GB2415700A - Building material derived from plastics - Google Patents

Building material derived from plastics Download PDF

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Publication number
GB2415700A
GB2415700A GB0414901A GB0414901A GB2415700A GB 2415700 A GB2415700 A GB 2415700A GB 0414901 A GB0414901 A GB 0414901A GB 0414901 A GB0414901 A GB 0414901A GB 2415700 A GB2415700 A GB 2415700A
Authority
GB
United Kingdom
Prior art keywords
plastics
mixer
mass
fed
per cent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB0414901A
Other versions
GB0414901D0 (en
Inventor
Howard Jeffery-Wright
Howard Lloyd Robinson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Tarmac Ltd
Original Assignee
TARMAC RECYCLING Ltd
Tarmac Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by TARMAC RECYCLING Ltd, Tarmac Ltd filed Critical TARMAC RECYCLING Ltd
Priority to GB0414901A priority Critical patent/GB2415700A/en
Publication of GB0414901D0 publication Critical patent/GB0414901D0/en
Priority to PCT/GB2005/002586 priority patent/WO2006003409A1/en
Publication of GB2415700A publication Critical patent/GB2415700A/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/0026—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting
    • B29B17/0042—Recovery of plastics or other constituents of waste material containing plastics by agglomeration or compacting for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/20—Agglomeration, binding or encapsulation of solid waste
    • B09B3/21—Agglomeration, binding or encapsulation of solid waste using organic binders or matrix
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/022—Agglomerated materials, e.g. artificial aggregates agglomerated by an organic binder
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/006—Waste materials as binder
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
    • B29K2105/0026—Flame proofing or flame retarding agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16—Fillers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Processing Of Solid Wastes (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)

Abstract

A method of manufacturing a building material comprises feeding a shredded plastics material with mineral fines (e.g. limestone) having less than 10 wt. % moisture to a mixer and mixing at elevated temperature. In one aspect of the invention, at least 80 wt. % of the shredded plastics has a particle size of less than 30 mm. In another aspect, the shredded material is a waste plastics material comprising at least 80 wt. % plastics. In a further aspect, the method is characterised by one or more of the following: the fines consist mainly of dust, at least 30 wt. % of the fines have a particle size greater than 63 microns and/or less than 4 mm, the materials are heated to 170-195{C during mixing, and a fire retardant is added to the materials in the mixer.

