Catalytic conversion of mixed polyolefins under mild atmospheric pressure

The chemical recycling of polyolefin presents a considerable challenge, especially as upcycling methods struggle with the reality that plastic wastes typically consist of mixtures of polyethylene (PE), polystyrene (PS), and polypropylene (PP). We report a catalytic aerobic oxidative approach for polyolefins upcycling with the corresponding carboxylic acids as the product. This method encompasses three key innovations. First, it operates under atmospheric pressure and mild conditions, using O2 or air as the oxidant. Second, it is compatible with high-density polyethylene, low-density polyethylene, PS, PP, and their blends. Third, it uses an economical and recoverable metal catalyst. It has been demonstrated that this approach can efficiently degrade mixed wastes of plastic bags, bottles, masks, and foam boxes.

Catalytic Strategies for the Upcycling of Polyolefin Plastic Waste

Chemical upgrading of waste plastics is currently one of the most important methods for addressing plastic pollution. In comparison to the current methods of incineration or landfill, chemical upgrading enables the utilization of carbon and hydrogen elements in waste plastics as resources. This process strongly relies on efficient catalysts and reaction systems. Through catalyst design, waste plastics can be converted into fuels or chemicals under the optimized reaction conditions, extending their life cycles. In this review, we systematically discuss various chemical conversion methods for polyolefin waste plastics, which account for a large proportion of waste plastics. We further explore the remaining challenges and future development trends in this field, including improving product value through product engineering and shifting research perspectives to exploring the tolerance of catalysts toward impurities in practical waste plastic waste rather than using pure plastic feedstock.

Controlling Product Distribution of Polyethylene Hydrogenolysis Using Bimetallic RuM3 (M = Fe, Co, Ni) Catalysts

Plastic hydrogenolysis is an attractive approach for producing value-added chemicals due to its mild reaction conditions, but controlling product distribution is challenging due to the formation of undesired CH4. This work reports several bimetallic RuM3/CeO2 (M = Fe, Co, Ni) catalysts that shift the product of low-density polyethylene hydrogenolysis toward longer-chain hydrocarbons. These catalysts were characterized by using X-ray absorption fine structure spectroscopy, electron microscopy imaging, and H2 temperature-programmed reduction. The combined catalytic evaluation and characterization results revealed that the product distribution was regulated by the formation of bimetallic alloys. A model compound, n-hexadecane, was selected to further understand the differences in hydrogenolysis over the Ru-based catalysts. Although a longer reaction time shifted the product toward smaller molecules, the bimetallic (RuCo3/CeO2) catalyst limited the further conversion of C2-C5 into CH4. This work highlights the role of bimetallic alloys in tailoring the interaction with hydrocarbons, thereby controlling the product distribution of polymer hydrogenolysis.

Polyethylene Upgrading to Liquid Fuels Boosted by Atomic Ce Promoters

Hydrocracking catalysis is a key route to plastic waste upgrading, but the acid site-driven C-C cleavage step is relatively sluggish in conventional bifunctional catalysts, dramatically effecting the overall efficiency. We demonstrate here a facile and efficient way to boost the reactivity of acid sites by introducing Ce promoters into Pt/HY catalysts, thus achieving a better metal-acid balance. Remarkably, 100 % of low-density polyethylene (LDPE) can be converted with 80.9 % selectivity of liquid fuels over the obtained Pt/5Ce-HY catalysts at 300 °C in 2 h. For comparison, Pt/HY only gives 38.8 % of LDPE conversion with 21.3 % selectivity of liquid fuels. Through multiple experimental studies on the structure-performance relationship, the Ce species occupied in the supercage are identified as the actual active sites, which possess remarkably-improved adsorption capability towards short-chain intermediates.

Unravelling potential reaction intermediates during catalytic pyrolysis of polypropylene with microscopy and spectroscopy

While plastics-to-plastics recycling via melting and re-extrusion is often the preferred option due to a relatively low CO2 footprint, this technique requires a highly sorted waste stream and plastic properties can often not be maintained. Obtaining aromatics, such as benzene, toluene, and xylene (BTX), via catalytic pyrolysis of polyolefins, such as polypropylene and polyethylene, offers another attractive recycling technology. In this process, a discarded crude oil refinery catalyst (ECAT) was previously shown to lower the unwanted formation of deactivating coke species compared to a fresh crude oil refinery catalyst (FCC-cat), while yielding 20 wt% aromatics from polypropylene. In this work, we study the underlying reaction mechanism for this chemical recycling process over the fresh and used refinery catalyst as well as a model system, not containing any zeolite material, using a combination of microscopy and spectroscopy. More specifically, by using in situ fluorescence microscopy, in situ infrared spectroscopy, in situ ultraviolet-visible spectroscopy as well as ex situ solid-state nuclear magnetic resonance, we observe highly fluorescent methylated aromatic intermediates that differ for the three catalyst materials under study both in their fluorescence, IR, UV-vis, and NMR spectroscopy features. This detailed micro-spectroscopic comparison informs which potential reaction intermediates lead to increased coke formation. Our results suggests that a next generation of catalyst materials for this process would profit from a higher accessibility and a milder acidity compared to an FCC-cat and shows the great potential of using ECAT to reduce coking and obtain a BTX stream, which could be become the chemical building blocks for the manufacturing of e.g., plastics and coating materials.

Circular olefin copolymers made de novo from ethylene and α-olefins

Ethylene/α-olefin copolymers are produced in huge scale and widely used, but their after-use disposal has caused plastic pollution problems. Their chemical inertness made chemical re/upcycling difficult. Ideally, PE materials should be made de novo to have a circular closed-loop lifecycle. However, synthesis of circular ethylene/α-olefin copolymers, including high-volume, linear low-density PE as well as high-value olefin elastomers and block copolymers, presents a particular challenge due to difficulties in introducing branches while simultaneously installing chemical recyclability and directly using industrial ethylene and α-olefin feedstocks. Here we show that coupling of industrial coordination copolymerization of ethylene and α-olefins with a designed functionalized chain-transfer agent, followed by modular assembly of the resulting AB telechelic polyolefin building blocks by polycondensation, affords a series of ester-linked PE-based copolymers. These new materials not only retain thermomechanical properties of PE-based materials but also exhibit full chemical circularity via simple transesterification and markedly enhanced adhesion to polar surfaces.

