Review of polymer technologies for improving the recycling and upcycling efficiency of plastic waste

Human society has become increasingly reliant on plastic because it allows for convenient and sanitary living. However, recycling rates are currently low, which means that the majority of plastic waste ends up in landfills or the ocean. Increasing recycling and upcycling rates is a critical strategy for addressing the issues caused by plastic pollution, but there are several technical limitations to overcome. This article reviews advancements in polymer technology that aim to improve the efficiency of recycling and upcycling plastic waste. In food packaging, natural polymers with excellent gas barrier properties and self-cleaning abilities have been introduced as environmentally friendly alternatives to existing materials and to reduce food-derived contamination. Upcycling and valorization approaches have emerged to transform plastic waste into high-value-added products. Recent advancements in the development of recyclable high-performance plastics include the design of super engineering thermoplastics and engineering chemical bonds of thermosets to make them recyclable and biodegradable. Further research is needed to develop more cost-effective and scalable technologies to address the plastic pollution problem through sustainable recycling and upcycling.

Dynamic crosslinking compatibilizes immiscible mixed plastics

The global plastics problem is a trifecta, greatly affecting environment, energy and climate1-4. Many innovative closed/open-loop plastics recycling or upcycling strategies have been proposed or developed5-16, addressing various aspects of the issues underpinning the achievement of a circular economy17-19. In this context, reusing mixed-plastics waste presents a particular challenge with no current effective closed-loop solution20. This is because such mixed plastics, especially polar/apolar polymer mixtures, are typically incompatible and phase separate, leading to materials with substantially inferior properties. To address this key barrier, here we introduce a new compatibilization strategy that installs dynamic crosslinkers into several classes of binary, ternary and postconsumer immiscible polymer mixtures in situ. Our combined experimental and modelling studies show that specifically designed classes of dynamic crosslinker can reactivate mixed-plastics chains, represented here by apolar polyolefins and polar polyesters, by compatibilizing them via dynamic formation of graft multiblock copolymers. The resulting in-situ-generated dynamic thermosets exhibit intrinsic reprocessability and enhanced tensile strength and creep resistance relative to virgin plastics. This approach avoids the need for de/reconstruction and thus potentially provides an alternative, facile route towards the recovery of the endowed energy and materials value of individual plastics.

Electrocatalytic Upcycling of Biomass and Plastic Wastes to Biodegradable Polymer Monomers and Hydrogen Fuel at High Current Densities

Transformation of biomass and plastic wastes to value-added chemicals and fuels is considered an upcycling process that is beneficial to resource utilization. Electrocatalysis offers a sustainable approach; however, it remains a huge challenge to increase the current density and deliver market-demanded chemicals with high selectivity. Herein, we demonstrate an electrocatalytic strategy for upcycling glycerol (from biodiesel byproduct) to lactic acid and ethylene glycol (from polyethylene terephthalate waste) to glycolic acid, with both products being as valuable monomers for biodegradable polymer production. By using a nickel hydroxide-supported gold electrocatalyst (Au/Ni(OH)₂), we achieve high selectivities of lactic acid and glycolic acid (77 and 91%, respectively) with high current densities at moderate potentials (317.7 mA/cm² at 0.95 V vs RHE and 326.2 mA/cm² at 1.15 V vs RHE, respectively). We reveal that glycerol and ethylene glycol can be enriched at the Au/Ni(OH)₂ interface through their adjacent hydroxyl groups, substantially increasing local concentrations and thus high current densities. As a proof of concept, we employed a membrane-free flow electrolyzer for upcycling triglyceride and PET bottles, attaining 11.2 g of lactic acid coupled with 9.3 L of H₂ and 13.7 g of glycolic acid coupled with 9.4 L of H₂, respectively, revealing the potential of coproduction of valuable chemicals and H₂ fuel from wastes in a sustainable fashion.