Description

24 1 5700 Improvements in or rGlating to building materials and their
production Tunis Invention relates to a building material incorporating a p]astlss material and to a method of rnanuLacturng such a material.
There have been various proposals for making building materials, for example, an aggregate material, including plastics material obtained from recycled waste material.
GB 2 291 419A, US 5,702,199 and US 6,000,877 all provide examples oL such proposals.
It is an object of the present invention to provide building materials and methods of manufacturing building materials that provide improvements over existing materials and methods. Such improvements may be represented, for example, by a better or more reliable quality of the final product or by enabling a product of the same quality to be obtained more economically.
According to a first aspect of the invention there is provided a method of manufacturing a building material comprising the following steps: providing plastics material, shredding the plastics material, providing mineral fines, feeding the shredded plastics material and the mineral fines to a mixer the mineral fines having a moisture content of less than 10 per cent by mass, and mixing the plastics material and the mineral fines in the mixer at an elevated temperature, wherein at least 80 per cent by mass of the shredded plastics material fed to the mixer has a particle size of less than 30mm.
Where reference is made herein to particle size, it should be understood that- the dimension given represents the longest dimension of the particle. The particles of shredded plastics material may be in the form of elongate flakes and in this case a flake has a particle size of less than 30mm lf the longest dimension of the flake IS less than 30mm.
We have found that by shredding the plastics material to the small size dctined above, the quality of the final product can be improved and its appearance enhanced. In a typical process some but not all the plastics material melts in the mixer. Shreciding the material to a small size promotes a uniform melting in the mixer of plastics material with a sufficiently low melting point and reduces the size oft any plastics material that does not melt, improving the physical properties and appearance of the product.
Where reference is made herein to "shredding" it should be understood that the term is to be construed broadly as covering any physical process that provides smaller particles of plastics material from larger ones.
We have also found that the method is much improved by keeping the moisture content of the mineral fines (defined as the mass of water as a percentage of the total mass of the moist fines) below 10 per cent. If the moisture content of the fines exceeds 10 per cent the heating of the materials in the mixer can be unduly affected. The mineral fines may, if necessary, be dried to reduce their moisture content before they are fed into the mixer. - 3
Preferably the shredded plastics material fed to the mixer is of a size such that at least 80 per cent by mass of the material has a partclc size of less than 20n.
The particle size of the mineral fines can be chosen to SUlt a particular application. Yrcferably at least 80 per cent by mass of the mineral floes fed Lo the mixer have a particle SlZC' of Loss than 4mm. Mineral fines are commonly divided in the industry into two groups: a first group referred to as "dust" and comprising principally particles in a size range of 4 nun down to about 63 microns, and a second group referred to as "filler" and comprising principally particles of less than 63 microns in particle size. In the present invention the mineral fines may be dust and/or filler. Thus at least 80 per cent by mass of the mineral fines fed to the mixer may have a particle size greater than 63 microns; in this case the mineral fines would be principally dust rather than filler. At least 30 per cent by mass of the mineral fines fed into the mixer may have a particle size greater than 63 microns; in this case the mineral fines may be principally dust or a mixture of dust and filler. A further possibility within the scope of the invention is that at least 80 per cent by mass of the mineral fines fed to the mixer have a particle size less than 63 microns; in this case the mineral fines will be principally filler.
After the mixing step one or more further processing steps are preferably carried out to provide a product of the method.
In one group of methods, the mixed plastics material and the mineral fines are compressed into agglomerates, for
-
example, avoids. The Avoids may have a particle size of 20 to 50mm. The mixed plastics material and the mineral fines may be compressed, for exarnp]e at a pressure of more third JO tonnes/in'. Thereafter the avoids may be crushed, for example, using a hammer mill, to produce graded aggregates.
The hammer mill may be operated at a low speed to reduce the amount of fines generated during the millir-g; alLcrnatlvcly a different kind of crushing process may be employed. It is preferred that the proportion of floes in the product lO immediately after crushing is less than 30 per cent by mass and more preferably less than 20 per cent by mass. If the crushing step results in an aggregate having more fines than desired, some or substantially all of those fines may be removed by sieving. If desired, some or all of the fines that are removed may be returned to the mixer.
In another group of methods, the mixed plastics material and the mineral fines are extruded. Further material, which may or may not be plastics material, may be added to the mixture of the plastics material and the mineral fines prior to extrusion. The further material may be selected from the group comprising Lyre waste, fibres and mineral fines, but other materials can also be added. The mixing of the further materials prior to extrusion may be carried out in a Z-Blade mixer.
