from recycled polypropelene (rpp) and …eprints.utem.edu.my/14724/1/characterization of composite...

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Faculty of Manufacturing Engineering

CHARACTERIZATION OF COMPOSITE TILES FABRICATED FROM RECYCLED POLYPROPELENE (rPP) AND SILICA USING

HOT PRESS METHOD

Samsul Anuar bin Sulong

Master of Manufacturing Engineering (Industrial Engineering)

2014

© Universiti Teknikal Malaysia Melaka

CHARACTERIZATION OF COMPOSITE TILES FABRICATED FROM RECYCLED POL YPROPELENE (rPP) AND SILICA

USING HOT PRESS METHOD

SAMSUL ANUAR BIN SULONG

A thesis submitted in fulfillment of the requirements for the degree of Master of

Manufacturing Engineering (Industrial Engineering)

Faculty of Manufacturing Engineering

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

2014


DECLARATION

I hereby, declared this report entitled ' Characterizations of composite tiles fabricated from

Recycle Polypropylenes (rPP) and Silica Using Hot Press Method ' is the results of my own

research except as cited in the references.

Signature ~ : .... ;r.1.~.I ........ .

Author' s Name : Samsul Anuar Bin Sulong

Date , ... . ..lrklt·······


APPROVAL

I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in

terms of scope and quality for the award of Master of Manufacturing Engineering

(Industrial Engineering).

Signature

Supervisor Name : Dr. Mohd Asyadi Azam Bin Mohd Abid

Date ..... 'JS)/?by ............... ....... .


DEDICATION

To my beloved wife, Masliza bte Mat Hussin, my lovely sons, Shaza Adelia Putri. Their

source of my inspiration and strength in pursuit of excellence. To my mother, Romlah bte

Jusoff also father and mother in law who always pray for us happiness. Thanks for all

support and encouraged towards the end.


ABSTRACT

The main purpose of this research is to determine the more specific nature of the physical and mechanical properties of a mixture of silica sand and polypropylene material (rPP) recycling in producing composite tile. In this study, rPP is the main ingredient in the binding details of silica through a process of melting and compression using hot press method. There are five weight percent of the composition rPP in producing composite tiles of 30%, 50%, 70%, 90% and 100% and particle size of the silica sand is the fine. After determine the mechanical and physical properties each composition, the results get the composition with better combination in flexural strength, tension, hardness and fire resistant is Sample CT70 which the matrix is 70% and the filler is 30%.


ABSTRAK

Tujuan utama kajian ini dilakukan adalah untuk mengkaji dengan lebih spesifik sifat-sifat fizikal dan mekanikal terhadap campuran pasir silika dan bahan polypropelene (rPP) kitar semula dalam menghasilkan jubin komposit. Dalam kajian ini, rPP digunakan sebagai bahan utama dalam mengikat butiran silika melalui proses pencairan dan pemampatan yang mengunakan kaedah pengacuan pemampatan. Terdapat lima komposisi peratusan berat rPP dalam menghasilkanjubin komposit iaitu 30%, 50%, 70%, 90% dan 100% serta saiz partikel pasir si/ika yang ha/us. Setelah diukur sifat mekanikal dan fizikal setiap komposisi, keputusan menunjukan bahawa komposisi yang lebih baik dari segi kombinasi kekuatan lenturan, teganggan, kekerasan dan rintangan api adalah sample CT70 yang mana kandungan matriknya sebanyak 70% dan pengisi sebanyak 30%.

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ACKNOWLEDGEMENTS

Assalamulaikum W.B.T.

First of all, I would like to express my gratitude to Allah S.W.T, for giving me infinite grace, love and blessing, to enable me to pursue my ambition up to this point of my live. Hope him will accept me as His servant. Most special thanks to my beloved Muhammad S.A. W, peace and greeting upon him for his sacrifice.

This work is a synergistic of many minds. I am grateful for the inspiration and wisdom of many profesionals and for the trans-generational sources and roots of this wisdom. Interdepence is higher value than independence.

Generously would like to take this opportunity to express my hearfelt appreciation and thanks to respectable Dr. Mohd Asyadi Azam bin Mohd Abid for his continuing guidance, encouragement, supervision, advice and effort in completing this master programme.

Sincere thanks to all involve in this project direct or indirectly help me in conducting the experimental work. As for my family members, no amount of gratitude could reply your kindness of being there as well as the patience to put with my whim. My deepest gratitude in meant for all of you.

