Integrated waste management by chemical production of composite materials extrusion

UDC 66.01
Publication date: 09.02.2017
International Journal of Professional Science №2-2017

Integrated waste management by chemical production of composite materials extrusion

Bashirov V.D., Korotkov V.G., Sagitov R.F., Vasilevskaya S.P., Voloshin E.V., Utyaganova Z.Z.
1. FGBOU VPO "Orenburg State University", Orenburg, Russia, e-mail:
2. Open Joint Stock Company "Scientific Research and Design Institute of Environmental Problems", Orenburg, Russia, e-mail:
3. Kumertau branch FGBOU VPO "Orenburg State University", Kumertau, RB, Russia, e-mail:
Abstract: Currently in Russia great attention is paid to the disposal and recycling of industrial and domestic waste. In various industries at the present time is accumulated and not recycled, a huge amount of waste. The bulk of food production waste (brewer's grain, distillery stillage, husks), or simply drained, in connection with impossibility of the enterprise to process or used as fuel (husk). If we talk about the timber industry and its wastes (chips, shavings, sawdust), you should also recycling these wastes are not. This may also include and waste polymer materials, which every year becomes more and more. The relevance of the use of waste food and wood processing, plastic industries, construction materials and articles associated primarily with the problems of preserving the environment - they are not subject to rot, corrosion, but also with the problem of resource conservation. Currently, widespread use of waste polymers in building materials industry, is also quite acute problem is disposal of waste food and wood processing industries are Particularly promising direction of recycling is obtaining highly filled plastics that can be used as composite construction materials. A promising method of obtaining high-quality extrudate is extrusion process using a single screw press because of the simplicity and reliability of its design. Despite long-term use of screw presses for the production of multicomponent mixtures, especially for highly filled plastics: technological forming process is studied in them is not enough, there are no universal methods of calculation of screw presses for production of highly filled plastics, so the research and study of the extrusion process in screw presses is important and promising.
Keywords: extrusion, household waste, industrial waste, auger, highly filled plastics.


In various industries of Russia now accumulates and is not a huge amount of waste recycled. The bulk of waste — waste chemical production, in particular polymeric materials. Collection and processing of polymeric materials are not properly carried out, all polymer wastes accumulate in landfills and have a long period of decay. In the Orenburg region waste petrochemical industry also constitute a significant segment in the field of waste resulting from the activities of this group of enterprises. Sufficiently strong argument for the speedy and complete as possible recycling is that, as a rule, are highly toxic petrochemical waste and pose a serious threat to the environment [1,2].

Based on the analysis of modern literature [1,3], it was concluded that there are two main ways of recycling and recycling of household and industrial wastes of various industries based on polymers:

1) The use of the polymers as fillers and additives in various industries;

2) thermal method of disposal. The second method is used mainly in industry hi¬micheskoy [4].

In various kinds of industry, the most widely spoken first method. One of the special cases — is to fill a variety of polymer components [5-6].

The technological process of adding filler to the polymer nazyvaet¬sya content. The filler content can vary widely prede¬lah, most often it is 40-50%. Plastics filler content in which three or more times greater than the polymer content are called highly filled plastics [7].

Recognize the three main ways of filling polymer [8]:

1) Mechanical mixing of the polymer with fillers.

2) Precipitation from a solution of the polymer on the filler surface.

3) Polymerization content.

An example of the first process for preparing highly filled plastics is shown below.

All steps of the production process of DNPK inseparable profile and mainly running on a single continuous line as follows:

— Chopping wood

— Drying of crushed wood (if necessary)

— Dosing of components

— Mixing of the components

— compounding

— Dosing of compound

— Molding products

— Trimming the length and width of the division (if required) [8].

Table 1

Number of waste by hazard class, used and disposed of businesses owners in % in the period from 2005 to 2012 [3-8]

Hazard class


2005 -* -* -* -* -*
2006 25,9 5,8 1,6 4,0 16,5
2007 0,1 4,7 7,0 13,2 8,1
2008 0 0,1 96 71,3 11,1
2009 -* -* -* -* -*
2010 -* -* -* -* -*
2011 221,9 0,1 123 -* -*
2012 -* -* -* -* -*

Note — * data in the press are not available or can not be found, for reasons beyond the control of the authors

2.Materials and methods

Another group consists of food production waste (spent grains, distillery grains, husk), less toxic, but large in terms of education. These wastes or simply merge, due to the inability of the enterprise process it, or used as a fuel (husk), the products of combustion which pollute the environment. If we talk about the timber industry and its waste (chips and sawdust), it is also proper recycling of this waste is not [4,5].

Relevance of integrated waste management by recycling chemical industries in the building materials and related products primarily to the problems of preserving the environment — they are not subject to rotting, corrosion, but also with the problem of resource. Especially promising direction is to obtain utilization of highly plastic, which can be used as building composite materials. It is known that the main aggregates to produce composite materials are screw presses (extruders) [7].

To this end, we have developed an integrated approach to waste management of chemical plants, food and wood processing industry by manufacturing composite materials by extrusion.

We have proposed technological scheme for environmentally sound waste material based on chemical, food and wood industries extrusion (Figure 1).

3.Results and Discussion

1 — boot device; 2 — sawdust crusher for crushing the LSC-1 (0.2 t / h, 7.5 kW); Crusher for crushing polyethylene MS-500 (180 kg / h 11 kW); crusher for crushing the husks PF -1007 (1000 kg / h, 37 kW); 3 — dispenser; 4 — intermediate hopper; 5 — dispenser; 6 — screw feeder; 7 — mixer; 8 — container; 9 — dispenser; 10 — container otvolazhivaniya; 11 — screw extruder press (180 kg / h, 7.5 kW); 12 — trolley for storage and cooling of finished products; 13 — intermediate vessel; 14 — crusher for crushing marriage RS-500 (180 kg / h, 11 kW)

Figure 1 — Flow diagram for production of ecologically safe material on the basis of chemical waste by extrusion

The proposed technology can be estimated coefficient of low-waste technology proposed КМПТ:


где: kМПТ – ratio of low-waste technology proposed;

       КПЕР.СЫР. – amount of feedstock;

       К ОБЩ.ПОЛ.ПРОД. – the total amount of product obtained;

       КНЕК.ПОЛ.ПРОД, — the total amount of the product obtained from substandard raw materials.


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