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Bangabandhu Sheikh Mujibur Rahman
Science & Technology University
Course Title: Industrial Hazards and Waste Management
Course Code: ACCE – 311
Submitted By Submitted To
Sheikh Shahadat Islam Shakil
Id No: 17ACE019
Session: 2017-18
Dept. of Applied Chemistry &
Chemical Engineering,
BSMRSTU, Gopalganj.
Farzana Yeasmin
Assistant Professor
Dept. of Applied Chemistry &
Chemical Engineering,
BSMRSTU, Gopalganj.
Department Applied Chemistry & Chemical Engineering
Date of Submission: 23.07.2021
Conservation and reuse of industrial wastes
CONSTRUCTION MATERIAL FROM WASTE
A large demand has been placed on building material industry especially in the last decade
owing to the increasing population that causes a chronic shortage of building materials. In
order to meet ever increasing housing demand, there is an exponential need of production of
construction materials like bricks, cement, aggregates, steel, aluminum, wood, cladding and
partitioning materials. The production of conventional building materials such as cement,
bricks and steel consume a lot of thermal and electrical energy and in turn pollute air, water
and land. The use of appropriate building materials has not received adequate attention.
Disposal of solid waste generated from agricultural and industrial production activity is
another serious problem in developing countries
So, we can produce construction Material from,
1. Tire Rubber: Whole tires have been used in artificial reefs, break waters, dock
bumpers, soil erosion control mats and playground equipment. Several studies have
shown that tire waste can be successfully used in concrete, grass turf, asphalt mix,
embankments, stone cladding, flow able fill and clay composite
2. Glass: Glass is composed of silica or sand and contains some amounts of limestone
and soda ash used to produce uniform quality and color.
3. Plastic: Glass cullet creates workability problems in concrete mix and the likely hood
of alkali-silica reaction. Beneficial uses are in the secondary applications, such as in the
manufacture of fiberglass insulation, roadbed aggregate, driving safety reflective
beads and decorative tile
4. Recycled Concrete Aggregate: Crushed aggregate has been used as base course or
granular base in highway construction. Its primary function is to increase the load
capacity of the pavement and to distribute the applied load to avoid damage to the
sub grade
5. Carpet: Old carpet is being recycled and used in composite lumber (both decking and
sheets), tile backer board, roofing shingles, rail road ties, automotive parts, carpet
cushion and stepping stones. It is proved that by adding fibers to concrete, both
toughness and tensile properties increased. Other benefits in adding carpet fiber to
concrete include reduction of shrinkage, improved fatigue strength, wear resistance
and durability.
6. Cement Kiln Dust: CKD (byproduct of manufacturing Portland cement) is fine grained,
highly alkaline waste, removed from the cement kiln exhaust gas by air pollution
control devices. Uses of CKD may include: soil stabilization, waste treatment, cement
replacement and asphalt pavement. CKD is perfect as soil stabilizer improving soils
strength and minimizing work and cost.
7. Slag: Slag is a co-product of the iron and steel making process. Once scorned as
useless, it is now recognized as a valuable material with many uses in agriculture,
environmental applications and in the construction industry. Air cooled course
aggregate is used in concrete and asphalt mixes, fill material in embankments, road
base material and as treatments for the improvement of soils. Ground Granulated
Blast Furnace Slag (GGBFS) has a positive effect on the flexural and compressive
strength of concrete. Expanded slag has low density allowing for good mechanical
binding with hydraulic cement paste. Bulk density, particle size, porosity, water
holding capacity and surface area makes it suitable for use as an adsorbent
8. Fly Ash: Fly Ash (FA) is the by-product of coal combustion in power generation. Coal
provides more than half of the nation’s electricity and continues to be the fuel of
choice for generating power. Fly Ash is a powdery substance laced with heavy metals
such as arsenic, mercury and lead. Fly ash can be an alternative to another industrial
resource, process, or application. These processes and application include, but are not
limited to, cement and concrete products, structural fill and cover material, roadway
and pavement utilization, infiltration barrier and underground void filling. It can be
used as partial replacement of cement because of its beneficial effects, such as, lower
water demand for similar workability, reduced bleeding, reduce cracking at early age
and lower evolution of heat. High-lime fly ash has permitted normal replacements of
25-40 and up to 75% of cement in concrete materials for parking lots, driveways and
roads
9. Foundry Sand: Foundry sand is a by-product of ferrous and nonferrous metal casting.
It is high quality silica sand with uniform physical characteristics. Foundry facilities
operate by purchasing high quality silica sand to make casting molds and reuse the
sand numerous times within the foundry. Beneficial reuse of foundry sand continues
to become a more accepted practice as more end-users are introduced to the concept.
Beneficial applications of foundry sand include aggregate replacement in asphalt
mixtures, Portland cement concrete, source material for Portland cement, sand used
in masonry mortar mixes, embankments, retaining walls, subbase, flow able fills,
barrier layers and HMA mixtures
10. Silica Fume: The environmental concerns necessitated the collection and landfilling of
silica fume to be mandatory. Perhaps the most important use of this material is as
mineral admixture in concrete. Silica fume is added to Portland cement concrete to
improve its properties, in particular its compressive strength, bond strength and
abrasion resistance. These improvements stem from both the mechanical
improvements resulting from addition of a very fine powder to the cement paste mix
as well as from the pozzolanic reactions between the silica fume and free calcium
hydroxide in the paste
11. Animal Fat: The use of animal fat has been used in the construction industry since
roman times. Animal fat also referred to as tall oil. TOP has a strong connection with
cement providing a chemical adsorption interaction
UTILIZATION OF AGRICULTURAL WASTE: MEDICINE
Furan compounds occur widely in nature and are cheap raw materials. Furfural is readily
obtainable from agricultural wastes such as corn cobs and hulls. Rural, which is produced
commercially by the reaction of corn cobs with sulphuric acid, is the basic material used
for the synthesis of nitro furans, These are important germicides used for treating cattle
diseases.
Nitrofurazone or furacin is now being used for treatment of eye, ear, sinus diseases,
vaginal infections End post-surgery skin infections, The commonly found bacteria in
stomach and intestine causing diseases as gastro-enteritis, typhoid, diarrhea and gastro
intestinal hemorrhage are effectively controlled by nitrofurans. Nitrofurans are widely
used in treating poultry diseases. An infectious disease called coccidiosis caused by
protozoa can be controlled by mixing nitro furan with the feed of young birds during the
period of susceptibility. It also cures white diarrhea of chicks caused by Salmonella
pullorum.
A related form furoxone, has been successfully used against Salmonella gallinarium and
paratyphoid’s of poultry. Mastitis, a chronic infection that causes drying up of mitch cattle
and permanent deformation of their teats. is now controlled by the use of nitro furazone-
penicillin mixture. Furan-ether exhibits germicides properties against molds which cause
great damage to crops and animals.