Electro-, thermo-, and photocatalysis of versatile nanocomposites toward tandem process

Tandem reactions involve multi-step processes conducted in one pot, offering a cost-effective, environmentally friendly, and efficient approach to chemical transformations with high atom economy. The catalytic systems employed in tandem reactions are crucial for achieving desirable activity, selectivity, and stability. Researchers worldwide have extensively explored catalytic processes driven by various energy fields, such as electrocatalysis, thermocatalysis, and photocatalysis, aiming to facilitate multiple reactions and bond transformations. Continuous advancements have been made in reaction conditions, catalyst design, and preparation methods. This review provides a comprehensive overview of recent progress in tandem reactions, specifically focusing on electro-, thermo-, and photocatalysis, and categorizes them into catalysts, reactors, and fields based on their applications. Furthermore, the review highlights the significance of rational design in nanomaterial catalysts and the integration of multiple energy sources, emphasizing their potential to enhance selectivity, performance, and the development of combined catalysis.

Simultaneous production of high-valued carbon nanotubes and hydrogen from catalytic pyrolysis of waste plastics: The role of cellulose impurity

Upcycling waste plastics into valuable carbon nanotubes (CNTs) and hydrogen via catalytic pyrolysis is a sustainable strategy to mitigate white pollution. However, real-world plastics are complex and generally contain organic impurities, such as cellulose, which have a non-negligible impact on the catalytic pyrolysis process and product distribution. In this study, cellulose was chosen as a model compound to distinguish the effects of oxygen-containing components on the CNTs and hydrogen production during the catalytic pyrolysis of waste polypropylene. Different amounts of cellulose were mixed with polypropylene to regulate the O/C mass ratio of the feedstock, and the relationship between the O/C mass ratio and the yield of products has been built quantificationally. The results revealed that the relative content of CNTs increased to over 95%, and the stability and purity of carbon deposition increased accordingly when the O/C mass ratio is 0.05. This could be ascribed to the etching effects caused by small amounts of H2O and CO2 on amorphous carbon. However, further increasing the amount of cellulose caused the deactivation of the Fe-Ni catalyst. This not only decreased the carbon yield but had an adverse impact on its morphology and graphitization, leading to the increase of amorphous carbon. This study can provide fundamental guidance for the efficient utilization of waste plastics that take advantage of organic impurities in waste plastic to promote the formation of high-purity CNTs.

Polyurethane with β-Selenocarbonyl Structure Enabling the Combination of Plastic Degradation and Waste Upcycling

Degradable polymers offer a promising solution to mitigate global plastic pollution, but the degraded products often suffer from diminished value. Upcycling is a more sustainable approach to upgrade polymer waste into value-added products. Herein, we report a β-selenocarbonyl-containing polyurethane (SePU), which can be directly degraded under mild conditions into valuable selenium fertilizers for selenium-rich vegetable cultivation globally, enabling both plastic degradation and waste upcycling. Under oxidation condition, this polymer can be easily and selectively degraded via selenoxide elimination reaction from mixed plastic waste. The degraded product can serve as effective selenium fertilizers to increase selenium content in radish and pak choi. The SePU exhibits excellent mechanical properties. Additionally, we observed the formation of spherulites-like selenium particles within the materials during degradation for the first time. Our research offers a successful application of selenoxide elimination reaction in the field of plastic degradation for the first time, endowing plastics with both degradability and high reusable value. This strategy provides a promising solution to reduce pollution and improve economy and sustainability of plastics.

Visualizing the Structure, Composition and Activity of Single Catalyst Particles for Olefin Polymerization and Polyolefin Decomposition

The structural and morphological characterization of individual catalyst particles for olefin polymerization, as well as for the reverse process of polyolefin decomposition, can provide an improved understanding for how these catalyst materials operate under relevant reaction conditions. In this review, we discuss an emerging analytical toolbox of 2D and 3D chemical imaging techniques that is suitable for investigating the chemistry and reactivity of related catalyst systems. While synchrotron-based X-ray microscopy still provides unparalleled spatial resolutions in 2D and 3D, a number of laboratory-based techniques, most notably focused ion beam-scanning electron microscopy, confocal fluorescence microscopy, infrared photoinduced force microscopy and laboratory-based X-ray nano-computed tomography, have helped to significantly expand the arsenal of analytical tools available to scientists in heterogeneous catalysis and polymer science. In terms of future research, the review outlines the role and impact of in situ and operando (spectro-)microscopy experiments, involving sophisticated reactors as well as online reactant and product analysis, to obtain real-time information on the formation, decomposition, and mobility of polymer phases within single catalyst particles. Furthermore, the potential of fluorescence microscopy, X-ray microscopy and optical microscopy is highlighted for the high-throughput characterization of olefin polymerization and polyolefin decomposition catalysts. By combining these chemical imaging techniques with, for example, chemical staining methodologies, selective probe molecules as well as particle sorting approaches, representative structure-activity relationships can be derived at the level of single catalyst particles.

Upcycling discarded polyethylene terephthalate plastics into superior tensile strength and impact resistance materials with a facile one-pot process

Discarding PET plastic (dPET) causes serious environmental pollution and enormous fossil resources waste. Processing techniques have mainly focused on the conversion of dPET into monomers, with minimal reports highlighting their transformation into high-value materials. This work intends to transform dPET into a high-performance material with potential alternative value in harsh production environments. The soft and hard segments of the thermoplastic polyester elastomeric (TPEE) molecular structure are reacted and cross-linked with dPET using a facile one-pot process, and two main polymers, (C8H4O4)n and ((C16H18O4)0.76·(C4H8O)0.24)n are generated after the reaction. Through chemical reactions between TPEE and dPET, new characteristic products and chemical bond-crossing structures are formed, while the resulting product particles or multiple TPEE particles are anchored by the high viscosity of dPET, which endows the material with superior tensile strength (34.21 MPa) and impact resistance. The glass transition temperature (Tg) of the material implies that neither the molecular chain nor the chain segments can move, while only the atoms or groups composing the molecule vibrate at their equilibrium positions. The development of this new treatment method may contribute to the reduction of environmental pollution and the improvement of the high-value conversion and utilization of dPET.