Analysis of the Scale of Global Human Needs and Opportunities for Sustainable Catalytic Technologies

We analyzed the enormous scale of global human needs, their carbon footprint, and how they are connected to energy availability. We established that most challenges related to resource security and sustainability can be solved by providing distributed, affordable, and clean energy. Catalyzed chemical transformations powered by renewable electricity are emerging successor technologies that have the potential to replace fossil fuels without sacrificing the wellbeing of humans. We highlighted the technical, economic, and societal advantages and drawbacks of short- to medium-term decarbonization solutions to gauge their practicability, economic feasibility, and likelihood for widespread acceptance on a global scale. We detailed catalysis solutions that enhance sustainability, along with strategies for catalyst and process development, frontiers, challenges, and limitations, and emphasized the need for planetary stewardship. Electrocatalytic processes enable the production of solar fuels and commodity chemicals that address universal issues of the water, energy and food security nexus, clothing, the building sector, heating and cooling, transportation, information and communication technology, chemicals, consumer goods and services, and healthcare, toward providing global resource security and sustainability and enhancing environmental and social justice.

Conversion of Polyethylene to High-Yield Fuel Oil at Low Temperatures and Atmospheric Initial Pressure

The transformation of waste plastics into fuels via energy-efficient and low-cost pyrolysis could incentivize better waste plastic management. Here, we report pressure-induced phase transitions in polyethylene, which continue to heat up without additional heat sources, prompting the thermal cracking of plastics into premium fuel products. When the nitrogen initial pressure is increased from 2 to 21 bar, a monotonically increasing peak temperature is observed (from 428.1 °C to 476.7 °C). At 21 bar pressure under different atmosphere conditions, the temperature change driven by high-pressure helium is lower than that driven by nitrogen or argon, indicating that phase transition is related to the interaction between long-chain hydrocarbons and intercalated high-pressure medium layers. In view of the high cost of high-pressure inert gases, the promotion or inhibition effect of low-boiling hydrocarbons (transitioning into the gaseous state with increasing temperature) on phase transition is explored, and a series of light components are used as phase transition initiators to replace high-pressure inert gases to experiment. The reason that the quantitative conversion of polyethylene to high-quality fuel products is realized through the addition of 1-hexene at a set temperature of 340 °C and the initial atmospheric pressure. This discovery provides a method for recycling plastics by low energy pyrolysis. In addition, we envisage recovering some of the light components after plastic pyrolysis as phase change initiators for the next batch of the process. This method is able to reduce the cost of light hydrocarbons or high-pressure gas insertion, reduce heat input, and improve material and energy utilization.

Conformations of polyolefins on platinum catalysts control product distribution in plastics recycling

The design of catalysts for the chemical recycling of plastic waste will benefit greatly from an intimate knowledge of the interfacial polymer-catalyst interactions that determine reactant and product distributions. Here, we investigate backbone chain length, side chain length, and concentration effects on the density and conformation of polyethylene surrogates at the interface with Pt(111) and relate them to experimental product distributions resulting from carbon-carbon bond cleavage. Using replica-exchange molecular dynamics simulations, we characterize the polymer conformations at the interface by the distributions of trains, loops, and tails and their first moments. We find that the preponderance of short chains, in the range of 20 carbon atoms, lies entirely on the Pt surface, whereas longer chains exhibit much broader distributions of conformational features. Remarkably, the average length of trains is independent of the chain length but can be tuned via the polymer-surface interaction. Branching profoundly impacts the conformations of long chains at the interface as the distributions of trains become less dispersed and more structured, localized around short trains, with the immediate implication of a wider carbon product distribution upon C-C bond cleavage. The degree of localization increases with the number and size of the side chains. Long chains can adsorb from the melt onto the Pt surface even in melt mixtures containing shorter polymer chains at high concentrations. We confirm experimentally key computational findings and demonstrate that blends may provide a strategy to reduce the selectivity for undesired light gases.

Hydrogenolysis-Isomerization of Waste Polyolefin Plastics to Multibranched Liquid Alkanes

Upcycling of waste polyolefin plastics still meets with economic and technological challenges in practice. In this work, the catalytic hydrogenolysis-isomerization of nondegradable polyolefin plastic waste to high-value gasoline, diesel, and light lubricants with highly branched chain is achieved over a bifunctional Rh/Nb₂ O₅ catalyst under relatively mild conditions. Owing to the high efficiency of metallic Rh active sites, the dehydrogenation/hydrogenation of long carbon chains of polyolefins is enhanced. With the assistance of strong Brønsted acidity of Nb₂ O₅ , the cleavage of C-C bonds, skeletal rearrangements, as well as the β-scission of alkylcarbenium ions occurs, which boosts the one-step solvent-free catalytic hydrogenolysis and isomerization of polyolefins. In addition, the preliminary economic analysis shows that this technology is economical, feasible, and has great potential in accelerating the transition to a circular plastics economy for sustainable development.

