UNIVERSITI TEKNIKAL MALAYSIA MELAKA

ASSIGNMENT (PAIR WORK)

BMFB 2213

MATERIAL ENGINEERING

SEMESTER 1 SESSION 2010/2011

FACULTY OF MANUFACTURING ENGINEERING

ROBOTIC AND AUTOMATION (BMFA)

NAME OF MEMBERS:

NORAIDAH BTE BLAR B050910225

RADIN PUTERI HAZIMAH BINTI RADIN MONAWIR B050910192

NAME OF LECTURER:

EN. JEEFFERIE BIN ABD. RAZAK

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ACKNOWLEDGEMENT

First and foremost, we would like to thank to our lecturer for our Material Engineering subject,

Mr. Jeefferie bin Abd. Razak for his valuable guidance and advice. His willingness to motivate

us contributed tremendously to our project and our study for this subject. We also would like to

thank him for showing us some example that related to the topic of our project.

Besides, we would like to thank the authority of all hostels in Universiti Teknikal Malaysia

Melaka (UTeM) for providing us with a good environment and facilities to complete this project.

Finally, an honorable mention goes to our families and friends for their understandings and

supports on us in completing this project. Without helps of the particular that mentioned above,

we would face many difficulties while doing this project.

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ABSTRACT

Nowadays, the world is facing with the gigantic problems on the wastes from human. Everyday,

people will consume large amount of waste. Therefore, quick action should be taken to overcome

these dangerous problems. One of the effective steps is by recycling the waste according to its

categories. Wastes that can be recycled include glass, paper, metal, plastic, textiles,

and electronics. Among all these recycled waste, we choose plastics as our research. We choose

plastics because to find out types of recycle materials and select a material to be studied, to

appreciate the engineering material for sustainable use by studying the process of plastic recycle,

to recognize the properties of recyclable plastics and the its product of recycled, to investigate

the manufacturing process that involved in the plastic recycling process, and to find out the latest

advanced technology and recycle of plastics. Besides that, we find a lot of information about

plastics as recyclable materials: types, characteristics, symbols etc. Next, we were searching on

the advanced technology on recycling plastics. There are many products that can be produced by

the recycled plastics. In this report, we include two products along with their process of making.

First, we discover that recycled plastic bags can be used as biofuel. Second, the recycled plastic

bottles can be used as mini car. Overall, we found out that there are many products can be

produced by the waste materials and how important recycling in human daily life.

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TABLE OF CONTENT

CHAPTER TOPIC PAGE

ACKNOWLEDGEMENT 2

ABSTRACT 3

1 INTRODUCTION

1.1 Background 5-6

1.2 Objectives 6

1.3 Scope 6

2 PLASTICS RECYCLING 7-17

3 RESULTS AND DISCUSSION 18-25

4 CONCLUSION 26

REFERENCES 27

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CHAPTER 1

INTRODUCTION

1.1 Background

Recycling involves processing used materials (waste) into new products to prevent waste

of potentially useful materials, reduce the consumption of fresh raw materials, reduce energy

usage, reduce air pollution (from incineration) and water pollution (from landfilling) by

reducing the need for "conventional" waste disposal, and lower greenhouse gas emissions as

compared to virgin production. Recycling is a key component of modern waste reduction and

is the third component of the "Reduce, Reuse, Recycle" waste hierarchy.

Recyclable materials include many kinds of glass, paper, metal, plastic, textiles, and

electronics. Although similar in effect, the composting or other reuse of biodegradable waste

– such as food or garden waste – is not typically considered recycling. Materials to be

recycled are either brought to a collection center or picked up from the curbside, then sorted,

cleaned, and reprocessed into new materials bound for manufacturing.

In a strict sense, recycling of a material would produce a fresh supply of the same

material—for example, used office paper would be converted into new office paper, or used

foamed polystyrene into new polystyrene. However, this is often difficult or too expensive

(compared with producing the same product from raw materials or other sources), so

"recycling" of many products or materials involve their reuse in producing different materials

(e.g., paperboard) instead. Another form of recycling is the salvage of certain materials from

complex products, either due to their intrinsic value (e.g., lead from car batteries, or gold

from computer components), or due to their hazardous nature (e.g., removal and reuse of

mercury from various items).