Precise activation of C-C bonds for recycling and upcycling of plastics

The rapid accumulation of plastic waste has led to a severe environmental crisis and a noticeable imbalance between manufacturing and recycling. Fortunately, chemical upgradation of plastic waste holds substantial promise for addressing these challenges posed by white pollution. During plastic upcycling and recycling, the key challenge is to activate and cleave the inert C-C bonds in plastic waste. Therefore, this perspective delves deeper into the upcycling and recycling of polyolefins from the angle of C-C activation-cleavage. We illustrate the importance of C-C bond activation in polyolefin depolymerization and integrate molecular-level catalysis, active site modulation, reaction networks and mechanisms to achieve precise activation-cleavage of C-C bonds. Notably, we draw potential inspiration from the accumulated wisdom of related fields, such as C-C bond activation in lignin chemistry, alkane dehydrogenation chemistry, C-Cl bond activation in CVOC removal, and C-H bond activation, to influence the landscape of plastic degradation through cross-disciplinary perspectives. Consequently, this perspective offers better insights into existing catalytic technologies and unveils new prospects for future advancements in recycling and upcycling of plastic.

Polyethylene upcycling to aromatics by pulse pressurized catalytic pyrolysis

To address the challenging issues of waste plastic pollution and petroleum shortage, we report herein a pulse pressurized catalytic pyrolysis process where polyethylene is continuously converted into aromatics using HZSM-5 catalyst incorporated with hydrated SiO2. Pressurization improves the activity of single-pulse pyrolysis of polyethylene by 14.42%. In contrast to the linear decrease of BTEXS relative yield with a K value of - 0.23 under non-pressurized conditions, pressurization results in a notable stability in the latter stage, characterized by a K value of only - 0.063. Comprehensive catalyst characterization demonstrates that pressurization promotes the release of water from hydrated SiO2, enabling HZSM-5 to effectively undergo dealumination and obtain suitable acidity and pore structure, and ultimately enhancing the resistance to carbon deposition. In summary, pressurization improves both pyrolysis activity and catalysis stability, offering a promising strategy for the high-value utilization of waste plastics.

Catalytic depolymerization of polyester plastics toward closed-loop recycling and upcycling

Catalytic depolymerization of polyester plastics toward closed-loop recycling and upcycling

Isoreticular Metal-Organic Frameworks Confined Mononuclear Ru-Hydrides Enable Highly Efficient Shape-Selective Hydrogenolysis of Polyolefins

Upcycling nonbiodegradable plastics such as polyolefins is paramount due to their ever-increasing demand and landfills after usage. Catalytic hydrogenolysis is highly appealing to convert polyolefins into targeted value-added products under mild reaction conditions compared with other methods, such as high-temperature incineration and pyrolysis. We have developed three isoreticular zirconium UiO-metal-organic frameworks (UiO-MOFs) node-supported ruthenium dihydrides (UiO-RuH2), which are efficient heterogeneous catalysts for hydrogenolysis of polyethylene at 200 °C, affording liquid hydrocarbons with a narrow distribution and excellent selectivity via shape-selective catalysis. UiO-66-RuH2 catalyzed hydrogenolysis of single-use low-density polyethylene (LDPE) produced a C12 centered narrow bell-shaped distribution of C8-C16 alkanes in >80% yield and 90% selectivity in the liquid phase. By tuning the pore sizes of the isoreticular UiO-RuH2 MOF catalysts, the distribution of the products could be systematically altered, affording different fuel-grade liquid hydrocarbons from LDPE in high yields. Our spectroscopic and theoretical studies and control experiments reveal that UiO-RuH2 catalysts enable highly efficient upcycling of plastic wastes under mild conditions owing to their unique combination of coordinatively unsaturated single-site Ru-active sites, uniform and tunable pores, well-defined porous structure, and superior stability. The kinetics and theoretical calculations also identify the C-C bond scission involving β-alkyl transfer as the turnover-limiting step.

Dual Photo-Responsive Diphenylacetylene Enables PET In-Situ Upcycling with Reverse Enhanced UV-Resistance and Strength

A novel in situ chemical upcycling strategy for plastic waste is proposed by the customized diphenylacetylene monomer with dual photo-response. That is, diphenylacetylene reactive monomers are in situ inserted into the macromolecular chain of polyethylene terephthalate (PET) plastics/fibers through one-pot transesterification of slight-depolymerization and re-polymerization. On the one hand, the diphenylacetylene group absorbs short-wave high-energy UV rays and then releases long-wave low-energy harmless fluorescence. On the other hand, the UV-induced photo-crosslinking reaction among diphenylacetylene groups produces extended π-conjugated structure, resulting in a red-shift (due to decreased HOMO-LUMO separation) in the UV absorption band and locked crosslink points between PET chains. Therefore, with increasing UV exposure time, the upcycled PET plastics exhibit reverse enhanced UV resistance and mechanical strength (superior to original performance), instead of serious UV-photodegradation and damaged performance. This upcycling strategy at oligomer-scale not only provides a new idea for traditional plastic recycling, but also solves the common problem of gradual degradation of polymer performance during use.

Quantitative analyses of products and rates in polyethylene depolymerization and upcycling

Depolymerization and upcycling are promising approaches to managing plastic waste. However, quantitative measurements of reaction rates and analyses of complex product mixtures arising from depolymerization of polyolefins constitute significant challenges in this emerging field. Here, we detail techniques for recovery and analysis of products arising from batch depolymerization of polyethylene. We also describe quantitative analyses of reaction rates and products selectivity. This protocol can be extended to depolymerization of other plastics and characterization of other product mixtures including long-chain olefins. For complete details on the use and execution of this protocol, please refer to Sun et al.1.

Rapid Polyolefin Hydrogenolysis by a Single-Site Organo-Tantalum Catalyst on a Super-Acidic Support: Structure and Mechanism

The novel electrophilic organo-tantalum catalyst AlS/TaNpx (1) (Np=neopentyl) is prepared by chemisorption of the alkylidene Np3 Ta=CHt Bu onto highly Brønsted acidic sulfated alumina (AlS). The proposed catalyst structure is supported by EXAFS, XANES, ICP, DRIFTS, elemental analysis, and SSNMR measurements and is in good agreement with DFT analysis. Catalyst 1 is highly effective for the hydrogenolysis of diverse linear and branched hydrocarbons, ranging from C2 to polyolefins. To the best of our knowledge, 1 exhibits one of the highest polyolefin hydrogenolysis activities (9,800 (CH2 units) ⋅ mol(Ta)-1  ⋅ h-1 at 200 °C/17 atm H2 ) reported to date in the peer-reviewed literature. Unlike the AlS/ZrNp2 analog, the Ta catalyst is more thermally stable and offers multiple potential C-C bond activation pathways. For hydrogenolysis, AlS/TaNpx is effective for a wide variety of pre- and post-consumer polyolefin plastics and is not significantly deactivated by standard polyolefin additives at typical industrial concentrations.

