claimed in claim 1, wherein the separation and cleaning chamber for separating each plastic waste comprises: an infrared LEDs array for projecting infrared light from the plastic waste to one or more detectors to provide a spectral content, with at least two distinct frequency components, through the waste; a computing device for evaluating the spectral content of the infrared light that is reflected by the plastic waste; and a central processor for comparing the spectral content of the infrared light transmitted through the plastic waste to known spectral content profiles for two or more materials to evaluate which of the two or more materials comprise the plastic waste.

8. The system as claimed in claim 1, wherein waste plastic is selected from waste elements of plastic bottles, Plastic containers, Reusable water bottles), plastic bags (low-density polyethylene plastic), Shampoo Bottles, an Grocery bags (high-density polyethylene plastic).

9. A method for the production of recycled plastic tiles with steel reinforcement, the method comprises: collecting plastic waste through a robotic collection device; separating each plastic waste from a bunch of plastic waste and washing the plastic chips to remove glue, paper labels, dirt, and any remnants of the product they once contained using a separation and cleaning chamber; chopping the plastic waste into smaller pieces upon deploying a shredding machine; transferring the chopper plastic waste via a transporting and operating trailer platform; receiving chopped plastic waste in a metal drum through the transporting and operating trailer platform for melting the chopped plastic waste by a heating device coupled to the metal drum and mixing steel fibers along with chemicals with continuous stirring; receiving mixture into a mold for pressing the mixture by a hydraulic press device to obtain a compact and hard tile, wherein the hot mixture in the mold is allowed to set for a few minutes, wherein the mold is cooled and the tile is removed from the mold; and smoothening an upper surface of the de-molded tile to get a smooth and shiny finish using a tile smoothening machine.

10. The method as claimed in claim 9, wherein the plastic waste is separated upon evaluating the plastic waste, in which analyzing includes: projecting infrared light from the plastic waste to one or more detectors to provide a spectral content, with at least two distinct frequency components, through the waste; evaluating the spectral content of the infrared light that is reflected by the plastic waste; and comparing the spectral content of the infrared light transmitted through the plastic waste to known spectral content profiles for two or more materials to evaluate which of the two or more materials comprise the plastic waste.