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TABLE OF CONTENTS

DECLARATION

DEDICATION

ABSTRACT

ABSTRAK

ACKNOWLEDGEMENTS

TABLE OF CONTENTS

LIST OFT ABLES

LIST OF FIGURES

LIST OF APPENDICES

LIST OF ABBREVIATIONS

CHAPTER

1.0 INTRODUCTION

1.1 1.2 1.3 1.4

Background of study Problem statement Aim and objectives Research scope

2.0 LITERATURE REVIEW

2.1 2.2

Background of plastic waste Material 2.2.1 Plastic waste 2.2.2 Silica 2.2.3 Alumina

2.3 2.4 2.5 2.6

Important parameter in composite material fabrication Composite tile composition. Hot press process Characterizations and testing

3.0 METHODOLOGY

3.1 3.2 3.3 3.4

Project flow chart K-Chart for project implements Material Manufacture of tiles 3.4.1 Material preparation

3.4.1.1 Melt the rPP 3.4.1.2 Add and mix the matrix with Fillers

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PAGE

ii

iii

iv

vi

vii

ix

x

1 3 5 5

6 7 8 8 9 10 13 14 16

17 17 19 20 20 20 21

3.4.1.3 Cooling the composition 3.4.1.4 Crushing the matrix

3.4.2 Sample Fabrication 3.5 Characterization and Testing

3.5.1 Mechanical Tests 3.5.1.1 Flexural Tests 3.5.1.2 Tensile Tests 3.5.1.3 Hardness Tests

3.5.2 Physical Tests 3.5.2.1 Burning Rate Tests 3.5.2.2 Morphology Tests

3.4 Design of experiment

4.0 RESULT AND DISCUSSION

4.1

4.2

4.3

Mechanical Properties Analysis 4.1.1 Flexural Tests 4.1 .2 Tensile Tests 4 .1.3 Hardness Test Physical Properties Analysis 4.2. l Burning Rate Tests 4.2.2 SEM-EDX Analysis oftop view sample surface Rank Method Analysis

5.0 CONCLUSION AND RECOMMENDATIONS

5.1 5.2

Conclusion Recommendations

REFERRENCES

APPENDICES

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21 21 22 23 23 24 26 27 27 27 28 29

30 30 33 36 39 40 41 45

46 47

48

52

LIST OF TABLES

TABLE TITLE PAGE

2.1 Typical properties of PP 7

3.1 Compositions of the tiles studied 20

3.2 Design of experiment 29

4.1 Result of Flexural test 31

4.2 Result of Tensile test. 34

4.3 Data of Hardness 37

4.4 Data of linear burning rate 40

4.5 EDX results 42

4.6 Analysis of results using Rank Method 45

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LIST OF FIGURES

FIGURE TITLE PAGE

l.1 Schematic Hot Pressing Technique 3

2.1 The fire triangle according to Emmons 10

2.2 Schematic of polymer pyrolysis 10

2.3 Schematic representation of the mold used for compression molding

of polyester composite tiles (PCT) 15

3.1 Flow chart of the experiment 18

3.2 K- chart of project implementation 19

3.3 Mode of material making process. (a) Casting of the

plastic. (b) Addition and mix the silica and Alumina oxide. 22

( c) Cooling the matrix of the tile. ( d) Crushing the matrix to get

the pallet

3.4 Hot Press Machine 23

3.5 Flexural stress- strain diagram of PC tiles prepared by

using fine, medium, and coarse grade marble, with 25

and without glass fibre mats

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LIST OF FIGURES

FIGURE TITLE PAGE

3.6 Allowable Range of Loading Nose and Support Radii (ASTM

0368) (a) Minimum radius = 3.2 mm (1;8 in.). (b) Maximum 25

radius supports 1.6 times specimen depth; maximum radius

loading nose = 4times specimen depth.