In recent years, the presence of toxic heavy metal ions in agricultural and industrial waste
attracted the attention of scientists. Now many mining and manufacturing concerns are
finding it extremely difficult to meet economically and increasingly stringent limits
imposed by WHO on the metal ion concentration in the waste streams. Metals like Cd. Hg.
Pb. Co, Cu, Zn. Ni. As and Mn even in trace quantities are extremely toxic.
Treatment methods generally employed for the removal of metal ions from waste dis-
charges include ion-exchange, solvent extraction, reverse osmosis, electro dialysis,
precipitation, cementation and adsorption. These methods, used to scavenge heavy metal
ions from waste waters are either economically non-feasible or are unable to satisfy the
stringent water quality limits for waste effluents.
UTILIZATION OF AGRICULTURAL WASTE: BIOFUEL
Biofuel is the fuel derived from living organisms primarily from plants and microorganisms.
Biofuel derived from natural sources could help in reducing greenhouse gases from the
atmosphere and helping in maintaining the carbon balance in the environment.
The two major categories of biofuels are
Primary biofuels and
Secondary biofuels.
Classification of Agricultural waste:
Production of Bio fuel:
IMPORTANT STEPS IN BIOCHEMICAL ROUTES FOR BIOFUEL PRODUCTION
Fig: BIOFUEL PRODUCTION
Urban Waste & Bagasse for Electricity
Waste-to-energy plants burn solid waste, often called garbage or trash, to produce steam in
a boiler that is used to generate electricity.
It is a mixture of energy-rich materials such as paper, plastics, yard waste, and products made
from wood. For every 100 pounds of urban waste in the United States, about 85 pounds can
be burned as fuel to generate electricity. Waste-to-energy plants reduce 2,000 pounds of
garbage to ash weighing about 300 pounds to 600 pounds, and they reduce the volume of
waste by about 87%.
There are different types of waste-to-energy systems or technologies. The most common type
used in the United States is the mass-burn system, where unprocessed urban waste is burned
in a large incinerator with a boiler and a generator for producing electricity.
Fig: A mass-burn waste-to-energy plant
The process of generating electricity in a mass-burn waste-to-energy plant has seven stages:
1. Waste is dumped from garbage trucks into a large pit.
2. A giant claw on a crane grabs waste and dumps it in a combustion chamber.
3. The waste (fuel) is burned, releasing heat.
4. The heat turns water into steam in a boiler.
5. The high-pressure steam turns the blades of a turbine generator to produce electricity.
6. An air pollution control system removes pollutants from the combustion gas before it is
released through a smoke stack.
7. Ash is collected from the boiler and the air pollution control system.
Plastic For Heat and electricity generation
It is possible by the process of Incineration
Incineration with energy recovery is one of several waste-to-energy technologies such as
gasification, pyrolysis, and anaerobic digestion. While incineration and gasification
technologies are similar in principle, the energy produced from incineration is high-
temperature heat whereas combustible gas is often the main energy product from
gasification. Incineration and gasification may also be implemented without energy and
materials recovery.
Two of the primary advantages of incineration are that waste volumes are reduced by an
estimated 80-95% and the need for land and landfill space is greatly reduced For urban areas,
this can be especially important, as urban land is often at a premium.
Waste incineration plants can be located near where waste is generated, which decreases the
costs and energy associated with transporting waste Through Waste-to-Energy processes,
incineration can be used to produce electricity and the heat that can be used to power and
heat nearby buildings, and the ash produced can be used by the construction industry
Fig: plastic to heat/electricity production
Oil from Plastic Waste
Recycling of plastic is difficult and costly because of the restrictions on contamination of water
and labor intensive segregation of different plastics before recycle which is labor intensive.
Segregation of different plastic materials are essential since they are made of different resin
compound for difference in transparency and color. Dyed or pigmented plastics have a lower
market value too. Clearly transparent plastics can be easily dyed to transform into new
products, have greater flexibility and are mostly desirable by the manufacturers.
Recycling plastic is energy intensive too. As there is an alarming depletion of energy sources,
means of energy recovery from plastic waste is a good option. Pyrolysis is a suitable method
for energy recovery from plastic waste and is one of the finest techniques for the conversion
of mass to energy with liquid and gaseous products with high energy values. The processes
involved in the pyrolysis of plastic.
Pyrolysis or thermal cracking involves thermal degradation of long chain polymer molecules
In to less complex smaller molecules. The process takes place in the absence of oxygen at
increased pressure and temperature for a short duration. Pyrolysis process is proposed by
many researchers since the process is able to produce large quantity of liquid oil up to 80 wt%
at temperatures around 500°C. The process parameters can be altered to generate products
based on personal preferences. Hence pyrolysis is often referred as a flexible process. The
liquid oil produced is of high quality as it can be used in multiple applications without any
upgradation or treatment. The gaseous fuel produced as the byproduct of pyrolysis, can be
reused to compensate the energy requirement of the pyrolysis plant.
Fig: Oil from Plastic
Particle Board from Rice husk
The construction industry is growing at a rapid pace as a consequence of increasing
population and standard of living. High performance synthetic materials for construction such
as glass fiber and carbon fiber reinforced composites are available today. However, these
materials are mainly used for high-tech applications in aerospace and motor sports due to
their high costs. Therefore, lightweight and high-strength wood and wood-based composite
boards are still the preferred option for construction due to their reasonable costs.
The reasons behind the use of RH in the construction industry are its high availability, low bulk
density (90-150kg/m3), toughness, abrasive in nature, resistance to weathering and unique
composition. The main components in Rice Husk are silica, cellulose and lignin.
SiO2: 18.80 – 22.30%
Lignin: 9 – 20%
Cellulose: 28 – 38%
Protein: 1.90 – 3.0%
Fat: 0.30 – 0.80%
Other nutrients: 9.30 – 9.50%
Production:
Producing particleboard panels requires combining wood particles, such as wood chips, saw
dust and rice husks with suitable binders while applying pressure in the presence or absence
of heat. RH is quite fibrous by nature and requires little energy input to prepare the husk for
board manufacture. RH density is less than 500kg/m3. Low density boards possess better
thermal and acoustic insulation properties compared to medium-density boards. These
boards are resistant to attack by termites, wood-boring insects and wood decaying organisms.
Fig: Schematic of the process involved in the production of RH particleboards
Silica from Rice husk
As mentioned Before, Rice husk contains a large percentage of silica as SiO2 18.80 – 22.30%
In this Production , The raw material Rice Husk were supplied by rice-growing farms of three
different rice growing regions All obtained RHs were washed with deionized water to remove
soluble contaminants, air dried in fume hood overnight in order to prevent steaming during
the oven drying and finally dried in bench oven for 8 h at 105 _C. Washed and dried RHs were
stored in polyethylene zip-lock bags at room temperature until use. The overview of synthesis
procedure is shown in bellow
Fig: Scheme RH to silica treatment methods
Acid pre-treatment delignifies RH and improves subsequent calcination via loosening of its
rigid structure.
Calcination is the process in which the material is heated to high temperature in the absence
or limited supply of air or oxygen. In this process the calcination temperature of 6000C. The
washed and dried husks were calcined in air for 4 h using a ceramic crucible and a
thermocouple equipped muffle furnace.