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Although there are many types of recyclable material, plastics are the most common

waste product that usually polluted the landfill. Just imagine, the amount of solid waste

generated in Peninsular Malaysia was 19,100 tons in 2005, and 24 % of it was plastics

waste. In Europe for example, it is estimated that 100 million tonnes of plastics are produced

each year. As we are believing that this all plastic waste is not a really a waste but a wage, we

decided to do a study on plastic recycling process. In order to complete this assignment, we

gathered the information about the basic chemical and physical properties of plastics, process

to recycle it and the product that able to be produced from it. The most interesting part is the

advanced technology, where the latest research and find of recycled plastics is unearthed.

1.2 Objectives

The main objectives of this assignment are:

i. to find out types of recycle materials and select a material to be studied.

ii. to appreciate the the engineering material for sustainable use by studying the

process of plastic recycle.

iii. to recognize the properties of recyclable plastics and the its product of

recycled.

iv. to investigate the manufacturing process that involved in the plastic recycling

process.

v. to find out the latest advanced technology and recycle of plastics.

1.3 Scopes

In this assignment, we have limited the scope of recycling materials to plastic only. Only

certain characteristic of plastic which is related to its ability to be recycled is discussed;

properties that make the plastic can be recycled and type of plastics that can be recycled. In this

assignment, although we have stated many types of recycle product of plastic, we only highlight

a product which is plastic lumber to be discussed in term of its manufacturing process and used.

For advanced technology, a few example of latest research is stated.

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CHAPTER 2

PLASTIC RECYCLING

2.1 Plastic as a recyclable material

Plastic recycling is the process of recovering scrap or waste plastics and reprocessing the

material into useful products, sometimes completely different in form from their original

state. For instance, this could mean melting down soft drink bottles and then casting them as

plastic chairs and tables. Typically a plastic is not recycled into the same type of plastic, and

products made from recycled plastics are often not recyclable.

2.1.1 Properties of plastic

The term “plastics” is used to describe a wide variety of resins or polymers with different

characteristics and uses. Polymers are long chains of molecules, a group of many units, taking its

name from the Greek “poly” (meaning “many”) and “meros” (meaning “parts” or “units”).

The term “polymer” is often used as a synonym for plastic, but many other types of

molecules — biological and inorganic — are also polymeric. While all plastics are polymers, not

all polymers are plastic. Polymers are rarely useful in themselves and are most often modified or

compounded with additives (including colours) to form useful materials. The compounded

product is generally termed a plastic. Most people have little contact with "polymers" because

most articles that they come across are actually modified and coloured and therefore are actually

plastics. Polymers can be classified in many ways, based on how they are developed and

perform. For this discussion of recycling, an understanding of two basic types of polymers is

helpful:

 

Thermoplastic polymers can be heated and formed, then heated and formed again and

again. The shapes of the polymer molecules are generally linear or slightly branched.

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This means that the molecules can flow under pressure when heated above their melting

point.

Thermoset polymers undergo a chemical change when they are heated, creating a three-

dimensional network. After they are heated and formed, these molecules cannot be re-

heated and re-formed.

Comparing these types, thermoplastics are much easier to adapt to recycling.

2.1.2 Properties that make plastic hard to be recycled

When compared to other materials like glass and metal materials, plastic polymers

require greater processing to be recycled. Plastics have a low entropy of mixing, which is due to

the high molecular weight of their large polymer chains. A macromolecule interacts with its

environment along its entire length, so its enthalpy of mixing is large compared to that of an

organic molecule with a similar structure. Heating alone is not enough to dissolve such a large

molecule; because of this, plastics must often be of nearly identical composition in order to mix

efficiently.

When different types of plastics are melted together they tend to phase-separate, like oil

and water, and set in these layers. The phase boundaries cause structural weakness in the

resulting material, meaning that polymer blends are only useful in limited applications.

Another barrier to recycling is the widespread use of dyes, fillers, and other additives in

plastics. The polymer is generally too viscous to economically remove fillers, and would be

damaged by many of the processes that could cheaply remove the added dyes. Additives are less

widely used in beverage containers and plastic bags, allowing them to be recycled more

frequently. The use of biodegradable plastics is increasing. If some of these get mixed in the

other plastics for recycling, the reclaimed plastic is not recyclable because the variance in

properties and melt temperatures.