A circular polyester platform based on simple gem-disubstituted valerolactones

Geminal disubstitution of cyclic monomers is an effective strategy to enhance the chemical recyclability of their polymers, but it is utilized for that purpose alone and often at the expense of performance properties. Here we present synergistic use of gem-α,α-disubstitution of available at-scale, bio-based δ-valerolactones to yield gem-dialkyl-substituted valerolactones ([Formula: see text]), which generate polymers that solve not only the poor chemical recyclability but also the low melting temperature and mechanical performance of the parent poly(δ-valerolactone); the gem-disubstituted polyesters ([Formula: see text]) therefore not only exhibit complete chemical recyclability but also thermal, mechanical and transport properties that rival or exceed those of polyethylene. Through a fundamental structure-property study that reveals intriguing impacts of the alkyl chain length on materials performance of [Formula: see text], this work establishes a simple circular, high-performance polyester platform based on [Formula: see text] and highlights the importance of synergistic utilization of gem-disubstitution for enhancing both chemical recyclability and materials performance of sustainable polyesters.

Converting Plastic Wastes to Naphtha for Closing the Plastic Loop

To solve the serious environmental problem and huge resource waste of plastic pollution, we report a tandem catalytic conversion of low-density polyethylene (LDPE) into naphtha, the key feedstock for renewable plastic production. Using β zeolite and silicalite-1-encapsulated Pt nanoparticles (Pt@S-1), a naphtha yield of 89.5% is obtained with 96.8% selectivity of C5-C9 hydrocarbons at 250 °C. The acid sites crack long-chain LDPE into olefin intermediates, which diffuse within the channels of Pt@S-1 to encounter Pt nanoparticles. The hydrogenation over confined metal matches cracking steps by selectively shipping the olefins with right size, and the rapid diffusion boosts the formation of narrow-distributed alkanes. A conceptual upgrading indicates it is suitable for closing the plastic loop, with a significant energy saving of 15% and 30% reduced greenhouse gas emissions.

Conversion of Polyethylenes into Fungal Secondary Metabolites

Waste plastics represent major environmental and economic burdens due to their ubiquity, slow breakdown rates, and inadequacy of current recycling routes. Polyethylenes are particularly problematic, because they lack robust recycling approaches despite being the most abundant plastics in use today. We report a novel chemical and biological approach for the rapid conversion of polyethylenes into structurally complex and pharmacologically active compounds. We present conditions for aerobic, catalytic digestion of polyethylenes collected from post-consumer and oceanic waste streams, creating carboxylic diacids that can then be used as a carbon source by the fungus Aspergillus nidulans. As a proof of principle, we have engineered strains of A. nidulans to synthesize the fungal secondary metabolites asperbenzaldehyde, citreoviridin, and mutilin when grown on these digestion products. This hybrid approach considerably expands the range of products to which polyethylenes can be upcycled.

Bio-oil and biochar from the pyrolytic conversion of biomass: A current and future perspective on the trade-off between economic, environmental, and technical indicators

Over the years, the transformation of biomass into a plethora of renewable value-added products has been identified as a promising strategy to fulfil high energy demands, lower greenhouse gas emissions, and exploit under-utilized resources. Techno-economic analysis (TEA) and life-cycle assessment (LCA) are essential to scale up this process while lowering the conversion cost. In this study, trade-offs are made between economic, environmental, and technical indicators produced from these methodologies to better evaluate the commercialization potential of biomass pyrolysis. This research emphasizes the necessity of combining LCA and TEA variables to assess the performance of the early-stage technology and associated constraints. The important findings based on the LCA analysis imply that most of the studies reported in literature focussed on the global warming potentials (GWP) under environmental category by considering greenhouse gases (GHGs) as evaluation parameter, neglecting many other important environmental indices. In addition, the upstream and downstream processes play an important role in understanding the life cycle impacts of a biomass based biorefinery. Under upstream conditions, the use of a specific type of feedstock may influence the LCA conclusions and technical priority. Under downstream conditions, the product utilization as fuels in different energy backgrounds is crucial to the overall impact potentials of the pyrolysis systems. In view of the TEA analysis, investigations towards maximizing the yield of valuable co-products would play an important role in the commercialization of pyrolysis process. However, comprehensive research to compare the conventional, advanced, and emerging approaches of biomass pyrolysis from the economic perspective is currently not available in the literature.