The temperature of the material in the mixer is preferably controlled. Preferably the temperature of the material remains below 200 C since at higher temperatures harmful gases are liable to be released from the plastics material. The temperature of the walls of the mixer may be higher than the temperature of the material in the mixer and may even be higher than 2000C. In that case the residence Lime of tile materials in the mixer must of course be rcc,tricted. Preferably the temperature of the mixer is monitored and preferably it is also controllecl. In addition or ln,Lcad, the Lcmperature of the product leaving the mixer may be montcred and the process may be adjusted (for cxampe, by alterrlg the temperature of the mixer or by alterirl the resdencc time in the mixer) to control. the temperature of the product leaving the mixer. The temperature of the product leaving the mixer is preferably not Less than]. 600C. For most applications the temperature of the product leaving the mixer is preferably In the range of 1/O C to 195rC and more preferably in the range of 175 C to]95 C. This good control of the temperature of the product leaving the mixer allows a product of consistent quality to be produced.
The plastics material may be obtained from any suitable source but in an especially preferred embodiment of the invention the plastics material is plastics waste material.
It is also possible, if desired, to incorporate hazardous waste material either in the plastics waste material provided at the beginning of the method, or by adding such material during the extrusion step. Examples of such hazardous waste materials that may be incorporated are incinerator flue ash and sewage sludge. The waste material may become encapsulated within the mixture and in that way rendered harmless.
The method of the invention may be carried out with a wide variety of plastics materials. It is preferable that a component of the plastics material melts at a temperature 6 - below 200 C. Typically this component is represented principally by po] yoleIin plastics materials. The plastics material may include other plastics materials which do not melt In the mixer. Even a relatively small proportion of the component of low melting point may be sulticient: for example, in some applications a proportion by mass of at least 5 per cent in the final product may be adequate while In other applications a proportion by mass of at least 10 per cent IS preferred.
The proportion of plastics waste material to fines can also be varied over a relatively wide range. For example, we have made useful products from a mixture by mass of 80 per cent fines to 20 per cent plastics waste material and also of per cent fines to 60 per cent plastics waste material. In the case of a material having only 20 per cent by mass of plastics waste material, it is preferred that a relatively large proportion (at least 25 per cent by mass) melts in the mixer, whereas in the case of a material having 60 per cent by mass of plastics waste material, a much lower proportion of the plastics waste material is required to melt.
We have found that it is especially advantageous if the plastics waste material has a relatively high proportion of plastics material. Preferably the proportion of plastics material in the waste material that is fed to the mixer is at least 80 per cent by mass and more preferably more than 90 per cent by mass. We have found that whilst a wide variation in the composition of the plastics materials can be accommodated in many applications, it is disadvantageous for there to be a large proportion of non-plastics material. If necessary the plastics waste material may be pre-treated to - 7 increase the proportion of plastics material to above 80 per cent and preferably to above 90 per cent.
the moisture content of the mineral fines fed to the mixer is preferably less than 5 per Gent, by mass.
Products of the method of the invention may be used in a wide range of apE'licatlons Including: asphalt-, concrete blocks, pourable concrete, paviours, herbs as well as in other applications outside the building industry, for example, as a building material for an article usually made from a pure plastics material.
There may also be advantage in including other components in the final products of the method. In particular, for some applications of the product It is especially advantageous to include a fire retardant. That fire retardant may be added at an appropriate stage of the method; for example, it may be added to the plastics material or to the fines before they are fed into the mixer, it may be fed separately to the mixer or it may be mixed with the mixture taken from the mixer. Examples of fire retardants that may be employed are aluminum tribydroxide and antimony trioxide.
The use of plastics waste material having a high proportion of plastics material is an especially significant feature of the present invention and one which may be employed even with larger particles of shredded plastics material than those required according to the first aspect of the invention. Thus, according to a second aspect of the invention, the present invention provides a method of manufacturing a building material comprising the following steps: - 8 providing plastics waste material, shredding the plastics waste material, Providence mineral fines, feccting the shredded plastics waste material and the fines to a mxcr the mineral tines having a moisture content of less than 10 per Gent by mass, and mixing the plastics waste material and the fines in a mixer at an elevated temperature, wherein the proportion of plastics material in the plastics waste material that is fed to the mixer is at least per cent by mass, based on the mass of the plastics waste material.
lhc method according to the second aspect of the invention may also incorporate any of the optional and preferred features described above with reference to the first aspect of the invention.