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Figure 1: mixed waste plastic requiring sorting before it can recycled

Hence, in order to recycle plastic, we have to separate the plastic according to

identification code first. The recycling process is easier when different types of plastic are not

mixed together.

2.1.3 Plastic identification code

Plastic Identification code (PIC), PIC was introduced by the Society of the Plastics

Industry, Inc. which provides a uniform system for the identification of different polymer types

and helps recycling companies to separate different plastics for processing.

Figure 2: Plastic Identification Code(PIC) of Polyethylene

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Type number of plastic polymer

Indicate the plastic can be recycled

Abbreviation of plastic name

Consumers can identify the plastic types based on the codes usually found at the base or

at the side of the plastic products, including food/chemical packaging and containers. The PIC is

usually not present on packaging films, as it is not practical to collect and recycle most of this

type of waste.

Plastic

Identification

Code

Type of plastic polymer Properties Common Packaging

Applications

Polyethylene terephthalate

(PET, PETE)Clarity, strength,

toughness, barrier to

gas and moisture.

Soft drink, water and

salad dressing bottles;

peanut butter and jam

jars

High-density polyethylene

(HDPE)Stiffness, strength,

toughness, resistance

to moisture,

permeability to gas

Water pipes, Hula-

Hoop (children's

game) rings, Milk,

juice and water

bottles; the occasional

shampoo / toiletry

bottle

Polyvinyl chloride (PVC) Versatility, clarity,

ease of blending,

strength, toughness

Juice bottles; cling

films; PVC piping

Low-density polyethylene

(LDPE) Ease of processing,

strength,toughness,

flexibility, ease of

sealing, barrier to

moisture.

Frozen food bags;

squeezable bottles,

e.g. honey, mustard;

cling films; flexible

container lids.

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Polypropylene (PP Strength, toughness,

resistance to heat,

chemicals, grease and

oil, versatile, barrier

to moisture.

Reusable

microwaveable ware;

kitchenware; yogurt

containers; margarine

tubs; microwaveable

disposable take-away

containers; disposable

cups

Polystyrene (PS) Versatility, clarity,

easily formed

Egg cartons; packing

peanuts; disposable

cups, plates, trays and

cutlery; disposable

take-away containers;

Other (often polycarbonate

or ABS)

Dependent on

polymers or

combination of

polymers

Beverage bottles;

baby milk bottles;

electronic casing.

Table 1: Plastic Identification Code (PIC) table

2.2 Recycle process of plastic

Industrial waste (or primary waste) can often be obtained from the large plastics

processing, manufacturing and packaging industries. Rejected or waste material usually has good

characteristics for recycling and will be clean. Although the quantity of material available is

sometimes small, the quantities tend to be growing as consumption, and therefore production,

increases. Commercial waste is often available from workshops, craftsmen, shops, supermarkets

and wholesalers. A lot of the plastics available from these sources will be PE, often

contaminated. The following flow chart is plastic reprocessing in low income country.

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Figure 3: Flow chart of a typical plastic reprocessing in a low-income country.

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-Plastic is washed and chopped into flakes.

-mixed plastic sorting into floatation tank,some types of plastic will float, other sink.

-plastic are dired in tumble dryer

-drying flakes fed into ectruder, melt by pressure and heat.

-different plastic melt at different temperature

-molten plastic forced through fine screen,remove any contaminant.

-molten plastic is then formed into strands

-stands is cooled in water and then chopped into uniform pellets.

Figure 4: Plastic manufacturing techniques; extrusion (top), blow molding (middle) and

injection molding (bottom).

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2.3 Common product of recycled plastics

There is an almost limitless range of products that can be produced from plastic.

However, the market for recycled plastic products is limited due to the inconsistency of the raw

material. Many manufacturers will only incorporate small quantities of well-sorted recycled

material in their products whereas others may use a much higher percentage of recycled

polymers. Much depends on the quality required.

In developing countries, where standards are often lower and raw materials very

expensive, there is a wider scope for use of recycled plastic material. The range of products

varies from building materials to shoes, kitchen utensils to office equipment, sewage pipe to

beauty aids. The type of plastic and its product of recycled is shown as in the table below:

Type of plastic Product of recycled

Polyethylene

terephthalate

Cleaning products or other non-food containers, egg

cartons, strapping, surfboards, sailboat hulls, industrial

paints, and fiber products (t-shirts, jackets and carpets).