WRH collected after calcination was mixed with 100ml of 2M NaOH at 900C under continuous
vigorous stirring for 2 h in order to convert the solid silica into water-soluble sodium silicate
(SS). The SS solution was filtered through cellulose membrane filter (Millipore, 0.45 mm) in
order to remove insoluble residues and carbonizates (black ashes). SS was then converted
into insoluble silicic acid via titration with 2M HCl under continuous stirring. The final product
was washed with hot deionized water to pH 7 and then dried in a bench oven for 4 h at 1050C.
2NaOH + xSiO2 = Na2SiO3 + H2O
Na2SiO3 + 2HCl = SiO3(gel) +2NaCl + H2O
Jute Waste Into Paper and Board
Jute is a long, soft, shiny bast fiber that can be spun into coarse, strong threads. It is produced
from flowering plants in the genus Corchorus, which is in the mallow family Malvaceae.
The waste of jute production is the dry matter that cannot be used as fibre, each ton of dry
fiber generates 4.5 tones of dry leaves and sticks.
Jute pulp, also called hemp pulp, it is the generic terms of paper pulp made from bast-fiber.
The hemp belongs to the bast fiber, it has long and strong fiber. The bast-fibers for
papermaking generally use the wastes of different hemp, not the raw hemp. The jute pulp
can be applied to manufacture various fine papers and industrial and technical paper like
banknote paper and cigarette paper.
Jute pulp types: In general, the different kind of jute pulp is all named after the name of raw
material like flax pulp, kenaf pulp, jute pulp, hemp pulp, etc.
Jute pulp market: The most kinds of hemp can be applied to paper and pulp making, currently,
the whole stalk jute or whole stalk kenaf is widely used. In 1960, the United States confirmed
that kenaf is most suitable non-wood fiber for papermaking among 500 different kinds of
therophyte. Bangladesh and India are two main jute and kenaf growing countries in the world.
These countries try to replace bamboo, wood with jute or jute fibers.
Jute pulp processing: Jute pulp processing can be divided into material storage, material
preparation, pulp cooking, pulp washing and pulp bleaching.
Material preparation: The hemp cutter is necessary for material preparation. The modern
hem cutter will improve the yield, and it is easy to feed and with no winding. If whole jute
stalk has the large content of water, the yield will be lower; if the content water is smaller, it
will be easy to cut, but also easy to separate stalk and husk.
Pulp cooking process: The study of jute pulping shows that Kraft pulping, soda cooking of
whole jute stalk is available. CNBM has 50 years’ experience in paper pulp production line
customization and paper pulper machines manufacture. We summed different cooking
processes and related working conditions.
Pulp washing: Whole jute stalk pulp has high adaptability to washing equipment and good
drainability. Common washing equipment for the jute pulping process includes vacuum drum
washer and belt filter press, horizontal belt filter. The horizontal belt filter has high efficiency
and a high clean degree.
Pulp bleaching: From the point of pulp bleaching process, the total chlorine dosage is about
8%. Through the CEH or CEPH three-stage bleaching, the bleaching degree can reach 82.84%,
the whiteness up to 75-79% after reversion. If the jute pulp adopts CEPH three-stage
bleaching, there are two advantages, firstly, improve the brightness of jute pulp. Secondly,
jute pulp has less fiber loss.
WEALTH FROM FLY ASH
Fly ash, a principal byproduct of coal burning power plants, is an industrial waste product
containing large amounts of silica, alumina and small amount of unburned carbon, which
pollutes environment. This fly ash has real disposal problems, and should hence be
Utilized effectively for various purposes.
Fig: Fly Ash
ASH with Portland Cement Concrete
Fly ash can be used with Portland Cement Concrete as a cement extender to enhance the
performance of the concrete. Some of the resulting benefits are:
• Higher Ultimate Strength
• Increased Durability,
• Improved Workability
• Reduced Bleeding
• Increased Resistance to Sulfate Attack
• Reduced Shrinkage
FLY ASH BRICKS
Fly ash possesses both ceramic as well as pozollanic properties and therefore can be utilized
in a unique way for manufacturing bricks. This proves to be very useful for building
construction. These bricks produced by the new process are superior in quality as they offer
higher cold crushing strength and smooth, uniform size and less weight
Economic Savings are,
 Low cost of brick as compared to clay brick as same quality.
 Number of bricks required per unit volume of construction is less.
 Less consumption of mortar.
 Less number of joints in case of blocks.
 Plastering is not required if it required
 Reduces excavation of clay.
FLY ASH FOR ROAD
Fly ash can be used for construction of road and embankment. This utilization has many
advantages over conventional methods.
• Saves top soil which otherwise is conventionally used.
• Avoids creation of low lying areas (by excavation of soil to be used for construction of
embankments).
• Avoids recurring expenditure on excavation of soil from one place for construction
and filling up of low lying areas thus created
• Increased stability as its self-supporting properties provide stable conditions for
shallow trenches and other excavations
• Immediate and increasing strength. For example, field tests on existing embankments
have demonstrated the positive strength gain and long-term stability of PFA. In
addition, PFA will absorb water and therefore is not easily saturated, allowing
construction work to continue in bad weather conditions
• No internal settlement
SOIL STABILIZATION
• Soil stabilization is the alteration of soil properties to improve the engineering
performance of soils.
• Modification of soil properties is the temporary enhancement of subgrade stability to
expedite construction.
• Stabilization can increase the shear strength of a soil and/or control the shrink-swell
properties of a soil, thus improving the load-bearing capacity of a sub-grade to support
pavements and foundations.
• Stabilization can be used to treat a wide range of sub-grade materials from expansive
clays to granular materials.
Biomass into rural power
A study conducted by scientists reveals that all energy requirements of a village can be met
locally from the available Biomass, using Fluidized of air through it in a reactor. The material
in the resulting fluidized bed, which resembles a boiling viscous mass, is more accessible to
chemical reactions than the same material in a solid, static state. This process ensure about
98% combustion. Moreover, the process is environment friendly, since emission of NOx are
almost negligible. The biomass required for a plant of 3MW capacity based on 35% overall
efficiency or package boilers e.g., can be designed to produce stream for power generation.
Similarly, Standalone external furnaces to thermal fluid heaters can be set up to produce hot
water to meet domestic and village industry requirements. Meanwhile, the union Ministry of
Human Resource Development has also started to build pilot plants based on FBT systems for
rural development
Converting Garbage In to Fuel:
There are, however, several methods for transforming waste into fuel, such as hydrothermal
liquefaction and gasification. The resulting energy products include natural gas, bio-char, bio-
oil and hydrocarbon fuels.
Converting Garbage into fertilizer & Power
Waste those are bio-degradable organic can be convert into fertilizer which is called compost.