Heterogeneous Pt-catalyzed transfer dehydrogenation of long-chain alkanes with ethylene

The dehydrogenation of long-chain alkanes to olefins and alkylaromatics is a challenging endothermic reaction, typically requiring harsh conditions which can lead to low selectivity and coking. More favorable thermodynamics can be achieved by using a hydrogen acceptor, such as ethylene. In this work, the potential of heterogeneous platinum catalysts for the transfer dehydrogenation of long-chain alkanes is investigated, using ethylene as a convenient hydrogen acceptor. Pt/C and Pt-Sn/C catalysts were prepared via a simple polyol method and characterized with CO pulse chemisorption, HAADF-STEM, and EDX measurements. Conversion of ethylene was monitored via gas-phase FTIR, and distribution of liquid products was analyzed via GC-FID, GC-MS, and 1H-NMR. Compared to unpromoted Pt/C, Sn-promoted catalysts show lower initial reaction rates, but better resistance to catalyst deactivation, while increasing selectivity towards alkylaromatics. Both reaction products and ethylene were found to inhibit the reaction significantly. At 250 °C for 22 h, TON up to 28 and 86 mol per mol Pt were obtained for Pt/C and PtSn2/C, respectively, with olefin selectivities of 94% and 53%. The remaining products were mainly unbranched alkylaromatics. These findings show the potential of simple heterogeneous catalysts in alkane transfer dehydrogenation, for the preparation of valuable olefins and alkylaromatics, or as an essential step in various tandem reactions.

Photocatalytic production of ethylene and propionic acid from plastic waste by titania-supported atomically dispersed Pd species

Current chemical recycling of bulk synthetic plastic, polyethylene (PE), operates at high temperature/pressure and yields a complex mixture of products. PE conversion under mild conditions and with good selectivity toward value-added chemicals remains a practical challenge. Here, we demonstrate an atomic engineering strategy to modify a TiO2 photocatalyst with reversible Pd species for the selective conversion of PE to ethylene (C2H4) and propionic acid via dicarboxylic acid intermediates under moderate conditions. TiO2-supported atomically dispersed Pd species exhibits C2H4 evolution of 531.2 μmol gcat-1 hour-1, 408 times that of pristine TiO2. The liquid product is a valuable chemical propanoic acid with 98.8% selectivity. Plastic conversion with a C2 hydrocarbon yield of 0.9% and a propionic acid yield of 6.3% was achieved in oxidation coupled with 3 hours of photoreaction. In situ spectroscopic studies confirm a dual role of atomic Pd species: an electron acceptor to boost charge separation/transfer for efficient photoredox, and a mediator to stabilize reaction intermediates for selective decarboxylation.

Polymer Multi-Block and Multi-Block+ Strategies for the Upcycling of Mixed Polyolefins and Other Plastics

Due to a continued rise in the production and use of plastic products, their end-of-life pollution has become a pressing global issue. One of the biggest challenges in plastics recycling is the separation of different polymers. Multi-block copolymers (MBCPs) represent an efficient strategy for the upcycling of mixed plastics via induced compatibilization, but this approach is limited by difficulties associated with synthesis and structural modification. In this contribution, several synthetic strategies are explored to prepare MBCPs with tunable microstructures, which were then used as compatibilizer additives to upcycle mixtures of polyolefins with other plastics. A multi-block+ strategy based on a reactive telechelic block copolymer platform was introduced, which enabled block extension during the in situ melt blending of mixed plastics, leading to better compatibilizing properties as well as better 3D printing capability. This strategy was also applicable to more complex ternary plastic blends. The polymer multi-block strategy enabled by versatile MBCPs synthesis and the multi-block+ strategy enabled by in situ block extension show exciting opportunities for the upcycling of mixed plastics.

Closed-Loop Recyclable Silica-Based Nanocomposites with Multifunctional Properties and Versatile Processability

Most plastics originate from limited petroleum reserves and cannot be effectively recycled at the end of their life cycle, making them a significant threat to the environment and human health. Closed-loop chemical recycling, by depolymerizing plastics into monomers that can be repolymerized, offers a promising solution for recycling otherwise wasted plastics. However, most current chemically recyclable polymers may only be prepared at the gram scale, and their depolymerization typically requires harsh conditions and high energy consumption. Herein, it reports less petroleum-dependent closed-loop recyclable silica-based nanocomposites that can be prepared on a large scale and have a fully reversible polymerization/depolymerization capability at room temperature, based on catalysis of free aminopropyl groups with the assistance of diethylamine or ethylenediamine. The nanocomposites show glass-like hardness yet plastic-like light weight and toughness, exhibiting the highest specific mechanical strength superior even to common materials such as poly(methyl methacrylate), glass, and ZrO2 ceramic, as well as demonstrating multifunctionality such as anti-fouling, low thermal conductivity, and flame retardancy. Meanwhile, these nanocomposites can be easily processed by various plastic-like scalable manufacturing methods, such as compression molding and 3D printing. These nanocomposites are expected to provide an alternative to petroleum-based plastics and contribute to a closed-loop materials economy.

Entropy Confinement Promotes Hydrogenolysis Activity for Polyethylene Upcycling

Chemical upcycling that catalyzes waste plastics back to high-purity chemicals holds great promise in end-of-life plastics valorization. One of the main challenges in this process is the thermodynamic limitations imposed by the high intrinsic entropy of polymer chains, which makes their adsorption on catalysts unfavorable and the transition state unstable. Here, we overcome this challenge by inducing the catalytic reaction inside mesoporous channels, which possess a strong confined ability to polymer chains, allowing for stabilization of the transition state. This approach involves the synthesis of p-Ru/SBA catalysts, in which Ru nanoparticles are uniformly distributed within the channels of an SBA-15 support, using a precise impregnation method. The unique design of the p-Ru/SBA catalyst has demonstrated significant improvements in catalytic performance for the conversion of polyethylene into high-value liquid fuels, particularly diesel. The catalyst achieved a high solid conversion rate of 1106 g ⋅ gRu -1  ⋅ h-1 at 230 °C. Comparatively, this catalytic activity is 4.9 times higher than that of a control catalyst, Ru/SiO2 , and 14.0 times higher than that of a commercial catalyst, Ru/C, at 240 °C. This remarkable catalytic activity opens up immense opportunities for the chemical upcycling of waste plastics.