Assembly strategies for polyethylene-degrading microbial consortia based on the combination of omics tools and the "Plastisphere"

Numerous microorganisms and other invertebrates that are able to degrade polyethylene (PE) have been reported. However, studies on PE biodegradation are still limited due to its extreme stability and the lack of explicit insights into the mechanisms and efficient enzymes involved in its metabolism by microorganisms. In this review, current studies of PE biodegradation, including the fundamental stages, important microorganisms and enzymes, and functional microbial consortia, were examined. Considering the bottlenecks in the construction of PE-degrading consortia, a combination of top-down and bottom-up approaches is proposed to identify the mechanisms and metabolites of PE degradation, related enzymes, and efficient synthetic microbial consortia. In addition, the exploration of the plastisphere based on omics tools is proposed as a future principal research direction for the construction of synthetic microbial consortia for PE degradation. Combining chemical and biological upcycling processes for PE waste could be widely applied in various fields to promote a sustainable environment.

A systematic review on plastic waste conversion for a circular economy: recent trends and emerging technologies

Our biosphere has been adversely affected by plastic waste pollution, especially non-biodegradables in landfills, which induces hazardous chemical leaching and toxic gas emissions on burning into the atmosphere.

Catalytic Chemical Recycling of Post-Consumer Polyethylene

Among commercial plastics, polyolefins are the most widely produced worldwide but have limited recyclability. Here, we report a chemical recycling route for the conversion of post-consumer high-density polyethylene (HDPE) into telechelic macromonomers suitable for circular reprocessing. Unsaturation was introduced into HDPE by catalytic dehydrogenation using an Ir-POCOP catalyst without an alkene acceptor. Cross-metathesis with 2-hydroxyethyl acrylate followed by hydrogenation transformed the partially unsaturated HDPE into telechelic macromonomers. The direct repolymerization of the macromonomers gave a brittle material due to the low overall weight-average molecular weight. Aminolysis of telechelic macromonomers with a small amount of diethanolamine increased the overall functionality. The resulting macromonomers were repolymerized through transesterification to generate a polymer with comparable mechanical properties to the starting post-consumer HDPE waste. Depolymerization of the repolymerized material catalyzed by an organic base regenerated the telechelic macromonomers, thereby allowing waste polyethylene materials to enter a chemical recycling pathway.

Exploiting valuable supramolecular materials from waste plastics

A new family of supramolecular materials is exploited from waste thermosets via a one-step retrosynthetic approach, which exhibits distinguished adhesion properties in dry/wet environments, good corrosion resistance and dynamic reversibility. This work opens up a wide design space for supramolecular materials with excellent performances and proposes a new strategy for efficient utilization of hybrid degraded products.

Rapid atom-efficient polyolefin plastics hydrogenolysis mediated by a well-defined single-site electrophilic/cationic organo-zirconium catalyst

Polyolefins comprise a major fraction of single-use plastics, yet their catalytic deconstruction/recycling has proven challenging due to their inert saturated hydrocarbon connectivities. Here a very electrophilic, formally cationic earth-abundant single-site organozirconium catalyst chemisorbed on a highly Brønsted acidic sulfated alumina support and characterized by a broad array of experimental and theoretical techniques, is shown to mediate the rapid hydrogenolytic cleavage of molecular and macromolecular saturated hydrocarbons under mild conditions, with catalytic onset as low as 90 °C/0.5 atm H2 with 0.02 mol% catalyst loading. For polyethylene, quantitative hydrogenolysis to light hydrocarbons proceeds within 48 min with an activity of > 4000 mol(CH2 units)·mol(Zr)-1·h-1 at 200 °C/2 atm H2 pressure. Under similar solventless conditions, polyethylene-co-1-octene, isotactic polypropylene, and a post-consumer food container cap are rapidly hydrogenolyzed to low molecular mass hydrocarbons. Regarding mechanism, theory and experiment identify a turnover-limiting C-C scission pathway involving ß-alkyl transfer rather than the more common σ-bond metathesis.