WASTEWATER REUSE
Wastewater treatment is the process of removing contaminants from water through
engineered physical, chemical and biological processes to produce an effluent that can
be safely reused or discharged to the environment. There are four major stages of
wastewater treatment:
1. Preliminary treatment involves screening and grit-removal units to remove large and
coarse objects found in the raw wastewater (sanitary items, plastics and rags, hair, rocks
and gravel) that may block or damage mechanical equipment.
2. Primary treatment separates the suspended solid matter from the wastewater by
discharging the wastewater into sedimentation tanks to allow the solids to settle. The
settled solids, called sludge, are scraped from the bottom of the tanks by large scrapers
and pumped away for further treatment.
3. Secondary treatment removes the biodegradable organics, suspended solids and
nutrients by pumping the wastewater into aeration systems and biological treatment
systems.
4. Tertiary treatment removes specific constituents that cannot be removed by the
previous steps, such as refractory organics, heavy metals and dissolved solids
Fig: Wastewater treatment process
Rubber from Old Tyres
Tyres contains natural & synthetic rubber febric and wire along with carbon black and other
chemical compound
From Old tyre we can get crumb rubber by following two process
1. Ambient Process.
2. Cryogenic Process.
Ambient Process: Ambient grinding can be accomplished in two ways: granulation or
cracker mills. In an ambient system, the rubber, tires or other feedstock remain at room
temperature as they enter the cracker mill or granulator. Ambient grinding is conducive to
any size particle, including whole tires. It can be accomplished in granulation or cracker mills.
In an ambient system, the rubber, tires or other feedstock remain at room temperature as
they enter the cracker mill or granulator.
Ambient grinding is a multi-step processing technology that uses a series of machines (usually
three) to separate the rubber, metal, and fabric components of the tire. Whether using
granulation equipment or cracker mills, the first processing step typically reduces the original
feedstock to small chips. The second machine in the series will grind the chips to separate the
rubber from the metal and fabric. Then a finishing mill will grind the material to the required
product specification. After each processing step, the material is classified by sifting screens
that return oversize pieces to the granulator or mill for further processing. Magnets are used
throughout the processing stages to remove wire and other metal contaminants. In the final
stage, fabric is removed by air separators.
Rubber particles produced in the granulation process generally have a cut surface shape and
rough texture, with similar dimensions on the cut edges. Uses for the crumb rubber or
granulate produced in this process include safety and cushioning surfaces for playgrounds,
horse arenas and walking/jogging paths.
Cracker mills – primary, secondary or finishing mills – are all very similar and operate on
basically the same principle: they use two large rotating rollers with serrations cut in one or
both of them. The roll configurations are what make them different. These rollers operate
face-to-face in close tolerance at different speeds. Product size is controlled by the
clearance between the rollers. Cracker mills are low speed machines operating at about 30-
50 RPM. The rubber usually passes through two to three mills to achieve various particle
size reductions and further liberate the steel and fiber components.
These mills do not have screens built into the mill and as such the mill itself does not control
the final particle. A stand-alone screening system will separate “sized” particles from
oversize granules following the mill and re-circulate the oversize products. The crumb
rubber particles produced by the cracker mill are typically long and narrow in shape and
have a high surface area.
Fig: Ambient Process
Cryogenic Process: Cryogenic processing refers to the use of liquid nitrogen or other
materials/methods to freeze tire chips or rubber particles prior to size reduction. Most rubber
becomes embrittled or “glass-like” at temperatures below -80°C. The use of cryogenic
temperatures can be applied at any stage of size reduction of scrap tires. Typically, the size of
the feed material is a nominal 2 inch chip or smaller. The material can be cooled in a tunnel
style chamber, immersed in a “bath” of liquid nitrogen, or sprayed with liquid nitrogen to
reduce the temperature of the rubber or tire chip. The cooled rubber is ground in an impact
type reduction unit, usually a hammer mill. This process reduces the rubber to particles
ranging from 1/4 inch minus to 30 mesh, with the majority of the particle distribution
between 1/4 inch minus and 20 mesh. A typical throughput is 4,000 to 6,000 pounds per hour.
Cryogenic grinding avoids heat degradation of the rubber and produces a high yield of product
that is free of almost all fiber or steel, which is liberated during the process.
For scrap tire derived rubber, the steel is separated out of the product by the use of magnets.
The fiber is removed by aspiration and screening. The resulting material appears shiny, has
clean, fractured surfaces and low steel and fiber content. The final product has a range of
particle sizes, which can be used as is or further size-reduced. Production of finer (40 to 60
mesh) and very fine crumb rubber (60 minus and smaller mesh) requires a secondary high
intensity grinding stage.
Fig: Cryogenic Process
Application: Crumb rubber is used in a growing number of products and applications in a
growing number of diverse markets. The following list is intended as a reference to the
kind of markets and end-use applications that can or currently use tire-derived crumb
rubber. It is in no way comprehensive. Major markets for crumb rubber
 Athletic surfaces and fields
 Agrimats and equestrian footing
 Automotive parts and tires
 Construction/indoor
 Landscape, trails and walkways
 Molded and extruded products
 Playground and other safety surfaces
 Rubber modified asphalt and sealants
 Rubber and plastic blends
Referances
1. UTILIZATION OF RECYCLED AND WASTE MATERIALS IN VARIOUS CONSTRUCTION APPLICATIONS
Johnny Bolden, Taher Abu-Lebdeh and Ellie Fini
Department of Civil, Architectural and Environmental Engineering,
North Carolina A and T State University, Greensboro, 27411, North Carolina, United States
2. Biofuels from agricultural wastes
Lopa Pattanaik, Falguni Pattnaik, Devesh Kumar Saxena and Satya Narayan Naik
Centre for Rural Development and Technology, Indian Institute of Technology Delhi, New Delhi, India
3. https://www.eia.gov/energyexplained/biomass/waste-to-energy-in-depth.php
4. Pyrolysis process to produce fuel from different types of plastic – a review
Anandhu Vijayakumar1*, Jilse Sebastian2 1 Graduate Student
Mechanical Engineering Department, St. Joseph’s College of Engineering and Technology, Palai, Kerala, India
2 Assistant Professor Mechanical Engineering Department, St. Joseph’s College of Engineering and Technology,
Palai, Kerala, India
5. https://www.researchgate.net/figure/Pyrolysis-Process-of-generating-fuel-oil-from-the-waste-plastics-
12_fig1_249316025
6. Particleboards from Rice Husk: A Brief Introduction to Renewable Materials of Construction by Dr Anbu
Clemensis Johnson and Y. Bhg. Dato’ Engr. Dr Nordin bin Yunus Sustainable production of pure silica from rice
husk waste in Kazakhstan S. Azat a, b, A.V. Korobeinyk a, c, K. Moustakas d, V.J. Inglezakis a, e, * Environmental
Science & Technology Group (ESTg), Chemical & Materials Engineering Department, School of Engineering,
Nazarbayev University
7. https://www.slideshare.net/samueljebaraj3914/fly-ash-wealth-or-waste?from_action=save
8. https://energy.mit.edu/news/turning-waste-into-clean-fuels/
9. https://www.fertilizer-machines.com/solution/fertilizer-technology/biogas-digestate-compost-fertilizer-
produ.html
10. https://water.fanack.com/specials/wastewater-treatment-reuse-mena-countries/
11. https://scraptirenews.com/information-center/crumb-rubber/
12. https://www.fisheriesindia.com/2020/08/classification-of-plastics-materials.html

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Conservation and reuse of industrial wastes