Hydrodeoxygenation of Oxygen-Containing Aromatic Plastic Wastes to Liquid Organic Hydrogen Carriers

To address the global plastic pollution issues and the challenges of hydrogen storage and transportation, we report a system, based on the hydrodeoxygenation (HDO) of oxygen-containing aromatic plastic wastes, from which organic hydrogen carriers (LOHCs) can be derived. We developed a catalytic system comprised of Ru-ReOx /SiO2 +HZSM-5 for direct HDO of polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyphenylene oxide (PPO), and their mixtures, to cycloalkanes as LOHCs, with high yields up to 99 %, under mild reaction conditions. The theoretical hydrogen storage capacity reaches ca. 5.74 wt%. The reaction pathway involves depolymerization of PC into C15 aromatics and C15 monophenols by direct hydrogenolysis of the C-O bond between the benzene ring and ester group, and subsequent parallel hydrogenation of C15 aromatics and HDO of C15 monophenols. HDO of cyclic alcohol is the rate-determining step. The active site is Ru metallic nanoparticles with partially covered ReOx species. The excellent performance is attributed to the synergetic effect of oxophilic ReOx species and Ru metallic sites for C-O hydrogenolysis and hydrogenation, and the promotion effect of HZSM-5 for dehydration of cyclic alcohol. The highly efficient and stable dehydrogenation of cycloalkanes over Pt/γ-Al2 O3 confirms that HDO products can act as LOHCs.

Solvent-Free Depolymerization of Plastic Waste Enabled by Plastic-Catalyst Interfacial Engineering

Depolymerization of condensation polymers by chemolysis often suffers from the large usage of solvents and homogeneous catalysts such as acids, bases, and metal salts. The catalytic efficiency of heterogeneous catalysts is largely constrained by the poor interfacial contact between solid catalysts and solid plastics below melting points. We report here our discovery of autogenous heterogeneous catalyst layer on polyethylene terephthalate surfaces during the generally believed homogeneous catalytic depolymerization process. Inspired by the "contact mass" concept in industrial chlorosilane production, we further demonstrate that the construction of plastic-catalyst solid-solid interfaces enables solvent-free depolymerization of polyethylene terephthalate by vapor phase methanolysis at relatively low temperatures. Trace amounts of earth-abundant element (zinc) introduced by electrostatic adsorption is sufficient for catalyzing the depolymerization. The concept of plastic-catalyst contact mass interfacial catalysis might inspire new pathways for tackling plastic waste problems.

High-Value Oil-Water Separation Materials Prepared from Waste Polyethylene Terephthalate

As one of the most common forms of waste, waste PET is a serious pollutant in natural and human living environments. There is an urgent need to recycle PET. For this study, the complete degradation of PET was realized at a low temperature. A lipophilic hydrophobic membrane was formed on the surface of a stainless steel mesh (SSM) using a simple dip coating method, and an oil-water separation material was successfully prepared. After loading with degradation products, the surface roughness of SSM increased from 19.09 μm to 62.33 μm. The surface changed from hydrophilic to hydrophobic, and the water contact angle increased to 123°. The oil-water separation flux of the modified SSM was 9825 L/(m2·h), and the separation efficiency was 98.99%. The modified SSM had good reuse performance. This hydrophobic modification method can also be used to modify other porous substrates, such as activated carbon, filter paper, foam, and other materials. The porous substrate modified by the degradation product of waste PET was used to prepare oil-water separation materials, not only solving the problem of white pollution but also reducing the dependence on non-renewable resources in the conventional methods used for the preparation of oil-water separation materials. This study provides new raw materials and methods for the industrial production of oil-water separation materials, which have important application prospects.

Chemically recyclable polyolefin-like multiblock polymers

Polyolefins are the most important and largest volume plastics produced. Unfortunately, the enormous use of plastics and lack of effective disposal or recycling options have created a plastic waste catastrophe. In this work, we report an approach to create chemically recyclable polyolefin-like materials with diverse mechanical properties through the construction of multiblock polymers from hard and soft oligomeric building blocks synthesized with ruthenium-mediated ring-opening metathesis polymerization of cyclooctenes. The multiblock polymers exhibit broad mechanical properties, spanning elastomers to plastomers to thermoplastics, while integrating a high melting transition temperature (Tm) and low glass transition temperature (Tg), making them suitable for use across diverse applications (Tm as high as 128°C and Tg as low as -60°C). After use, the different plastics can be combined and efficiently deconstructed back to the fundamental hard and soft building blocks for separation and repolymerization to realize a closed-loop recycling process.

Mixed Plastics Wastes Upcycling with High-Stability Single-Atom Ru Catalyst

Mixed plastic waste treatment has long been a significant challenge due to complex composition and sorting costs. In this study, we have achieved a breakthrough in converting mixed plastic wastes into a single chemical product using our innovative single-atom catalysts for the first time. The single-atom Ru catalyst can convert ∼90% of real mixed plastic wastes into methane products (selectivity >99%). The unique electronic structure of Ru sites regulates the adsorption energy of mixed plastic intermediates, leading to rapid decomposition of mixed plastics and superior cycle stability compared to traditional nanocatalysts. The global warming potential of the entire process was evaluated. Our proposed carbon-reducing process utilizing single-atom catalysts launches a new era of mixed plastic waste valorization.

A recyclable polyester library from reversible alternating copolymerization of aldehyde and cyclic anhydride

Our society is pursuing chemically recyclable polymers to accelerate the green revolution in plastics. Here, we develop a recyclable polyester library from the alternating copolymerization of aldehyde and cyclic anhydride. Although these two monomer sets have little or no thermodynamic driving force for homopolymerization, their copolymerization demonstrates the unexpected alternating characteristics. In addition to readily available monomers, the method is performed under mild conditions, uses common Lewis/Brønsted acids as catalysts, achieves the facile tuning of polyester structure using two distinct monomer sets, and yields 60 polyesters. Interestingly, the copolymerization exhibits the chemical reversibility attributed to its relatively low enthalpy, which makes the resulting polyesters perform closed-loop recycling to monomers at high temperatures. This study provides a modular, efficient, and facile synthesis of recyclable polyesters using sustainable monomers.