Plastic Waste Upcycling: A Sustainable Solution for Waste Management, Product Development, and Circular Economy

Plastic waste pollution, including non-biodegradable landfills, leaching of toxic chemicals into soil and waterways, and emission of toxic gases into the atmosphere, is significantly affecting our environment. Conventional plastic waste recycling approaches generally produce lower value materials compared to the original plastic or recover inefficient heat energy. Lately, upcycling or the valorization approach has emerged as a sustainable solution to transform plastic waste into value-added products. In this review, we present an overview of recent advancements in plastic waste upcycling, such as vitrimerization, nanocomposite fabrication, additive manufacturing, catalytic transformation, and industrial biotechnology, envisaged with technical challenges, future developments, and new circular economy opportunities.

Hydrogenolysis of Polyethylene and Polypropylene into Propane over Cobalt-Based Catalysts

The development of technologies to recycle polyethylene (PE) and polypropylene (PP), globally the two most produced polymers, is critical to increase plastic circularity. Here, we show that 5 wt % cobalt supported on ZSM-5 zeolite catalyzes the solvent-free hydrogenolysis of PE and PP into propane with weight-based selectivity in the gas phase over 80 wt % after 20 h at 523 K and 40 bar H2. This catalyst significantly reduces the formation of undesired CH4 (≤5 wt %), a product which is favored when using bulk cobalt oxide or cobalt nanoparticles supported on other carriers (selectivity ≤95 wt %). The superior performance of Co/ZSM-5 is attributed to the stabilization of dispersed oxidic cobalt nanoparticles by the zeolite support, preventing further reduction to metallic species that appear to catalyze CH4 generation. While ZSM-5 is also active for propane formation at 523 K, the presence of Co promotes stability and selectivity. After optimizing the metal loading, it was demonstrated that 10 wt % Co/ZSM-5 can selectively catalyze the hydrogenolysis of low-density PE (LDPE), mixtures of LDPE and PP, as well as postconsumer PE, showcasing the effectiveness of this technology to upcycle realistic plastic waste. Cobalt supported on zeolites FAU, MOR, and BEA were also effective catalysts for C2-C4 hydrocarbon formation and revealed that the framework topology provides a handle to tune gas-phase selectivity.

Recycling plastic using a hybrid process

Integrating oxidation and bioconversion provides a solution to recycle mixed plastics.

Catalytic deconstruction of waste polyethylene with ethylene to form propylene

The conversion of polyolefins to monomers would create a valuable carbon feedstock from the largest fraction of waste plastic. However, breakdown of the main chains in these polymers requires the cleavage of carbon-carbon bonds that tend to resist selective chemical transformations. Here, we report the production of propylene by partial dehydrogenation of polyethylene and tandem isomerizing ethenolysis of the desaturated chain. Dehydrogenation of high-density polyethylene with either an iridium-pincer complex or platinum/zinc supported on silica as catalysts yielded dehydrogenated material containing up to 3.2% internal olefins; the combination of a second-generation Hoveyda-Grubbs metathesis catalyst and [PdP(tBu)3(μ-Br)]2 as an isomerization catalyst selectively degraded this unsaturated polymer to propylene in yields exceeding 80%. These results show promise for the application of mild catalysis to deconstruct otherwise stable polyolefins.

Chemical Recycling of Polyethylene by Tandem Catalytic Conversion to Propylene

Although polyethylene (PE) and polypropylene (PP) are by far the world's largest volume plastics, only a tiny fraction of these energy-rich polyolefins are currently recycled. Depolymerization of PE to its constituent monomer, ethylene, is highly endothermic and conventionally accessible only through unselective, high-temperature pyrolysis. Here, we provide experimental demonstrations of our recently proposed tandem catalysis strategy, which uses ethylene to convert PE to propylene, the commodity monomer used to make PP. The approach combines rapid olefin metathesis with rate-limiting isomerization. Monounsaturated PE is progressively disassembled at modest temperatures via many consecutive ethenolysis events, resulting selectively in propylene. Fully saturated PE can be converted to unsaturated PE starting with a single transfer dehydrogenation to ethylene, which produces a small amount of ethane (1 equiv per dehydrogenation event). These principles are demonstrated using both homogeneous and heterogeneous catalysts. While selectivity under batch conditions is limited at high conversion by the formation of an equilibrium mixture of olefins, high selectivity to propylene (≥94%) is achieved in a semicontinuous process due to the continuous removal of propylene from the reaction mixture.