High-density polyethylene

Plastic lumber, base cups for soft drink bottles, flower

pots, plastic toys, traffic barrier cones, bottle carriers,

trash cans, detergent bottles, garbage bags and grocery

bags.

polyvinyl chloride

drainage piping, fencing, handrails and house siding

polypropylene auto parts, batteries, bird feeders, furniture, pails, water

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meter boxes, bag dispensers, golf equipment, carpets,

recycling containers, and industrial fibers.

polystyrene or

polystyrene foam

polystyrene products as well as insulation, plastic

lumber, license plate frames, cafeteria trays, and hard

plastic pens.

Table 2: Type of plastic and recycled product

2.3.1 Lumber plastic as a product of recycled plastic

Plastic lumber (PL) is a 100% recyclable material lumber or timber made

of recycled plastic. It is composed of virgin or waste plastics

including HDPE, PVC, PP, ABS, PS and PLA. The powder or pellets are mixed to a dough-

like consistency at roughly 400 degrees F and then extruded or molded to the desired shape.

Additives such as colorants, coupling agents, stabilizers, blowing agents, reinforcing agents,

foaming agents, lubricants help tailor the end product to the target area of application. The

material is formed into both solid and hollow profiles or into injection molded parts and

products.

Resin, regrind, and most of the additives are combined and processed in a pelletizing

extruder. The new material pellets are formed in mold and cooled. Pre-distribution testing

can help determine the optimal combination of chemical agents, design, agitation and other

flow aid strategies for the specific material in use. Modern testing facilities are available to

evaluate materials and determine the optimal combination of equipment components to

assure the highest level of accuracy and reliability. Computerized performance test reports

document equipment performance.

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Figure 5: Various colour of plastic lumber

Figure 6: Table that make of plastic lumber

Plastic Lumber is still a very new material relative to the long history of natural lumber as

a building material but can be substituted in many instances. Besides being 100% resistant

to rot, the major advantage of this category of building materials is its ability to add another

stage of reusability. Unlike wood-plastic composite lumber, plastic lumber is 100%

recyclable after its original intended use.

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A major advantage over wood is the ability of the material to be molded to meet almost

any desired spatial conditions. It can also be bent and fixed to form strong arching curves.

Plastic lumber behaves like wood and can be shaped using conventional woodworking

tools. At the same time, it is water proof and resists all types of rot and mold, although they

are not as rigid as wood and may slightly deform in extremely hot weather. The material is

not sensitive to staining from a variety of agents. A major selling point of this material is its

lack of need of paint as it is manufactured in a variety of colors, but are widely available in

grays and earth tones.

Plastic lumber is more environmentally friendly and requires less maintenance than the

alternatives of wood/plastic composites or solid wood of rot-resistant species. Impervious to

cracking and splitting (with correct installation), these materials can be molded with or

without simulated wood grain details. Even with the wood grain design these materials are

still visually easy to distinguish from natural timber as the grains are the same uniform color

as the rest of the material. Well-known trade names include MAXiTUF and Bear Board.

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CHAPTER 3

DISCUSSION AND RESULTS

3.0 Advanced Technology of Plastics

3.1 Definition

The terms chemical recycling and feedstock recycling of plastics, sometimes collectively

referred to as advanced recycling technologies, describe a family of plastics recycling processes

that convert solid plastic materials into smaller molecules (chemical intermediates). These

chemical intermediates, which can be liquids or gases or solids, are suitable for use as feedstocks

for the production of new petrochemicals and plastics. The process can be likened to separating a

long freight train into its individual railroad cars in a freight yard, and then putting the train back

together, perhaps in a slightly different form, at a later time. These technologies can complement

conventional mechanical recycling, a process that directly recovers clean plastics for reuse as

high molecular weight plastics in the manufacture of new plastic products.  The intention of

advanced recycling technologies continues to be the processing of materials not suitable for

successful mechanical recycling into useful chemicals.  The challenge has been to find robust

technologies and satisfactory business models.

Like all plastics recycling processes, technical and economic feasibility and overall commercial

viability of advanced recycling methods must be considered at each step of the recycling chain.