Tandem oxidative and thermal cracking of polypropylene at low temperatures

Polypropylene waste was upcycled into terminal functionalized long-chain chemicals with the aid of anionic surfactants. The reaction only needs to be heated at 80 °C for 5 min by coupling exothermic oxidative cracking with endothermic thermal cracking. This work opens a new way to rapidly convert plastic waste into high-value-added chemicals under mild conditions.

Two Mesoporous Domains Are Better Than One for Catalytic Deconstruction of Polyolefins

Catalytic hydrogenolysis of polyolefins into valuable liquid, oil, or wax-like hydrocarbon chains for second-life applications is typically accompanied by the hydrogen-wasting co-formation of low value volatiles, notably methane, that increase greenhouse gas emissions. Catalytic sites confined at the bottom of mesoporous wells, under conditions in which the pore exerts the greatest influence over the mechanism, are capable of producing less gases than unconfined sites. A new architecture was designed to emphasize this pore effect, with the active platinum nanoparticles embedded between linear, hexagonal mesoporous silica and gyroidal cubic MCM-48 silica (mSiO2/Pt/MCM-48). This catalyst deconstructs polyolefins selectively into ∼C20-C40 paraffins and cleaves C-C bonds at a rate (TOF = 4.2 ± 0.3 s-1) exceeding that of materials lacking these combined features while generating negligible volatile side products including methane. The time-independent product distribution is consistent with a processive mechanism for polymer deconstruction. In contrast to time- and polymer length-dependent products obtained from non-porous catalysts, mSiO2/Pt/MCM-48 yields a C28-centered Gaussian distribution of waxy hydrocarbons from polyolefins of varying molecular weight, composition, and physical properties, including low-density polyethylene, isotactic polypropylene, ultrahigh-molecular-weight polyethylene, and mixtures of multiple, post-industrial polyolefins. Coarse-grained simulation reveals that the porous-core architecture enables the paraffins to diffuse away from the active platinum site, preventing secondary reactions that produce gases.

Chemical upcycling of polyethylene, polypropylene, and mixtures to high-value surfactants

Conversion of plastic wastes to fatty acids is an attractive means to supplement the sourcing of these high-value, high-volume chemicals. We report a method for transforming polyethylene (PE) and polypropylene (PP) at ~80% conversion to fatty acids with number-average molar masses of up to ~700 and 670 daltons, respectively. The process is applicable to municipal PE and PP wastes and their mixtures. Temperature-gradient thermolysis is the key to controllably degrading PE and PP into waxes and inhibiting the production of small molecules. The waxes are upcycled to fatty acids by oxidation over manganese stearate and subsequent processing. PP ꞵ-scission produces more olefin wax and yields higher acid-number fatty acids than does PE ꞵ-scission. We further convert the fatty acids to high-value, large-market-volume surfactants. Industrial-scale technoeconomic analysis suggests economic viability without the need for subsidies.

Functionalization of polyethylene with hydrolytically-stable ester groups

Low-density (LD) and high-density polyethylene (HDPE), recycled or not, incorporates up to 7 wt% of ester groups after reacting either with ethyl diazoacetate (EDA) under catalytic and solvent free-reaction conditions, or with maleic anhydride (MA) and acrylates (AC) under catalytic radical conditions. The resulting upcycled polyethylene esters are hydrolytically stable at extreme pH (0-14) and can be further transformed into carboxylic acids, carboxylates, other esters and amides.

Up-cycling plastic waste into swellable super-sorbents

Environmental pollution caused by plastic waste and oil spills has emerged as a major concern in recent years. Consequently, there has been a growing interest in exploring innovative solutions to address these challenges. Herein, we report a method to upcycle polyolefins-based plastic waste by converting it into a bimodal super-oleophilic sorbent using dissolution, spin-coating, and annealing techniques. The resulting sorbent possesses an extensive network of pores and cavities with a size range from 0.5 to 5 µm and 150-200 µm, respectively, with an average of 600 cavities per cm². Each cavity can swell up to twenty times the thickness of the sorbent, exhibiting sponge-like behavior. The sorbent had an oil uptake capacity of 70-140 g/g, depending on the type of sorbate and dripping time. Moreover, the sorbent can be mechanically or manually squeezed to recover the sorbed oil. Our integrated methodology provides a promising approach to upcycling plastic waste as an abundant source of value-added materials.

Computer-aided discovery of a novel thermophilic laccase for low-density polyethylene degradation

Polyethylene (PE) and industrial dyes are recalcitrant pollutants calling for the development of sustainable solutions for their degradation. Laccases have been explored for removal of contaminants and pollutants, including dye decolorization and plastic degradation. Here, a novel thermophilic laccase from PE-degrading Lysinibaccillus fusiformis (LfLAC3) was identified through a computer-aided and activity-based screening. Biochemical studies of LfLAC3 indicated its high robustness and catalytic promiscuity. Dye decolorization experiments showed that LfLAC3 was able to degrade all the tested dyes with decolorization percentage from 39% to 70% without the use of a mediator. LfLAC3 was also demonstrated to degrade low-density polyethylene (LDPE) films after eight weeks of incubation with either crude cell lysate or purified enzyme. The formation of a variety of functional groups was detected using Fourier transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS). Damage on the surfaces of PE films was observed via scanning electron microscopy (SEM). The potential catalytic mechanism of LfLAC3 was disclosed by structure and substrate-binding modes analysis. These findings demonstrated that LfLAC3 is a promiscuous enzyme that has promising potential for dye decolorization and PE degradation.