In its broader aspects, the invention may comprise any of a wide variety of features. Accordingly, in a third aspect of the invention there IS provided a method of manufacturing a building material comprising the following steps: providing plastics material, shredding the plastics material, providing mineral fines, feeding the shredded plastics material and the mineral fines to a mixer, and mixing the plastics material and the mineral fines in the mixer at an elevated temperature, the method being further characterized by one or more of the following features: - 9 T) the plastics material is plastics waste material and the proportion of plastlGs material in the plastics waste material that is fed to the mixer is at least 80 per cent by mass, based on the mass of the plastics waste material; i) the mineral T loos that are fed to the mixer have a moisture content of loss that 10 per cent by mass; ii) the mineral fines fed to the mixer consist substarltially of dust; iv) at least 30 per cent by mass of the mineral fines fed to the mixer have a particle size greater than 63 microns; v) at least 80 percent by mass of the mineral flees fed to the mixer have a particle size of less than 4mmi vi) at least 80 per cent by mass of the shredded plastics material fed to the mixer have a particle size less than 30mm; vii) the materials are heated to a temperature in the range of 110 C to 195 C during the mixing; and/or viii) a fire retardant is incorporated in the materials in the mixer.
By way of example, various methods embodying the invention will now be described.
The method of a first embodiment of the invention may conveniently be regarded as comprising the following steps: 1. Providing a plastics waste material.
2. Shredding the plastics waste material.
3. Providing mineral fines.
4. Feeding the shredded plastics waste material and the mineral fines into a mixer and mixing the plastics waste material and the mineral fines in the mixer at an elevated temperature.
5. ComprGs.sing the heated mixture into avoids.
6. Crushing the Avoids to form an aggregate.
Each of the steps above Will] he described in more detail below.
The plastics waste material Is delivered as bulk mixed plastics material and comes from sources such as agricultural waste, general consumer waste, vehicle manufacturing or dismantling waste or other sources. The plastics waste material comprises some plastics materials, typically polyolefins, which melt at a temperature below 195 C and other plastics materials with hgEcr melting points (above 200 C). About 95 per cent by mass of the waste material is represented by plastics materials, the remaining small fraction being foreign material such as wood, ferrous and non-ferrous metals.
The plastics waste material is passed through a shredder which may be of a design known per se and is then fed through a hammer mild with a 20mm output mesh. The resulting material is in the form of flakes of an elongate shape having a particle size of the order of 20mm or less.
The mineral fines may be obtained from various sources including surplus quarry fines, canal dredgings, gravel pit settling lagoons and china clay waste. The fines have a particle size of less than 4mm and a moisture content of less than 10 per cent. A small amount of foreign material in the mineral fines can be tolerated.
The shredded plastics waste material and the mineral fines are fed to a mixer which may be of a kind known per se.
In the described embodiment the mixer IS a twelve-paddle horizontal shaft type mixer operating at approximately 60rpm - 11 wlth an oil-heated jacket. The oil temperature in the jacket as maintained at about 260 C. In the described embodiment a batch mixing process is adopted with each batch comprising about 200kg of material. rldc fines are fed into the mixer first via a side access hatch, the mixer is then started and a conveyor feeds in the shredded plastics waste material through a top- loadir-g door. As mixing takes place the matorals are heated and any moisture is driven off. After a mixing time of typically 6 to 8 minutes, the materials have reached a temperature of between 175 C and 195 ( with some of the plastics materials, in particular polyolefins such as polyethylene, having melted, thereby binding the mixture into a loose blend which Is then removed from the mixer. If the dwell time In the mixer is too short the mixture will not bind together or will be very coarse and "granular". If the dwell time in the mixer is too long the mixture becomes more cohesive and there is a risk of its temperature becoming so high that some polymers break down and release toxic fumes.
The mixture taken from the mixer is discharged to a conveyor system that feeds a press such as a briquette press.
The briquette press is of a type known per se and provides moulds in which 38mm ovoids can be formed by applying an appropriate pressure. The ovoids are then allowed to cool.
The cooled ovoids are then fed to a crushing machine, again of a type known per se, where they are crushed to provide a graded aggregate. The crushing machine is designed to produce a relatively low proportion of fines. If desired, the aggregate material can be screened to remove some or all of the fines. - 12
In a particular example of the invention, a blend of 60 parts by mass of limestone fines and 40 parts by mass of General Plastics Waste was mixed for 7 minutes. The mixture reached a temperature of 170 C and after pressing, crushing and screenrlg was used to form concrete blocks.
In other particular examples of the invention, a blend of 60 parts by mass of gritst one fines and 40 parts by mass of automotive waste plastic was mixed for 6 to 7 minutes and reached temperatures in the range of]64- 188 C. After pressing, crushing and screening an aggregate with particle sizes in the range of 4mm to lOmm was obtained and subsequently used as 10 per cent by volume replacement of the aggregate in an asphalt mix.
In an alternative embodiment of the invention, the mixture removed from the mixer is fed to a 7-Blade mixer, additional material such as Lyre waste or fibres is added and the product its then extruded via a ram system and fed to a mould.