  • 1. Bangabandhu Sheikh Mujibur Rahman Science & Technology University Course Title: Industrial Hazards and Waste Management Course Code: ACCE – 311 Submitted By Submitted To Sheikh Shahadat Islam Shakil Id No: 17ACE019 Session: 2017-18 Dept. of Applied Chemistry & Chemical Engineering, BSMRSTU, Gopalganj. Farzana Yeasmin Assistant Professor Dept. of Applied Chemistry & Chemical Engineering, BSMRSTU, Gopalganj. Department Applied Chemistry & Chemical Engineering Date of Submission: 23.07.2021 Conservation and reuse of industrial wastes
  • 2. CONSTRUCTION MATERIAL FROM WASTE A large demand has been placed on building material industry especially in the last decade owing to the increasing population that causes a chronic shortage of building materials. In order to meet ever increasing housing demand, there is an exponential need of production of construction materials like bricks, cement, aggregates, steel, aluminum, wood, cladding and partitioning materials. The production of conventional building materials such as cement, bricks and steel consume a lot of thermal and electrical energy and in turn pollute air, water and land. The use of appropriate building materials has not received adequate attention. Disposal of solid waste generated from agricultural and industrial production activity is another serious problem in developing countries So, we can produce construction Material from, 1. Tire Rubber: Whole tires have been used in artificial reefs, break waters, dock bumpers, soil erosion control mats and playground equipment. Several studies have shown that tire waste can be successfully used in concrete, grass turf, asphalt mix, embankments, stone cladding, flow able fill and clay composite 2. Glass: Glass is composed of silica or sand and contains some amounts of limestone and soda ash used to produce uniform quality and color. 3. Plastic: Glass cullet creates workability problems in concrete mix and the likely hood of alkali-silica reaction. Beneficial uses are in the secondary applications, such as in the manufacture of fiberglass insulation, roadbed aggregate, driving safety reflective beads and decorative tile 4. Recycled Concrete Aggregate: Crushed aggregate has been used as base course or granular base in highway construction. Its primary function is to increase the load capacity of the pavement and to distribute the applied load to avoid damage to the sub grade 5. Carpet: Old carpet is being recycled and used in composite lumber (both decking and sheets), tile backer board, roofing shingles, rail road ties, automotive parts, carpet cushion and stepping stones. It is proved that by adding fibers to concrete, both toughness and tensile properties increased. Other benefits in adding carpet fiber to concrete include reduction of shrinkage, improved fatigue strength, wear resistance and durability. 6. Cement Kiln Dust: CKD (byproduct of manufacturing Portland cement) is fine grained, highly alkaline waste, removed from the cement kiln exhaust gas by air pollution control devices. Uses of CKD may include: soil stabilization, waste treatment, cement replacement and asphalt pavement. CKD is perfect as soil stabilizer improving soils strength and minimizing work and cost.
  • 3. 7. Slag: Slag is a co-product of the iron and steel making process. Once scorned as useless, it is now recognized as a valuable material with many uses in agriculture, environmental applications and in the construction industry. Air cooled course aggregate is used in concrete and asphalt mixes, fill material in embankments, road base material and as treatments for the improvement of soils. Ground Granulated Blast Furnace Slag (GGBFS) has a positive effect on the flexural and compressive strength of concrete. Expanded slag has low density allowing for good mechanical binding with hydraulic cement paste. Bulk density, particle size, porosity, water holding capacity and surface area makes it suitable for use as an adsorbent 8. Fly Ash: Fly Ash (FA) is the by-product of coal combustion in power generation. Coal provides more than half of the nation’s electricity and continues to be the fuel of choice for generating power. Fly Ash is a powdery substance laced with heavy metals such as arsenic, mercury and lead. Fly ash can be an alternative to another industrial resource, process, or application. These processes and application include, but are not limited to, cement and concrete products, structural fill and cover material, roadway and pavement utilization, infiltration barrier and underground void filling. It can be used as partial replacement of cement because of its beneficial effects, such as, lower water demand for similar workability, reduced bleeding, reduce cracking at early age and lower evolution of heat. High-lime fly ash has permitted normal replacements of 25-40 and up to 75% of cement in concrete materials for parking lots, driveways and roads 9. Foundry Sand: Foundry sand is a by-product of ferrous and nonferrous metal casting. It is high quality silica sand with uniform physical characteristics. Foundry facilities operate by purchasing high quality silica sand to make casting molds and reuse the sand numerous times within the foundry. Beneficial reuse of foundry sand continues to become a more accepted practice as more end-users are introduced to the concept. Beneficial applications of foundry sand include aggregate replacement in asphalt mixtures, Portland cement concrete, source material for Portland cement, sand used in masonry mortar mixes, embankments, retaining walls, subbase, flow able fills, barrier layers and HMA mixtures 10. Silica Fume: The environmental concerns necessitated the collection and landfilling of silica fume to be mandatory. Perhaps the most important use of this material is as mineral admixture in concrete. Silica fume is added to Portland cement concrete to improve its properties, in particular its compressive strength, bond strength and abrasion resistance. These improvements stem from both the mechanical improvements resulting from addition of a very fine powder to the cement paste mix as well as from the pozzolanic reactions between the silica fume and free calcium hydroxide in the paste
  • 4. 11. Animal Fat: The use of animal fat has been used in the construction industry since roman times. Animal fat also referred to as tall oil. TOP has a strong connection with cement providing a chemical adsorption interaction UTILIZATION OF AGRICULTURAL WASTE: MEDICINE Furan compounds occur widely in nature and are cheap raw materials. Furfural is readily obtainable from agricultural wastes such as corn cobs and hulls. Rural, which is produced commercially by the reaction of corn cobs with sulphuric acid, is the basic material used for the synthesis of nitro furans, These are important germicides used for treating cattle diseases. Nitrofurazone or furacin is now being used for treatment of eye, ear, sinus diseases, vaginal infections End post-surgery skin infections, The commonly found bacteria in stomach and intestine causing diseases as gastro-enteritis, typhoid, diarrhea and gastro intestinal hemorrhage are effectively controlled by nitrofurans. Nitrofurans are widely used in treating poultry diseases. An infectious disease called coccidiosis caused by protozoa can be controlled by mixing nitro furan with the feed of young birds during the period of susceptibility. It also cures white diarrhea of chicks caused by Salmonella pullorum. A related form furoxone, has been successfully used against Salmonella gallinarium and paratyphoid’s of poultry. Mastitis, a chronic infection that causes drying up of mitch cattle and permanent deformation of their teats. is now controlled by the use of nitro furazone- penicillin mixture. Furan-ether exhibits germicides properties against molds which cause great damage to crops and animals. In recent years, the presence of toxic heavy metal ions in agricultural and industrial waste attracted the attention of scientists. Now many mining and manufacturing concerns are finding it extremely difficult to meet economically and increasingly stringent limits imposed by WHO on the metal ion concentration in the waste streams. Metals like Cd. Hg. Pb. Co, Cu, Zn. Ni. As and Mn even in trace quantities are extremely toxic. Treatment methods generally employed for the removal of metal ions from waste dis- charges include ion-exchange, solvent extraction, reverse osmosis, electro dialysis, precipitation, cementation and adsorption. These methods, used to scavenge heavy metal ions from waste waters are either economically non-feasible or are unable to satisfy the stringent water quality limits for waste effluents.