Efficient solvent- and hydrogen-free upcycling of high-density polyethylene into separable cyclic hydrocarbons

Plastic pollution is a planetary threat that has been exacerbated by the COVID-19 pandemic due to the surge in medical waste, personal protective equipment and takeaway packaging. A socially sustainable and economically viable method for plastic recycling should not use consumable materials such as co-reactants or solvents. Here we report that Ru nanoparticles on zeolitic HZSM-5 catalyse the solvent- and hydrogen-free upcycling of high-density polyethylene into a separable distribution of linear (C1 to C6) and cyclic (C7 to C15) hydrocarbons. The valuable monocyclic hydrocarbons accounted for 60.3 mol% of the total yield. Based on mechanistic studies, the dehydrogenation of polymer chains to form C=C bonds occurs on both Ru sites and acid sites in HZSM-5, whereas carbenium ions are generated on the acid sites via the protonation of the C=C bonds. Accordingly, optimizing the Ru and acid sites promoted the cyclization process, which requires the simultaneous existence of a C=C bond and a carbenium ion on a molecular chain at an appropriate distance, providing high activity and cyclic hydrocarbon selectivity.

A reusable, impurity-tolerant and noble metal-free catalyst for hydrocracking of waste polyolefins

One-step conversion of low-purity polyolefins to value-added products without pretreatments represents a great opportunity for chemical recycling of waste plastics. However, additives, contaminants, and heteroatom-linking polymers tend to be incompatible with catalysts that break down polyolefins. Here, we disclose a reusable, noble metal-free and impurity-tolerant bifunctional catalyst, MoS_x-Hbeta, for hydroconversion of polyolefins into branched liquid alkanes under mild conditions. The catalyst works for a wide scope of polyolefins, including different kinds of high-molecular weight polyolefins, polyolefins mixed with various heteroatom-linking polymers, contaminated polyolefins, and postconsumer polyolefins with/without cleaning under 250°C and 20 to 30 bar H₂ in 6 to 12 hours. A 96% yield of small alkanes was successfully achieved even at a temperature as low as 180°C. These results demonstrate the great potentials of hydroconversion in practical use of waste plastics as a largely untapped carbon feedstock.

Chemically Recyclable Polymer System Based on Nucleophilic Aromatic Ring-Opening Polymerization

The development of chemically recyclable polymers with desirable properties is a long-standing but challenging goal in polymer science. Central to this challenge is the need for reversible chemical reactions that can equilibrate at rapid rates and provide efficient polymerization and depolymerization cycles. Based on the dynamic chemistry of nucleophilic aromatic substitution (S_NAr), we report a chemically recyclable polythioether system derived from readily accessible benzothiocane (BT) monomers. This system represents the first example of a well-defined monomer platform capable of chain-growth ring-opening polymerization through an S_NAr manifold. The polymerizations reach completion in minutes, and the pendant functionalities are easily customized to tune material properties or render the polymers amenable to further functionalization. The resulting polythioether materials exhibit comparable performance to commercial thermoplastics and can be depolymerized to the original monomers in high yields.

Zeolite Supported Pt for Depolymerization of Polyethylene by Induction Heating

We demonstrate that for polyethylene depolymerization with induction heating (IH), using a bifunctional (Pt- or Pt-Sn-containing zeolite) hydrocracking catalyst, we can obtain high hydrocarbon product yields (up to 95 wt % in 2 h) at a relatively low surface temperature (375 °C) and with a tunable product distribution ranging from light gas products to gasoline- to diesel-range hydrocarbons. Four zeolite types [MFI, LTL, CHA(SSZ-13), and TON] were chosen as the supports due to their varying pore sizes and structures. These depolymerization results are obtained at atmospheric pressure and without the use of H₂ and result in an alkane/alkene mixture with virtually no methane, aromatics, or coke formation. We also demonstrate how IH helps overcome diffusional resistances associated with conventional thermal heating and thereby shortens reaction times.

Acetolysis of waste polyethylene terephthalate for upcycling and life-cycle assessment study

To reduce environmental pollution and reliance on fossil resources, polyethylene terephthalate as the most consumed synthetic polyester needs to be recycled effectively. However, the existing recycling methods cannot process colored or blended polyethylene terephthalate materials for upcycling. Here we report a new efficient method for acetolysis of waste polyethylene terephthalate into terephthalic acid and ethylene glycol diacetate in acetic acid. Since acetic acid can dissolve or decompose other components such as dyes, additives, blends, etc., Terephthalic acid can be crystallized out in a high-purity form. In addition, Ethylene glycol diacetate can be hydrolyzed to ethylene glycol or directly polymerized with terephthalic acid to form polyethylene terephthalate, completing the closed-loop recycling. Life cycle assessment shows that, compared with the existing commercialized chemical recycling methods, acetolysis offers a low-carbon pathway to achieve the full upcycling of waste polyethylene terephthalate.

Global plastic upcycling during and after the COVID-19 pandemic: The status and perspective

Plastic pollution has become one of the most pressing environmental issues worldwide since the vast majority of post-consumer plastics are hard to degrade in the environment. The coronavirus disease (COVID-19) pandemic had disrupted the previous effort of plastic pollution mitigation to a great extent due to the overflow of plastic-based medical waste. In the post-pandemic era, the remaining challenge is how to motivate global action towards a plastic circular economy. The need for one package of sustainable and systematic plastic upcycling approaches has never been greater to address such a challenge. In this review, we summarized the threat of plastic pollution during COVID-19 to public health and ecosystem. In order to solve the aforementioned challenges, we present a shifting concept, regeneration value from plastic waste, that provides four promising pathways to achieve a sustainable circular economy: 1) Increasing reusability and biodegradability of plastics; 2) Transforming plastic waste into high-value products by chemical approaches; 3) The closed-loop recycling can be promoted by biodegradation; 4) Involving renewable energy into plastic upcycling. Additionally, the joint efforts from different social perspectives are also encouraged to create the necessary economic and environmental impetus for a circular economy.

Investigating the impact of TiO2 crystalline phases on catalytic properties of Ru/TiO2 for hydrogenolysis of polyethylene plastic waste

A series of TiO₂-supported Ru catalysts with different TiO₂ crystalline phases was synthesized and employed for the hydrogenolysis of polyethylene (PE). CO chemisorption, high-angle annular dark-field-scanning transmission electron microscopy, temperature-programmed reduction, and CO-Fourier transform infrared spectroscopy suggested that the degree of strong metal-support interactions (SMSIs) varied depending on the type of the TiO₂ phase and the reduction temperature, eventually influencing the catalysis of PE hydrogenolysis. Among the synthesized catalysts, Ru/TiO₂ with the rutile phase (Ru/TiO₂-R) exhibited the highest catalytic activity after high-temperature reduction at 500 °C, indicating that a certain degree of SMSI is necessary for ensuring high activity in PE hydrogenolysis. Ru/TiO₂-R could be successfully employed for the hydrogenolysis of post-consumer plastic wastes such as LDPE bottles to produce valuable chemicals (liquid fuel and wax) in high yields of 74.7%. This work demonstrates the possibility of harnessing the SMSIs in the design and synthesis of active catalysts for PE hydrogenolysis.