Electronic modulation of metal-support interactions improves polypropylene hydrogenolysis over ruthenium catalysts

Ruthenium (Ru) is the one of the most promising catalysts for polyolefin hydrogenolysis. Its performance varies widely with the support, but the reasons remain unknown. Here, we introduce a simple synthetic strategy (using ammonia as a modulator) to tune metal-support interactions and apply it to Ru deposited on titania (TiO₂). We demonstrate that combining deuterium nuclear magnetic resonance spectroscopy with temperature variation and density functional theory can reveal the complex nature, binding strength, and H amount. H₂ activation occurs heterolytically, leading to a hydride on Ru, an H⁺ on the nearest oxygen, and a partially positively charged Ru. This leads to partial reduction of TiO₂ and high coverages of H for spillover, showcasing a threefold increase in hydrogenolysis rates. This result points to the key role of the surface hydrogen coverage in improving hydrogenolysis catalyst performance.

Catalytic pathways of plastic waste valorization to lubricants are attractive avenues to foster circular economy. Tuning of catalyst electronic properties allows to significantly improve its activity due to boosted hydrogen storage on the surface.

A unified view on catalytic conversion of biomass and waste plastics

Originating from the desire to improve sustainability, producing fuels and chemicals from the conversion of biomass and waste plastic has become an important research topic in the twenty-first century. Although biomass is natural and plastic synthetic, the chemical nature of the two are not as distinct as they first appear. They share substantial structural similarities in terms of their polymeric nature and the types of bonds linking their monomeric units, resulting in close relationships between the two materials and their conversions. Previously, their transformations were mostly studied and reviewed separately in the literature. Here, we summarize the catalytic conversion of biomass and waste plastics, with a focus on bond activation chemistry and catalyst design. By tracking the historical and more recent developments, it becomes clear that biomass and plastic have not only evolved their unique conversion pathways but have also started to cross paths with each other, with each influencing the landscape of the other. As a result, this Review on the catalytic conversion of biomass and waste plastic in a unified angle offers improved insights into existing technologies, and more importantly, may enable new opportunities for future advances.

Environmental toxicity and decomposition of polyethylene

In the more than 100 years since the invention of plastics, various plastic polymers have been developed that exhibit different characteristics and have been widely used in production and life. In 2020 alone, nearly 400 million tons of plastics were produced globally. However, while plastic such as polyethylene brings us convenience, it also threatens environmental sustainability and human health. Due to insufficient recycling efficiency, millions of tons of polyethylene pollutants accumulate in terrestrial or marine environments each year. Polyethylene is elastic, chemically stable, and non-biodegradable, and the traditional disposal methods include landfilling and incineration. These methods are costly, unsustainable, and further increase the burden on the environment. Therefore, recent research has increasingly focused on the biodegradation of polyethylene. In this work, we briefly summarized polyethylene's properties and environmental toxicity. We also reviewed the recent advances in the biodegradation of polyethylene with a summary of traditional abiotic methods. Finally, we proposed a brief research direction in polyethylene study with the aspect of environmental toxicology and industrial applications of decomposition technology.

Circularly Recyclable Polymers Featuring Topochemically Weakened Carbon-Carbon Bonds

Closed-loop circular utilization of plastics is of manifold significance, yet energy-intensive and poorly selective scission of the ubiquitous carbon-carbon (C-C) bonds in contemporary commercial polymers pose tremendous challenges to envisioned recycling and upcycling scenarios. Here, we demonstrate a topochemical approach for creating elongated C-C bonds with a bond length of 1.57∼1.63 Å between repeating units in the solid state with decreased bond dissociation energies. Elongated bonds were introduced between the repeating units of 12 distinct polymers from three classes. In all cases, the materials exhibit rapid depolymerization via breakage of the elongated bond within a desirable temperature range (140∼260 °C) while otherwise remaining remarkably stable under harsh conditions. Furthermore, the topochemically prepared polymers are processable and 3D-printable while maintaining a high depolymerization yield and tunable mechanical properties. These results suggest that the crystalline polymers synthesized from simple photochemistry and without expensive catalysts are promising for practical applications with complete materials' circularity.