Claims (27)

  1. C.lalms I. A method of manufacturing a building material comprising the
    following steps: providing plastics matcral, shredding the plastics material, providing mineral flncs, feeding the shredded plastics material and the mineral fines to a mixer the mineral fines having a moisture content of less than 10 per cent by mass, and mixlog the plastics material and the mineral fines In the mixer at an elevated temperature, wherein at least 80 per cent by mass of the shredded plastics material fed to the mixer has a particle size of less than 30mm.
  2. 2. A method according to claim 1, in which at least 80 per cent by mass of the shredded plastics material fed to the mixer has a particle size of less than 20mm.
  3. 3. A method according to claim 1 or 2, in which the mineral fines consist substantially of dust.
  4. 4. A method according to any preceding claim, in which at least 80 per cent by mass of the mineral fines fed to the mixer have a particle size of less than 4mm.
  5. 5. A method according to any preceding claim, in which at least 80 per cent by mass of the mineral fines fed to the mixer have a particle size greater than 63 microns.
  6. 6. A method according to any preceding claim, in which at least 30 per cent by mass of the mineral fines fed to the mixer have a particle size greater than 63 microns. - 14
  7. 7. A method according to claim 1 or 2, in which the mineral fines consist substantially of filler.
  8. 8. A mcChod according to claim 7, in which at least, 80 per Gent by mass of' the mineral fines fed to the mixer have a particle size of less than 63 microns.
  9. 9. A method according to any preceding claim, further including tTle step of compressing the mixed plastics material and the mineral fines into agglomerates.
  10. 10. A method according to claiTn 9, in which the agglomerates are avoids.
  11. 11. A method according to claim 10, in which the ovoids have a particle size in the range of 20 to 50mm.
  12. 12. A method according to any of claims 9 to 11, further including the step of crushing the agglomerates to produce graded aggregates.
  13. 13. A method according to claim 12, in which less than 30 per cent by mass of the particles of the aggregates have a size of less than 4mm.
  14. 14. A method according to any of claims 1 to 8, in which the mixed plastics material and the mineral fines are extruded.
  15. 15. A method according to any preceding claim, in which the temperature of the materials remain below 200 C during the mixing.
  16. 16. A method according to claim 15, in which the materials are heated to a temperature in the range of 170 C to 195 C during the mixing.
  17. 17. A method according to any preceding claim, in which the plastics material comprises a plurality of different plastics materials.
  18. 18. A method according to any preceding claim, in which the - 15 plastlcs material Is a plastics waste material.
  19. 19. A met}lod according to claim 18, In which the proportio of plastics material in the plastics waste material that is fed to the mixer is at] east 80 per cent by mass, based on the mass of the plastics waste material.
  20. 20. A motrlc-'d according to claim IS, ire which the proportio of plastics material in the plastics waste material that is fed to the mixer is at least 90 per cent by mass, based on the mass of the plastics waste material.
  21. 21. A method according to any preceding claim, in which a fire retardant is incorporated in the materials In the mixer.
  22. 22. A method of manufacturing a building material comprising the following steps: providing plastics waste material, ]5 shredding the plastics waste material, providing mineral fines, feeding the shredded plastics waste material and the fines to a mixer, the mineral fines having a moisture content of less than 10 per cent by mass, and mixing the plastics waste material and the fines in a mixer at an elevated temperature, wherein the proportion of plastics material in the plastics waste material that is fed to the mixer is at least per cent by mass, based on the mass of the plastics waste material.
  23. 23. A method according to claim 22, in which the proportion of plastics material in the plastics waste material that is fed to the mixer is at least 90 per cent by mass, based on the mass of the plastics waste material. - 16
  24. 24. A method accord Log to claim 22 or 23, including any of the further features specified In any of claims 2 to 21.
  25. 25. A rnet}-od of manufacturing a building material comprising the following steps: proviriLnq plastics material, shredding the plastics material, provldrlg mineral fines, feeding the shredded plastics material and the mineral fines to a mixer, and mixing the plastics material and the mineral fines in the mixer at an elevated temperature, the method being further characterized by one or more of the following features: l) the plastics material is plastics waste material and the proportion of plastics material in the plastics waste material that is fed to the mixer is at least 80 per cent by mass, based on the mass of the plastics waste material; ii) the mineral fines that are fed to the mixer have a moisture content of less that 10 per cent by mass; iii) the mineral fines fed to the mixer consist substantially of dust; iv) at least 30 per cent by mass of the mineral fines fed to the mixer have a particle size greater than 63 microns; v) at least 80 percent by mass of the mineral fines fed to the mixer have a particle size of less than 4mm; vi) at least 80 per cent by mass of the shredded plastics material fed to the mixer have a particle size less than 30mm; vii) the materials are heated to a temperature in the range of 170 C to 195 C during the mixing; and/or viii) a fire retardant IS incorporated in the materials in the mixer.
  26. 26. A rncChod of manufacturing a building material, the method being substantially as herein described.
  27. 27. A product obtained from a method according to any preceding claim.
GB0414901A 2004-07-02 2004-07-02 Building material derived from plastics Pending GB2415700A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB0414901A GB2415700A (en) 2004-07-02 2004-07-02 Building material derived from plastics
PCT/GB2005/002586 WO2006003409A1 (en) 2004-07-02 2005-07-01 Artificial aggregate comprising plastic material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0414901A GB2415700A (en) 2004-07-02 2004-07-02 Building material derived from plastics