  • 5. UTILIZATION OF AGRICULTURAL WASTE: BIOFUEL Biofuel is the fuel derived from living organisms primarily from plants and microorganisms. Biofuel derived from natural sources could help in reducing greenhouse gases from the atmosphere and helping in maintaining the carbon balance in the environment. The two major categories of biofuels are Primary biofuels and Secondary biofuels. Classification of Agricultural waste: Production of Bio fuel:
  • 6. IMPORTANT STEPS IN BIOCHEMICAL ROUTES FOR BIOFUEL PRODUCTION Fig: BIOFUEL PRODUCTION
  • 7. Urban Waste & Bagasse for Electricity Waste-to-energy plants burn solid waste, often called garbage or trash, to produce steam in a boiler that is used to generate electricity. It is a mixture of energy-rich materials such as paper, plastics, yard waste, and products made from wood. For every 100 pounds of urban waste in the United States, about 85 pounds can be burned as fuel to generate electricity. Waste-to-energy plants reduce 2,000 pounds of garbage to ash weighing about 300 pounds to 600 pounds, and they reduce the volume of waste by about 87%. There are different types of waste-to-energy systems or technologies. The most common type used in the United States is the mass-burn system, where unprocessed urban waste is burned in a large incinerator with a boiler and a generator for producing electricity. Fig: A mass-burn waste-to-energy plant The process of generating electricity in a mass-burn waste-to-energy plant has seven stages: 1. Waste is dumped from garbage trucks into a large pit. 2. A giant claw on a crane grabs waste and dumps it in a combustion chamber. 3. The waste (fuel) is burned, releasing heat. 4. The heat turns water into steam in a boiler. 5. The high-pressure steam turns the blades of a turbine generator to produce electricity. 6. An air pollution control system removes pollutants from the combustion gas before it is released through a smoke stack. 7. Ash is collected from the boiler and the air pollution control system.
  • 8. Plastic For Heat and electricity generation It is possible by the process of Incineration Incineration with energy recovery is one of several waste-to-energy technologies such as gasification, pyrolysis, and anaerobic digestion. While incineration and gasification technologies are similar in principle, the energy produced from incineration is high- temperature heat whereas combustible gas is often the main energy product from gasification. Incineration and gasification may also be implemented without energy and materials recovery. Two of the primary advantages of incineration are that waste volumes are reduced by an estimated 80-95% and the need for land and landfill space is greatly reduced For urban areas, this can be especially important, as urban land is often at a premium. Waste incineration plants can be located near where waste is generated, which decreases the costs and energy associated with transporting waste Through Waste-to-Energy processes, incineration can be used to produce electricity and the heat that can be used to power and heat nearby buildings, and the ash produced can be used by the construction industry Fig: plastic to heat/electricity production
  • 9. Oil from Plastic Waste Recycling of plastic is difficult and costly because of the restrictions on contamination of water and labor intensive segregation of different plastics before recycle which is labor intensive. Segregation of different plastic materials are essential since they are made of different resin compound for difference in transparency and color. Dyed or pigmented plastics have a lower market value too. Clearly transparent plastics can be easily dyed to transform into new products, have greater flexibility and are mostly desirable by the manufacturers. Recycling plastic is energy intensive too. As there is an alarming depletion of energy sources, means of energy recovery from plastic waste is a good option. Pyrolysis is a suitable method for energy recovery from plastic waste and is one of the finest techniques for the conversion of mass to energy with liquid and gaseous products with high energy values. The processes involved in the pyrolysis of plastic. Pyrolysis or thermal cracking involves thermal degradation of long chain polymer molecules In to less complex smaller molecules. The process takes place in the absence of oxygen at increased pressure and temperature for a short duration. Pyrolysis process is proposed by many researchers since the process is able to produce large quantity of liquid oil up to 80 wt% at temperatures around 500°C. The process parameters can be altered to generate products based on personal preferences. Hence pyrolysis is often referred as a flexible process. The liquid oil produced is of high quality as it can be used in multiple applications without any upgradation or treatment. The gaseous fuel produced as the byproduct of pyrolysis, can be reused to compensate the energy requirement of the pyrolysis plant. Fig: Oil from Plastic
  • 10. Particle Board from Rice husk The construction industry is growing at a rapid pace as a consequence of increasing population and standard of living. High performance synthetic materials for construction such as glass fiber and carbon fiber reinforced composites are available today. However, these materials are mainly used for high-tech applications in aerospace and motor sports due to their high costs. Therefore, lightweight and high-strength wood and wood-based composite boards are still the preferred option for construction due to their reasonable costs. The reasons behind the use of RH in the construction industry are its high availability, low bulk density (90-150kg/m3), toughness, abrasive in nature, resistance to weathering and unique composition. The main components in Rice Husk are silica, cellulose and lignin. SiO2: 18.80 – 22.30% Lignin: 9 – 20% Cellulose: 28 – 38% Protein: 1.90 – 3.0% Fat: 0.30 – 0.80% Other nutrients: 9.30 – 9.50% Production: Producing particleboard panels requires combining wood particles, such as wood chips, saw dust and rice husks with suitable binders while applying pressure in the presence or absence of heat. RH is quite fibrous by nature and requires little energy input to prepare the husk for board manufacture. RH density is less than 500kg/m3. Low density boards possess better thermal and acoustic insulation properties compared to medium-density boards. These boards are resistant to attack by termites, wood-boring insects and wood decaying organisms. Fig: Schematic of the process involved in the production of RH particleboards
  • 11. Silica from Rice husk As mentioned Before, Rice husk contains a large percentage of silica as SiO2 18.80 – 22.30% In this Production , The raw material Rice Husk were supplied by rice-growing farms of three different rice growing regions All obtained RHs were washed with deionized water to remove soluble contaminants, air dried in fume hood overnight in order to prevent steaming during the oven drying and finally dried in bench oven for 8 h at 105 _C. Washed and dried RHs were stored in polyethylene zip-lock bags at room temperature until use. The overview of synthesis procedure is shown in bellow Fig: Scheme RH to silica treatment methods Acid pre-treatment delignifies RH and improves subsequent calcination via loosening of its rigid structure. Calcination is the process in which the material is heated to high temperature in the absence or limited supply of air or oxygen. In this process the calcination temperature of 6000C. The washed and dried husks were calcined in air for 4 h using a ceramic crucible and a thermocouple equipped muffle furnace. WRH collected after calcination was mixed with 100ml of 2M NaOH at 900C under continuous vigorous stirring for 2 h in order to convert the solid silica into water-soluble sodium silicate (SS). The SS solution was filtered through cellulose membrane filter (Millipore, 0.45 mm) in order to remove insoluble residues and carbonizates (black ashes). SS was then converted into insoluble silicic acid via titration with 2M HCl under continuous stirring. The final product was washed with hot deionized water to pH 7 and then dried in a bench oven for 4 h at 1050C. 2NaOH + xSiO2 = Na2SiO3 + H2O Na2SiO3 + 2HCl = SiO3(gel) +2NaCl + H2O