Recent development of end-of-life strategies for plastic in industry and academia: bridging their gap for future deployment

Plastics have advanced society as a lightweight, inexpensive material of choice, and consequently over 400 million metric tons of plastics are produced each year. The difficulty with their reuse, due to varying chemical structures and properties, is leading to one of the major global challenges of the 21st century-plastic waste management. While mechanical recycling has been proven successful for certain types of plastic waste, most of these technologies can only recycle single types of plastics at a time. Since most recycling collection streams today have a mixture of different plastic types, additional sorting is required before the plastic waste can be processed by recyclers. To combat this problem, academics have devoted their efforts to developing technologies such as selective deconstruction catalysts or compatibilizer for commodity plastics and new types of upcycled plastics. In this review, the strengths and challenges of current commercial recycling processes are discussed, followed by examples of the advancement in academic research. Bridging a gap to integrate new recycling materials and processes into current industrial practices will improve commercial recycling and plastic waste management, as well as create new economies. Furthermore, establishing closed-loop circularity of plastics by the combined efforts of academia and industry will contribute toward establishing a net zero carbon society by significant reduction of carbon and energy footprints. This review serves as a guide to understand the gap and help to create a path for new discovery in academic research to be integrated into industrial practices.

Homologous RuO2-Ru heterostructures for tandem catalytic upgrading of ethanol

The homologous RuO₂-Ru heterostructure was demonstrated as an efficient tandem catalyst for upgrading ethanol. The adjacent RuO₂ and Ru separately serve as aldol condensation/dehydration and dehydrogenation/hydrogenation sites for ethanol conversion.

Turning Polyethylene Waste to Hydrocarbons Using a Sustainable Acidic Carbocatalyst

Careless release of plastic waste is a pressing problem for marine and other eco-environments, and materials recycling of this stream is an open problem. For this purpose, a new metal-free acidic carbocatalyst with 8 wt % sulfur is constructed from a side product of the paper industry namely Na-lignosulfonate. The catalyst shows an extraordinary performance for the fragmentation of polymer waste which smoothly occurs above the ceiling temperature of the polymers. The reaction is run without hydrogen and at ambient pressure with commercially available high-density polyethylene (HDPE) as well as a real polymer waste mixture of high and low-density polyethylene (HDPE, LDPE). In all cases, a homologous series of n-alkanes and n-alkenes are obtained. The unique sulfur-rich carbonaceous structure (transfer hydrogenation functionality) and the metal-free character of the acidic carbocatalyst makes it inert against many typical catalyst poisons, among them water, salt, polar functionalities, and sulfur species. The described performance in plastic recycling, as well as the low cost and large-scale availability of lignosulfonate from the pulp industry, makes this metal-free acidic carbocatalyst promising for real-life environmental applications.

Catalytic Amounts of an Antibacterial Monomer Enable the Upcycling of Poly(Ethylene Terephthalate) Waste

Poly(ethylene terephthalate) (PET) is an important polymer with an annual output second only to polyethylene. The development of PET recycling technologies is therefore necessary to not only eliminate the harm associated with white pollution and microplastics, but also to reduce carbon emissions. Antibacterial PET, one of the most high-value advanced materials, has improved the ability to treat bacterial infections. However, current methods of manufacturing commercial antibacterial PET require blending with an excess of metal-based antibacterial agents, which leads to biotoxicity and a nonpersistent antibacterial activity. In addition, high-efficiency organic antibacterial agents have yet to be employed in antibacterial PET due to their poor thermal stabilities. Herein, a solid-state reaction for the upcycling of PET waste using a novel hyperthermostable antibacterial monomer is described. This reaction is catalyzed by the residual catalyst present in the PET waste. It is found that a catalytic amount of the antibacterial monomer enabled the low-cost upcycling of PET waste to produce high-value recycled PET with a strong and persistent antibacterial activity, as well as similar thermal properties to the virgin PET. This work provides a feasible and economic strategy for the large-scale upcycling of PET waste and exhibits potential for application in the polymer industry.

A Versatile Sulfur-Assisted Pyrolysis Strategy for High-Atom-Economy Upcycling of Waste Plastics into High-Value Carbon Materials

With the overconsumption of disposable plastics, there is a considerable emphasis on the recycling of waste plastics to relieve the environmental, economic, and health-related consequences. Here, a sulfur-assisted pyrolysis strategy is demonstrated for versatile upcycling of plastics into high-value carbons with an ultrahigh carbon-atom recovery (up to 85%). During the pyrolysis process, the inexpensive elemental sulfur molecules are covalently bonded with polymer chains, and then thermally stable intermediates are produced via dehydrogenation and crosslinking, thereby inhibiting the decomposition of plastics into volatile small hydrocarbons. In this manner, the carbon products obtained from real-world waste plastics exhibit sulfur-rich skeletons with an enlarged interlayer distance, and demonstrate superior sodium storage performance. It is believed that the present results offer a new solution to alleviate plastic pollution and reduce the carbon footprint of plastic industry.

Machine Learning and Informatics Based Elucidation of Reaction Pathways for Upcycling Model Polyolefin to Aromatics

Catalytic upcycling of plastics results in a complex network of potentially thousands of reactions and intermediates. Manual analysis of such a network using ab initio methods to identify plausible reaction pathways and rate-controlling steps is intractable. Here, we combine informatics-based reaction network generation and machine learning based thermochemistry calculation to identify plausible (nonelementary step) pathways involved in dehydroaromatization of a model polyolefin, n-decane, to form aromatic products. All 78 aromatic molecules found involve a sequence comprising dehydrogenation, β-scission, and cyclization steps (in slightly different order). The plausible flux-carrying pathway depends on the family of reactions that is rate-controlling while the thermodynamic bottleneck is the first dehydrogenation step of n-decane. The adopted workflow is system agnostic and can be applied to understand the overall thermochemistry of other upcycling systems.