Publications (2)

Publication Number Publication Date
GB0414901D0 GB0414901D0 (en) 2004-08-04
GB2415700A true GB2415700A (en) 2006-01-04

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB0414901A Pending GB2415700A (en) 2004-07-02 2004-07-02 Building material derived from plastics

Country Status (1)

Country Link
GB (1) GB2415700A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009087399A2 (en) * 2008-01-11 2009-07-16 Plastic Raw Materials Limited Method of processing and disposing of plastic waste
ITAP20080011A1 (en) * 2008-08-08 2010-02-09 Piergiuseppe Settimi "PROCESSING AND REALIZATION SYSTEM NEW TYPE OF 'CONCRETE' BASED ON INERT AND GLASS IN HETEROGENEOUS PLASTIC"
WO2014007648A1 (en) * 2011-12-23 2014-01-09 Peter Hamish Barrow Improvements in, or relating to, aggregate materials
US9969868B2 (en) 2011-06-20 2018-05-15 Imerys Minerals Limited Methods and compositions related to recycling polymer waste
WO2020130762A1 (en) * 2018-12-18 2020-06-25 Madani Zakaria Production of ecological blocks based on a new material composed of mining waste and of plastic waste using a new industrial method and new technology

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB666690A (en) * 1948-05-07 1952-02-20 Francis Robert Himsworth Improvements in and relating to acid resisting cements
EP0021028A2 (en) * 1979-06-21 1981-01-07 Chemische Werke Hüls Ag Method of producing a water-permeable surfacing for play and/or sports grounds
GB2291419A (en) * 1994-07-18 1996-01-24 Europ Environmental Recycling A method for recycling waste materials
US6310129B1 (en) * 1997-10-02 2001-10-30 Rebaseproducts Inc. Processing and use of carbide lime

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB666690A (en) * 1948-05-07 1952-02-20 Francis Robert Himsworth Improvements in and relating to acid resisting cements
EP0021028A2 (en) * 1979-06-21 1981-01-07 Chemische Werke Hüls Ag Method of producing a water-permeable surfacing for play and/or sports grounds
GB2291419A (en) * 1994-07-18 1996-01-24 Europ Environmental Recycling A method for recycling waste materials
US6310129B1 (en) * 1997-10-02 2001-10-30 Rebaseproducts Inc. Processing and use of carbide lime

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009087399A2 (en) * 2008-01-11 2009-07-16 Plastic Raw Materials Limited Method of processing and disposing of plastic waste
WO2009087399A3 (en) * 2008-01-11 2009-12-03 Plastic Raw Materials Limited Method of processing and disposing of plastic waste
GB2468614A (en) * 2008-01-11 2010-09-15 Plastic Raw Materials Ltd Method of processing and disposing of plastic waste
ITAP20080011A1 (en) * 2008-08-08 2010-02-09 Piergiuseppe Settimi "PROCESSING AND REALIZATION SYSTEM NEW TYPE OF 'CONCRETE' BASED ON INERT AND GLASS IN HETEROGENEOUS PLASTIC"
US9969868B2 (en) 2011-06-20 2018-05-15 Imerys Minerals Limited Methods and compositions related to recycling polymer waste
US10336891B2 (en) 2011-06-20 2019-07-02 Imertech Sas Methods and compositions related to recycling polymer waste
WO2014007648A1 (en) * 2011-12-23 2014-01-09 Peter Hamish Barrow Improvements in, or relating to, aggregate materials
WO2020130762A1 (en) * 2018-12-18 2020-06-25 Madani Zakaria Production of ecological blocks based on a new material composed of mining waste and of plastic waste using a new industrial method and new technology

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