3.7 Specimen size ASTM D 368 26

3.8 Test Fixture Burning Rate. 28

4.1 Varian's of Flexural Strength 32

4.2 Optical Image of sample after Flexural tests 33

4.3 Varian's of Tensile Strength 34

4.4 SEM Micrograph Fracture Break of Tensile Test (a) CT30,

(b) CT50, (c) CT70, (d) CT90 and (e) CTIOO. 35

4.5 Varian' s of Hardness 38

4.6 The structure of a 2: 1 layered silicate 39

4.7 EDX peak analysis (a) CT30, (b) CT50,

(c) CT70, (d) CT90 and (e) CTIOO. 44

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LIST OF APPENDICES

FIGURE TITLE PAGE

A Flexural Test Report CT30 52

B Flexural Test Report CT50 53

c Flexural Test Report CT70 54

D Flexural Test Report CT90 55

E Flexural Test Report CTI 00 56

F Tensile Test Report CT30 57

G Tensile Test Report CT50 58

H Tensile Test Report CT70 59

Tensile Test Report CT90 60

J Tensile Test Report CTI 00 61

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ASTM

A}i03

APP

EDX

ISO

L

MEKP

PC

PCT

PE

PET

PER

pp

rPP

SEM

Si02

t

UTM

v

LIST OF ABBREVIATIONS

American Society for Testing and Materials

Alumina

Ammonium polyphosphate

Energy Dispersion X-Ray

International Organization for Standardization

Length

Methyl Ethyl Ketone Peroxide

Plastic Composite

Plastic Composite Tile

Polyethylene

Polyethylene Terephthalate

Pentaerythritol

Polypropelene

Recycle Polypropelene

Scanning Electron Machine

Silicon Dioxide

Time

Universal Testing Machine

Volume

x


CHAPTERl

INTRODUCTION

1.1 Background of the study

Pollution and solid waste disposal give a big problem for every country in the

world including Malaysia If a country has a proper solid waste management then the

pollution problems will not occur thereby reducing global warming. The study conducted

in 2007 by Idrus et. al. have stated that the amount of solid waste in Malaysia was about

7.34 million tons per year. As a result of this issue, most countries including Malaysia have

encouraged their researchers to study on the method or new product that can be produced

from waste residues, in other words, to recycle of renewable resources. Therefore, studies

on the use of plastic waste from the Polypropylene (PP) as binding agent or matrix's mix

with filler between silica and alumina has a commercial value to study for produce the

composite tile.

As we know, the ceramic tiles are hard but brittle. Ceramic tiles are also relatively

heavier. In general, the ceramic tile weight with a thickness of 6 mm is between 14.26

kg/m2 to 18.46 kg/m2 for every one square meter (Tilersforum, 2013). From this fact, why

don't we produce the tiles that lighter, stronger and unbreakable? We also can reduce the

problem of solid waste disposal and improve certain properties of ceramic tiles, and then

the study to produce composite tiles from plastic waste can be obtained. Ceramic tile

ratings are set up in a grading system of 1 to 5, based on the tile's toughness and durability.

The rating 1 to 5, the tile applies only one aspect of tile like visible surface abrasion

resistance. A tile rating of 5 is the toughest in terms of standing up to scratching, dirt and

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traffic, one is the easiest to damage. See below for a quick breakdown of the l to 5 ceramic

tile ratings systems:

l . Grade 1, this is the weakest of all standard grade ceramic tiles. It's really only

suitable as a wall tile.

2. Grade 2, this is best for light traffic areas. Again, a great product for wall

tiles, but it will also work in residential bathrooms, where foot traffic is

minimal.

3. Grade 3 is most common in residential building, and perfect for light to

moderate traffic. This makes it a very sensible choice for residential kitchens,

countertops, residential flooring, and all areas that receive lighter wear and

tear.

4. Grade 4, this grade is a step up from grade 3 tile grades. It's still a good choice

for residential uses, such as tile floors and countertops, but it can also take the

heavier abuse of light commercial foot traffic.

5. Grade 5 is built to take a beating. It's mostly used in high traffic commercial

areas such as shopping malls and airports.

In this study, the hot press machine used to produce the composite tiles. The

material most commonly used in hot press are ceramics, composite and plastic materials.

However, in this study, the material used is a mixture matrix composite of plastic granule,

silica and alumina powder. The hot press machine is the simultaneous application of

temperature and pressure compression to compress the powder or particles to partially or

fully sintered components. But in the context to fabricate the composite tiles, the matrix

material will melts and solidifies when cooled. Hot press is used to fabricate the composite

tiles as same with the original production of ceramic tile using the cold press powder

machine. It also used to compress the powder between silica and feldspar. The hot press

2


machine is also relatively easier to use because the process is not complicated. The main

factor why this hot press machine is used because of the composition that can be processed

by the machine is unique to produce composite tiles. To view a clear process of hot press,

please refer to Figure 1.1.

•:n,llllr .......