  • 12. Jute Waste Into Paper and Board Jute is a long, soft, shiny bast fiber that can be spun into coarse, strong threads. It is produced from flowering plants in the genus Corchorus, which is in the mallow family Malvaceae. The waste of jute production is the dry matter that cannot be used as fibre, each ton of dry fiber generates 4.5 tones of dry leaves and sticks. Jute pulp, also called hemp pulp, it is the generic terms of paper pulp made from bast-fiber. The hemp belongs to the bast fiber, it has long and strong fiber. The bast-fibers for papermaking generally use the wastes of different hemp, not the raw hemp. The jute pulp can be applied to manufacture various fine papers and industrial and technical paper like banknote paper and cigarette paper. Jute pulp types: In general, the different kind of jute pulp is all named after the name of raw material like flax pulp, kenaf pulp, jute pulp, hemp pulp, etc. Jute pulp market: The most kinds of hemp can be applied to paper and pulp making, currently, the whole stalk jute or whole stalk kenaf is widely used. In 1960, the United States confirmed that kenaf is most suitable non-wood fiber for papermaking among 500 different kinds of therophyte. Bangladesh and India are two main jute and kenaf growing countries in the world. These countries try to replace bamboo, wood with jute or jute fibers. Jute pulp processing: Jute pulp processing can be divided into material storage, material preparation, pulp cooking, pulp washing and pulp bleaching. Material preparation: The hemp cutter is necessary for material preparation. The modern hem cutter will improve the yield, and it is easy to feed and with no winding. If whole jute stalk has the large content of water, the yield will be lower; if the content water is smaller, it will be easy to cut, but also easy to separate stalk and husk. Pulp cooking process: The study of jute pulping shows that Kraft pulping, soda cooking of whole jute stalk is available. CNBM has 50 years’ experience in paper pulp production line customization and paper pulper machines manufacture. We summed different cooking processes and related working conditions. Pulp washing: Whole jute stalk pulp has high adaptability to washing equipment and good drainability. Common washing equipment for the jute pulping process includes vacuum drum washer and belt filter press, horizontal belt filter. The horizontal belt filter has high efficiency and a high clean degree. Pulp bleaching: From the point of pulp bleaching process, the total chlorine dosage is about 8%. Through the CEH or CEPH three-stage bleaching, the bleaching degree can reach 82.84%, the whiteness up to 75-79% after reversion. If the jute pulp adopts CEPH three-stage bleaching, there are two advantages, firstly, improve the brightness of jute pulp. Secondly, jute pulp has less fiber loss.
  • 13. WEALTH FROM FLY ASH Fly ash, a principal byproduct of coal burning power plants, is an industrial waste product containing large amounts of silica, alumina and small amount of unburned carbon, which pollutes environment. This fly ash has real disposal problems, and should hence be Utilized effectively for various purposes. Fig: Fly Ash ASH with Portland Cement Concrete Fly ash can be used with Portland Cement Concrete as a cement extender to enhance the performance of the concrete. Some of the resulting benefits are: • Higher Ultimate Strength • Increased Durability, • Improved Workability • Reduced Bleeding • Increased Resistance to Sulfate Attack • Reduced Shrinkage FLY ASH BRICKS Fly ash possesses both ceramic as well as pozollanic properties and therefore can be utilized in a unique way for manufacturing bricks. This proves to be very useful for building construction. These bricks produced by the new process are superior in quality as they offer higher cold crushing strength and smooth, uniform size and less weight Economic Savings are,  Low cost of brick as compared to clay brick as same quality.  Number of bricks required per unit volume of construction is less.  Less consumption of mortar.  Less number of joints in case of blocks.  Plastering is not required if it required  Reduces excavation of clay. FLY ASH FOR ROAD Fly ash can be used for construction of road and embankment. This utilization has many advantages over conventional methods. • Saves top soil which otherwise is conventionally used. • Avoids creation of low lying areas (by excavation of soil to be used for construction of embankments).
  • 14. • Avoids recurring expenditure on excavation of soil from one place for construction and filling up of low lying areas thus created • Increased stability as its self-supporting properties provide stable conditions for shallow trenches and other excavations • Immediate and increasing strength. For example, field tests on existing embankments have demonstrated the positive strength gain and long-term stability of PFA. In addition, PFA will absorb water and therefore is not easily saturated, allowing construction work to continue in bad weather conditions • No internal settlement SOIL STABILIZATION • Soil stabilization is the alteration of soil properties to improve the engineering performance of soils. • Modification of soil properties is the temporary enhancement of subgrade stability to expedite construction. • Stabilization can increase the shear strength of a soil and/or control the shrink-swell properties of a soil, thus improving the load-bearing capacity of a sub-grade to support pavements and foundations. • Stabilization can be used to treat a wide range of sub-grade materials from expansive clays to granular materials. Biomass into rural power A study conducted by scientists reveals that all energy requirements of a village can be met locally from the available Biomass, using Fluidized of air through it in a reactor. The material in the resulting fluidized bed, which resembles a boiling viscous mass, is more accessible to chemical reactions than the same material in a solid, static state. This process ensure about 98% combustion. Moreover, the process is environment friendly, since emission of NOx are almost negligible. The biomass required for a plant of 3MW capacity based on 35% overall efficiency or package boilers e.g., can be designed to produce stream for power generation. Similarly, Standalone external furnaces to thermal fluid heaters can be set up to produce hot water to meet domestic and village industry requirements. Meanwhile, the union Ministry of Human Resource Development has also started to build pilot plants based on FBT systems for rural development
  • 15. Converting Garbage In to Fuel: There are, however, several methods for transforming waste into fuel, such as hydrothermal liquefaction and gasification. The resulting energy products include natural gas, bio-char, bio- oil and hydrocarbon fuels.