Collection, processing, and marketing are each critical to the success of chemical and feedstock

recycling. Today, with few exceptions, these technologies remain developmental and have not

yet proven themselves sustainable in a competitive market. Nevertheless, they remain of

considerable interest for their longer term potential.

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3.2 Plastic Bags to Power

Entrepreneurs have been trying for years to turn low-value wastes into high-value products.

Waste plastic is among the lowest in value, and gasoline or diesel fuel the highest, but machines

that carry out that conversion usually consume a lot of energy and get gummed-up by leftover

material that they cannot convert.

Rather than languishing in landfills or littering roadsides, plastic bags could make their way into

useful products like toner, lubricants, or rechargeable cell phone or laptop batteries, if new

research becomes commercialized. Plastic recycling is limited by the fact that different types of

plastic cannot be mixed. The quality of the resulting recycled plastic may also be poor. That is

why recycling is not very successful. If the plastics bags degraded, we can take the different

kinds of plastics together.

Figure 7: Plastic to Fuel Plant

In a process that is as simple as throwing bits of plastic in a chamber and heating it up, we can

turn the plastic into tiny spheres of pure carbon just a few microns across. These spheres, which

conduct heat and electricity, could be useful in a long list of applications from tires to batteries to

lubricants. Adding the spheres to tires, for instance, could dissipate the heat generated from

friction against the road, protecting the rubber from melting.

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It is also working very well as an anode for a lithium ion rechargeable battery. These are the

types of batteries used in mobile phones and laptops, for instance. Carbon nanotubes made from

plastic bags via a similar process for several applications including rechargeable batteries.

Carbon microspheres are also useful in lubricants, toner, paint and filters.

Rather than just melting the waste plastic and re-extruding it, the process continues to heat

plastic bags or other plastic waste past the point of melting. He holds the material in a sealed

container that builds up pressure as the material gets hotter and hotter and becomes a gas.

At high temperatures and pressures in the chamber, the plastic decomposes into its elements. If

the chamber is filled with inert gas instead of air, the hydrogen in the plastic becomes hydrogen

gas, which can be collected and used as hydrogen fuel.

The carbon in the plastic forms spheres or egg-shapes depends on the type of waste plastic used

in the reactor. The uniform size and shape make the spheres particularly useful for certain

applications, like filtration, where packing tightly together is useful. Microspheres are expensive

to make using the current technology.

Now a company in Washington, D.C., is trying out a new way — heating the plastic to a very

carefully controlled temperature range, with infrared energy.

The company, Envion, is expected to cut the ribbon on Wednesday morning on a $5 million

plant that it says will annually convert 6,000 tons of plastic into nearly a million barrels of

something resembling oil. The product can be blended with other components and sold as

gasoline or diesel.

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Figure 8: Process of Plastic to Fuel

The company is the world’s largest oil consumer and the world’s biggest producer of waste. The

chairman and chief executive of the company is Michael Han.

Montgomery County, just north of Washington, D.C., apparently agrees, at least to the extent

that it is giving Mr. Han a free supply of plastic and a spot at its waste transfer station to set up

shop.

Mr. Han pointed out bales of plastics waiting to be shredded and fed into his machine, including

planters, McDonald’s large-sized beverage cups, margarine containers and other materials

typical of what suburban residents put out in blue bins once a week for pick-up. His machine can

digest the blue bins too.

Indeed, the machine will take everything except PET (the bottle with the “1’’ on the bottom)

because those have a higher value on the recycling market. He will process the caps, though.

The finished product looks like a slightly murky lemonade and smells somewhere between

gasoline and diesel fuel. One company has already agreed to buy the material for blending into

motor fuel, and Mr. Han said he is in discussion with others. Envion would like to license its

technology for use around the world.

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Mr. Han and other company officials were a little vague on some details, which they said were

proprietary, but the plant essentially consists of a two-story-high chemical reactor with an

internal agitator (for mixing up the soup) and heating elements that give off infrared energy.

Another trick is to limit the amount of oxygen.

Because the process is driven by electricity and not with an open flame, the temperature can be

tightly controlled, so most of the material — about 82 percent, according to the company —

becomes liquid fuel.

Company executives predicted that they would have to shut down to clean out leftover sludge

two to four times a year (conventional processes get clogged much faster). The sludge can be

burned for energy too, but it has much lower value.