•• •• •

Figure 1.1: Schematic Hot Pressing Technique

1.2 Problem Statement

Generally, we have seen that ceramic tile is a product that can be classified as an

exclusive product because of the tedious process which begins with crushing and mixing

the silica and feldspar, followed by the cold- press process, then the process of sweeping

shiny and lastly is firing process. After conducting the examination and observation, it is

true that the production of ceramic tiles is very difficult and complex. In addition, a lot of

energy is used in ceramic production to make the ceramic tiles thereby increasing the cost

of production. From this we can see that, it is a good idea to produce tiles using a low cost

and simpler process. After reviewing some articles on the early researchers, came the idea

to produce a composite tile using the hot press process to fabricate the composite tile. The

reason why composite tile is selected, is because the mixture of the composite tiles is

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similar to the mixture of the ceramic tiles, the only difference is composite tile has

matrixes and fillers.

In addition, the weight factor of ceramic tiles also has been a problem for

construction labourers, especially during installation and delivery. For example, a ceramic

tile with a thickness of 6 mm has a weight of between 14.26 kg/m2 to 18:46 kg/m2 for

every one square meter (Tilersforum, 2013). This factor also paves the way for composite

tiles to replace ceramic tiles, especially in terms of product weight. This is because

composite tiles are lighter than ceramic tiles.

Nowadays pollution is very serious and is related to the plastic products. This is due

to the fact that plastic takes a long time to decompose. With abundant resources and

mechanical properties of thermoplastic, that can be recycled, Polypropylenes waste or

recycle Polypropylene (rPP) is chosen for the matrix's to make the composite tiles. After

fabricating the composite tiles, it is hoped that the study will reduce the environmental

pollution caused by plastic waste.

After using recycled plastic as the matrix in the composite tile, this study becomes

more interesting as the general nature of the plastic is flammable. To produce a composite

tile based plastic, the product needs to be the fire resistance is very important. After review

some previous studies, to make the products based plastic are fire resistant, it is necessary

to add flame retardant agent. In this study, the additive flame retardant used is aluminum

oxide aided by silica powder.

4


t.3 Aim and Objectives

The objectives of this study are:

i) To fabricate composite tile-based rPP as a matrix and a mixture of silica and

alumina powder as filler.

ii) To identify the best mechanical and physical properties of the fabricated

composite tiles.

1.4 Research Scopes

In achieving the objective, this study focuses on the following scope:

For objective 1:

i. Fabricate the composite tiJe using the hot press method.

ii. Fabricate samples as a percentage of the weight of the rPP 30%, 50%, 70%, 90%

and 100%.

For objective 2:

i. Conduct flexural strength test, tensile test and hardness test to identify the

mechanical properties of composite tile.

ii. Conduct burning rates test and SEM-EDX analysis of composite tiles to identify the

best physical properties.

5


CHAPTER2

LITERATURE REVIEW

2.1 Background of Plastic Waste

As we arrived in the 20th century, we are faced with many ecological problems

such as pollution which can be attributed to poor solid waste management. Thus, many

researchers took the initiative to improve the methods of disposing solid waste more

systematically and reuse waste material. Various methods can be done in managing solid

waste, either by recycling the material or make new materials or products. Therefore, the

uses of plastic waste can increase the recycling technologies will be developed and

improved since the early 70's (Allan and Kukacka, 1995). However, the amount of plastic

waste has increased throughout the world. Taking into account the needs and too much

wasted plastic material, Icduygu et. al. (2012) made a study of the production of polyester

composite tiles produced from the synthesis of PET blended with a micro marble

arrangement as filler. This shows that plastic waste can be mixed with other materials to

produce composite tile. Many researchers such as Choi et. al. (2005), Oehl et. al. (2007),

Wong (2010), and Konin (2011) has shown the addition of plastic waste material can be

used in various fields not only in tile and plastic products only, but plastic waste can be

recycled and used more extensively in the field structure of the buildings and pavements.