  • 16. Converting Garbage into fertilizer & Power Waste those are bio-degradable organic can be convert into fertilizer which is called compost. WASTEWATER REUSE Wastewater treatment is the process of removing contaminants from water through engineered physical, chemical and biological processes to produce an effluent that can be safely reused or discharged to the environment. There are four major stages of wastewater treatment: 1. Preliminary treatment involves screening and grit-removal units to remove large and coarse objects found in the raw wastewater (sanitary items, plastics and rags, hair, rocks and gravel) that may block or damage mechanical equipment. 2. Primary treatment separates the suspended solid matter from the wastewater by discharging the wastewater into sedimentation tanks to allow the solids to settle. The settled solids, called sludge, are scraped from the bottom of the tanks by large scrapers and pumped away for further treatment. 3. Secondary treatment removes the biodegradable organics, suspended solids and nutrients by pumping the wastewater into aeration systems and biological treatment systems. 4. Tertiary treatment removes specific constituents that cannot be removed by the previous steps, such as refractory organics, heavy metals and dissolved solids
  • 17. Fig: Wastewater treatment process Rubber from Old Tyres Tyres contains natural & synthetic rubber febric and wire along with carbon black and other chemical compound
  • 18. From Old tyre we can get crumb rubber by following two process 1. Ambient Process. 2. Cryogenic Process. Ambient Process: Ambient grinding can be accomplished in two ways: granulation or cracker mills. In an ambient system, the rubber, tires or other feedstock remain at room temperature as they enter the cracker mill or granulator. Ambient grinding is conducive to any size particle, including whole tires. It can be accomplished in granulation or cracker mills. In an ambient system, the rubber, tires or other feedstock remain at room temperature as they enter the cracker mill or granulator. Ambient grinding is a multi-step processing technology that uses a series of machines (usually three) to separate the rubber, metal, and fabric components of the tire. Whether using granulation equipment or cracker mills, the first processing step typically reduces the original feedstock to small chips. The second machine in the series will grind the chips to separate the rubber from the metal and fabric. Then a finishing mill will grind the material to the required product specification. After each processing step, the material is classified by sifting screens that return oversize pieces to the granulator or mill for further processing. Magnets are used throughout the processing stages to remove wire and other metal contaminants. In the final stage, fabric is removed by air separators. Rubber particles produced in the granulation process generally have a cut surface shape and rough texture, with similar dimensions on the cut edges. Uses for the crumb rubber or granulate produced in this process include safety and cushioning surfaces for playgrounds, horse arenas and walking/jogging paths. Cracker mills – primary, secondary or finishing mills – are all very similar and operate on basically the same principle: they use two large rotating rollers with serrations cut in one or both of them. The roll configurations are what make them different. These rollers operate face-to-face in close tolerance at different speeds. Product size is controlled by the clearance between the rollers. Cracker mills are low speed machines operating at about 30- 50 RPM. The rubber usually passes through two to three mills to achieve various particle size reductions and further liberate the steel and fiber components. These mills do not have screens built into the mill and as such the mill itself does not control the final particle. A stand-alone screening system will separate “sized” particles from oversize granules following the mill and re-circulate the oversize products. The crumb rubber particles produced by the cracker mill are typically long and narrow in shape and have a high surface area.
  • 19. Fig: Ambient Process Cryogenic Process: Cryogenic processing refers to the use of liquid nitrogen or other materials/methods to freeze tire chips or rubber particles prior to size reduction. Most rubber becomes embrittled or “glass-like” at temperatures below -80°C. The use of cryogenic temperatures can be applied at any stage of size reduction of scrap tires. Typically, the size of the feed material is a nominal 2 inch chip or smaller. The material can be cooled in a tunnel style chamber, immersed in a “bath” of liquid nitrogen, or sprayed with liquid nitrogen to reduce the temperature of the rubber or tire chip. The cooled rubber is ground in an impact type reduction unit, usually a hammer mill. This process reduces the rubber to particles ranging from 1/4 inch minus to 30 mesh, with the majority of the particle distribution between 1/4 inch minus and 20 mesh. A typical throughput is 4,000 to 6,000 pounds per hour. Cryogenic grinding avoids heat degradation of the rubber and produces a high yield of product that is free of almost all fiber or steel, which is liberated during the process. For scrap tire derived rubber, the steel is separated out of the product by the use of magnets. The fiber is removed by aspiration and screening. The resulting material appears shiny, has clean, fractured surfaces and low steel and fiber content. The final product has a range of particle sizes, which can be used as is or further size-reduced. Production of finer (40 to 60 mesh) and very fine crumb rubber (60 minus and smaller mesh) requires a secondary high intensity grinding stage.
  • 20. Fig: Cryogenic Process Application: Crumb rubber is used in a growing number of products and applications in a growing number of diverse markets. The following list is intended as a reference to the kind of markets and end-use applications that can or currently use tire-derived crumb rubber. It is in no way comprehensive. Major markets for crumb rubber  Athletic surfaces and fields  Agrimats and equestrian footing  Automotive parts and tires  Construction/indoor  Landscape, trails and walkways  Molded and extruded products  Playground and other safety surfaces  Rubber modified asphalt and sealants  Rubber and plastic blends
  • 21. Referances 1. UTILIZATION OF RECYCLED AND WASTE MATERIALS IN VARIOUS CONSTRUCTION APPLICATIONS Johnny Bolden, Taher Abu-Lebdeh and Ellie Fini Department of Civil, Architectural and Environmental Engineering, North Carolina A and T State University, Greensboro, 27411, North Carolina, United States 2. Biofuels from agricultural wastes Lopa Pattanaik, Falguni Pattnaik, Devesh Kumar Saxena and Satya Narayan Naik Centre for Rural Development and Technology, Indian Institute of Technology Delhi, New Delhi, India 3. https://www.eia.gov/energyexplained/biomass/waste-to-energy-in-depth.php 4. Pyrolysis process to produce fuel from different types of plastic – a review Anandhu Vijayakumar1*, Jilse Sebastian2 1 Graduate Student Mechanical Engineering Department, St. Joseph’s College of Engineering and Technology, Palai, Kerala, India 2 Assistant Professor Mechanical Engineering Department, St. Joseph’s College of Engineering and Technology, Palai, Kerala, India 5. https://www.researchgate.net/figure/Pyrolysis-Process-of-generating-fuel-oil-from-the-waste-plastics- 12_fig1_249316025 6. Particleboards from Rice Husk: A Brief Introduction to Renewable Materials of Construction by Dr Anbu Clemensis Johnson and Y. Bhg. Dato’ Engr. Dr Nordin bin Yunus Sustainable production of pure silica from rice husk waste in Kazakhstan S. Azat a, b, A.V. Korobeinyk a, c, K. Moustakas d, V.J. Inglezakis a, e, * Environmental Science & Technology Group (ESTg), Chemical & Materials Engineering Department, School of Engineering, Nazarbayev University 7. https://www.slideshare.net/samueljebaraj3914/fly-ash-wealth-or-waste?from_action=save 8. https://energy.mit.edu/news/turning-waste-into-clean-fuels/ 9. https://www.fertilizer-machines.com/solution/fertilizer-technology/biogas-digestate-compost-fertilizer- produ.html 10. https://water.fanack.com/specials/wastewater-treatment-reuse-mena-countries/ 11. https://scraptirenews.com/information-center/crumb-rubber/ 12. https://www.fisheriesindia.com/2020/08/classification-of-plastics-materials.html