Production depends on the plastic used as feedstock, but each ton of waste will produce 3 to 5

barrels of product, according to Envion. Producing a barrel consumes between 59 and 98

kilowatt-hours — two or three days’ worth of electricity for a typical house. The price of

electricity per gallon comes to 7 to 12 cents, the company says.

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3.3 Plastic Bottles to Mini Car

Figure 9: T25 Supermini Car

Gordon Murray, designer of the McLaren F1 Supercar, has designed a microcar concept that is

here to boast its green credentials. Dubbed the “T25 Supermini Car,” this futuristic vehicle is

easy to park thanks to its 4-foot width. What makes the car stand out is the fact that it is made

entirely of recycled plastic bottles.

The plastic material used for the car keep the car’s weight down to 600 kg. The reduced weight

of the car also results in excellent fuel efficiency. The small size lets three T25 cars park legally

in a standard, single car-parking bay. Apart from being aesthetically appealing, it will also save

the planet by diverting plastic bottles from landfills

The man behind one of the world's fastest production cars, the McLaren F1 (capable of 240

mph), has redesigned the manufacturing process for cars, calling it the iStream process. He

suggests that his new process could be "the biggest revolution in high-volume manufacture"

since Ford’s Model T from a hundred years ago.

The iStream process is based on the concept of using a separate chassis frame and a composite

body (in the case of the company's T.25, made from 720 upcycled plastic bottles), which

eliminates the need for pressed steel panels, cutting the tooling costs and simplifying the

carbuilding process. Different models can be built onto the same chassis, allowing cars, trucks,

or vans to go down the same assembly line, saving money, factory space, and energy.

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iSream Process

The process centres on a separate body chassis assembly process.

The assembly process is separate. During the first part, the powertrain, wiring harnesses, brakes,

suspension and all major components can be fitted directly onto the chassis prior to the body

panels being fitted.

The body panels are delivered to the line pre-painted.

The body panels are ‘married’ to the completed chassis near the end of the assembly process,

helping to reduce paint damage normally associated with a standard assembly line. All external

panels can be mechanically fixed to the chassis.

Figure 10: T25 Car can save space

Imagine a car so narrow that two can drive next to each other in one lane; a car so small and

short that three can park in one parking space.

Now imagine that the car is built in a shed from glass fibre, recycled plastic bottles and steel

tubes, using just a fifth of the material required to build a conventional car.

Such a vehicle would have the potential to prevent gridlock on the world's roads as the number

of cars quadruples to 2.5 billion by 2020.

It could also help hundreds of millions of people achieve their dream of owning a car, without

depleting scarce resources such as water, energy or steel.

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Figure 11: Characteristics of T25 Car

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CHAPTER 4

CONCLUSION

With the advanced technology, we don't have to invest new petroleum gases to make carbon

spheres or nanotubes. Because it's cost effective and it is reproducible. And, for now, it's a

product made from something many people want to get rid of. Not only are the resulting spheres

cheaper than today's sources, it also take care of plastic waste. It is helpful that the potential

applications for the spheres have huge markets to match the huge amount of plastic waste. It

makes sense to replace a mass level of waste with something that has a mass level of usage.

Using fewer and cheaper parts to build cars provides manufacturers with tremendous cost

savings, but perhaps more importantly it reduces investment risk as less money is required

upfront to get a project started, according to Prof Murray.

In the future, car factories could be smaller, cheaper and less polluting than they are today. The

actual factory that builds an iStream car - no matter what shape it is, no matter what size it is - is

about 20% of the capital investment and 20% of the size of a conventional car manufacturing

plant - and about half the energy. Such arguments are slowly winning over both conventional

carmakers and companies that have never sold cars before, so Prof Murray is hoping a number of

them will soon be manufacturing cars using his team's know-how.

In conclusion, nowadays our consumption levels have increased and our lives have become

better. The plastic waste problem has become worse. We should use a solution to solve this

problem. Recycling plastic is our best choice because it can reduce the waste of our resources

such as nonrenewable resource oil; it won’t generate any toxic substances and it can reduce the

amounts in landfills. In addition, it is good for the earth’s ecosystem; we can sustain the balance

of nature. It is a really good solution to dispose of the plastic waste. Due to the fact that our life

depends on the environment, we should regard this solution as an international issue; everyone

has the responsibility to join this plastic recycling program.

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