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2.2 Material

For the fabricated tiles with plastic wastes, the materials properties that are used:

Table 2.1: Typical properties of PP (Boedeker.com)

TYPICAL PROPERTIES of POLYPROPYLENE

ASTM Property ~~ Co- Flame

test Homopolyme I p ly Retardant o mer PHYSICAL

D792 Density (g/cm3) 0.905 0.897 0.988

D570 Water Absorption, 24 hrs(%) <0.01 0.01 0.02 MECHANICAL

D638 Tensile Strength (psi) 4,800 4,800 4,300 D638 Tensile Modulus (psi) 195,000 - -D638 Tensile Elongation at Yield(%) I 12 23 28 D790 Flexural Strength (psi) 7,000 5,400 -D790 Flexural Modulus (psi) 180,000 160,000 145,000 D695 1Compressive Strength (psi) 7,000 6,000 -D695 Compressive Modulus (psi) - - -D785 Hardness, Rockwell R 92 80 -D256 IZOD Notched Impact (ft-lb/in) 1.9 7.5 0.65

THERMAL

D696 Coefficient of Linear Thermal

6.2 6.6 Expansion (x 10-5 in./in./°F) -

D648 Heat Deflection Temp (°F I °C) 210 I 99 173 I 78 106 I 41 at 66 psi /at 264 psi 125 I 52 110 I 43 57 I 14

D3418 Melting Temperature (°C) 164 164 164 - Max Operating Temp (°C) 82 77 82

Thermal Conductivity (BTU-in/ft2-hr-0.76-0.81 - -C177 Of)

(x 104 cal/cm-sec-°C) 2.6-2.8 - -

UL94 Flammability Rating HB n.r. V-0 ELECTRICAL

Dl49 Dielectric Strength (V /mil) short time,

500-660 475 500-650 1/8" thick

D150 Dielectric Constant at 1 kHz 2.25 2.2-2.36 2.3 Dl50 Dissipation Factor at 1 kHz 0.0005-0.0018 0.0017 -D257 Volume Resistivity (ohm-cm) at 50%

8.5 x 1014 2 x 1016 101 5 RH

D495 Arc Resistance (sec) 160 100 -

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2.2.1 Plastic Waste

Plastics are the most common waste item, which represents over 30% of all waste

collected over the past 10 years. This includes drink containers, confectionery packets and

water bottles, all of which pose a huge threat to wildlife and our environment. Recycling

plastic saves energy, valuable resources and helps to protect our environment.

In this study, the polypropylene recycled (rPP) can be used. Polypropylene is an

extremely versatile material and used for a wide range of applications. PP is tough and yet

flexible and classed as semi-rigid. It is also extremely resistant to heat, chemicals and

fatigue. Furthermore, it is translucent and has an integral hinge property. Polypropylene

plastics have a high melting point and are also great to prevent the dampness transmission

and are almost inert in the face of things such as acids and solvents. To find the

polypropylene plastics very easy because it's used for medical tools, food containers,

automotive parts and etc. Table 2.1 shows the typical properties of PP. The reasons the rPP

are used is as follows:

i. It is a resource of thermoplastic that is easily moulded and become solid

when cooled.

ii. This plastics material is the second most widely used type of plastic after

polyethylene plastic in the manufacturing and packaging industry.

iii. In addition, the combustion does not emit toxic fumes.

2.2.2 Silica

Dolley and Bolen (2000) cited in their study that there are four types of silica sand

in the world, which are quartz crystals, special silica stone products, and tripoli . Most stone

are covered by a silica stone called novaculite. The tripoli includes own tripoli and other

8


fine-grained, porous silica materials that have similar properties and end uses, such as

rottenstone.

Industrial sand or stone, often called silica or silica sand with quartz sand, includes

sand and gravel with high content of silicon dioxide (Si02). Sand is very popularly used in

the manufacturing of glass, foundry, abrasive, and hydraulic fracturing (frac) applications

and for many other industrial uses. Specifications for each uses vary. But as a resource of

silica for most uses is still a lot. In this study, the source silica obtained from Concord

Chemical Sdn. Bhd. and size 45µm.

2.2.3 Alumina

In this study, understanding the mechanism and action of flame retardant is

important. We need to understand the fire triangle by Emmons as shown in Figure 2.1

because an initial source of heat is the start of a fire requires fuel and oxygen to be

sustained and expanded. Polymers provide a continuous flow of fuel pyrolysis and

decomposition products as temperature rise as Figure 2.2. Ambient conditions to provide

the oxygen needed to continue to decompose and create free radicals that propagate

combustion of polymer fragments in the gas phase. To stop the fire, this process can be

stopped at one or more levels. Thus flame retardant developed to prevent the process

according to the mechanism of action in one or more critical stage. In this study, alumina

used as a flame retardant. Source alumina was obtained from Concord Chemical Sdn. Bhd.

on equally sized 45µm.

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