Catalytic oxidation of polystyrene to aromatic oxygenates over a graphitic carbon nitride catalyst

The continuous increase in manufacturing coupled with the difficulty of recycling of plastic products has generated huge amounts of waste plastics. Most of the existing chemical recycling and upcycling methods suffer from harsh conditions and poor product selectivity. Here we demonstrate a photocatalytic method to oxidize polystyrene to aromatic oxygenates under visible light irradiation using heterogeneous graphitic carbon nitride catalysts. Benzoic acid, acetophenone, and benzaldehyde are the dominant products in the liquid phase when the conversion of polystyrene reaches >90% at 150 °C. For the transformation of 0.5 g polystyrene plastic waste, 0.36 g of the aromatic oxygenates is obtained. The reaction mechanism is also investigated with various characterization methods and procedes via polystyrene activation to form hydroxyl and carbonyl groups over its backbone via C-H bond oxidation which is followed by oxidative bond breakage via C-C activation and further oxidation processes to aromatic oxygenates.

First-Generation Organic Reaction Intermediates in Zeolite Chemistry and Catalysis

Zeolite chemistry and catalysis are expected to play a decisive role in the next decade(s) to build a more decentralized renewable feedstock-dependent sustainable society owing to the increased scrutiny over carbon emissions. Therefore, the lack of fundamental and mechanistic understanding of these processes is a critical "technical bottleneck" that must be eliminated to maximize economic value and minimize waste. We have identified, considering this objective, that the chemistry related to the first-generation reaction intermediates (i.e., carbocations, radicals, carbenes, ketenes, and carbanions) in zeolite chemistry and catalysis is highly underdeveloped or undervalued compared to other catalysis streams (e.g., homogeneous catalysis). This limitation can often be attributed to the technological restrictions to detect such "short-lived and highly reactive" intermediates at the interface (gas-solid/solid-liquid); however, the recent rise of sophisticated spectroscopic/analytical techniques (including under in situ/operando conditions) and modern data analysis methods collectively compete to unravel the impact of these organic intermediates. This comprehensive review summarizes the state-of-the-art first-generation organic reaction intermediates in zeolite chemistry and catalysis and evaluates their existing challenges and future prospects, to contribute significantly to the "circular carbon economy" initiatives.

Coking-Resistant Polyethylene Upcycling Modulated by Zeolite Micropore Diffusion

Although the mass production of synthetic plastics has transformed human lives, it has resulted in waste accumulation on the earth. Here, we report a low-temperature conversion of polyethylene into olefins. By mixing the polyethylene feed with rationally designed ZSM-5 zeolite nanosheets at 280 °C in flowing hydrogen as a carrier gas, light hydrocarbons (C₁-C₇) were produced with a yield of up to 74.6%, where 83.9% of these products were C₃-C₆ olefins with almost undetectable coke formation. The reaction proceeds in multiple steps, including polyethylene melting, flowing to access the zeolite surface, cracking on the zeolite surface, formation of intermediates to diffuse into the zeolite micropores, and cracking into small molecules in the zeolite micropores. The ZSM-5 zeolite nanosheets kinetically matched the cascade cracking steps on the zeolite external surface and within micropores by boosting the intermediate diffusion. This feature efficiently suppressed the intermediate accumulation on the zeolite surface to minimize coke formation. In addition, we found that hydrogen participation in the cracking process could hinder the formation of polycyclic species within zeolite micropores, which also contributes to the rapid molecule diffusion. The coking-resistant polyethylene upcycling process at a low temperature not only overturns the general viewpoint for facile coke formation in the catalytic cracking over the zeolites but also demonstrates how the polyethylene-based plastics can be upcycled to valuable chemicals. In addition to the model polyethylene, the reaction system worked efficiently for the depolymerization of multiple practically used polyethylene-rich plastics, enabling an industrially and economically viable path for dealing with plastic wastes.

Sustainably Recycling and Upcycling of Single-Use Plastic Wastes through Heterogeneous Catalysis

The huge amount of plastic waste has caused a series of environmental and economic problems. Depolymerization of these wastes and their conversion into desired chemicals have been regarded as a promising route for dealing with these issues, which strongly relies on catalysis for C-C and C-O bond cleavage and selective transformation. Here, we reviewed recent developments in catalysis systems for dealing with single-use plastics, such as polyethylene, polypropylene, and polyethylene glycol terephthalate. The recycling processes of depolymerization into original monomers and conversion into other economic-incentive chemicals were systemically discussed. Rational designs of catalysts for efficient conversion were particularly highlighted. Overall, improving the tolerance of catalysts to impurities in practical plastics, reducing the economic cost during the catalytic depolymerization process, and trying to obtain gaseous hydrogen from plastic wastes are suggested as the developing trends in this field.

Upcycling Plastic Wastes into Value-Added Products by Heterogeneous Catalysis

Plastics are playing essential roles in the modern society. The majority of them enter environment through landfilling or discarding after turning into wastes, causing severe carbon loss and imposing high risk to ecosystem and human health. Currently, physical recycling serves as the primary method to reuse plastic waste, but this method is limited to thermoplastic recycling. The quality of recycled plastics gradually deteriorates because of the undesirable degradation in the recycling process. Under such background, catalytic upcycling, which can upgrade various plastic wastes into value-added products under mild conditions, has attracted recent attention as a promising strategy to treat plastic wastes. This Review highlights recent advances in the development of efficient heterogeneous catalysts and useful strategies for upcycling plastics into liquid hydrocarbons, arene compounds, carbon materials, hydrogen, and other value-added chemicals. The functions of catalysts and the reaction mechanisms are discussed. The key factors that influence the catalytic performance are also analyzed.

Maximizing noble metal utilization in solid catalysts by control of nanoparticle location

Maximizing the utilization of noble metals is crucial for applications such as catalysis. We found that the minimum loading of platinum for optimal performance in the hydroconversion of n -alkanes for industrially relevant bifunctional catalysts could be reduced by a factor of 10 or more through the rational arranging of functional sites at the nanoscale. Intentionally depositing traces of platinum nanoparticles on the alumina binder or the outer surface of zeolite crystals, instead of inside the zeolite crystals, enhanced isomer selectivity without compromising activity. Separation between platinum and zeolite acid sites preserved the metal and acid functions by limiting micropore blockage by metal clusters and enhancing access to metal sites. Reduced platinum nanoparticles were more active than platinum single atoms strongly bonded to the alumina binder.

End-of-Life Management Options for Agricultural Mulch Films in the United States—A Review

Polyethylene plastic mulches are widely used in specialty cropping systems in the United States due to the horticultural benefits they provide. However, polyethylene mulch is reapplied seasonally, generating large volumes of plastic waste that contribute to plastic pollution concerns. This review synthesizes scientific and industry findings to provide a state of current end-of-life options of polyethylene mulch in the United States and identifies opportunities that can improve plastic waste management with a special emphasis on soil-biodegradable plastic mulches. Major points discussed are: (1) polyethylene mulch use in specialty cropping systems, (2) economic, environmental and waste management impacts of polyethylene mulch use, (3) current common end-of-life pathways of used polyethylene mulch, (4) use of soil-biodegradable plastic mulch as an alternative to reduce the amount of plastic waste in the environment and offset the negative impacts associated with residual non-degradable plastics, (5) socioeconomic factors that reduce the adoption of soil-biodegradable plastic mulch, and (6) limitations of soil-biodegradable mulch. The results of this review conclude that recycling and upcycling of used polyethylene mulch can be a more sustainable disposal option, however cleaning and decontaminating used polyethylene mulch is costly and commercial technology is often not accessible nor economically viable in many regions in the current economic and political situation. To make recycling a viable pathway in the future, research and policy developments are necessary to refine and encourage recycling. Soil-biodegradable plastic mulches can offer an additional opportunity to help address these limitations, but they are not permitted in organic agriculture in the United States. Further studies are necessary to address the current knowledge gaps and gain a better understanding of the factors influencing the degradation of soil-biodegradable mulches under diverse field conditions. Improved end-of-life strategies should continue to be pursued that balance sustainable use of plastic mulch while minimizing environmental risks.

Unleashing the Power of Knowledge Extraction from Scientific Literature in Catalysis

Valuable knowledge of catalysis is often hidden in a large amount of scientific literature. There is an urgent need to extract useful knowledge to facilitate scientific discovery. This work takes the first step toward the goal in the field of catalysis. Specifically, we construct the first information extraction benchmark data set that covers the field of catalysis and also develop a general extraction framework that can accurately extract catalysis-related entities from scientific literature with 90% extraction accuracy. We further demonstrate the feasibility of leveraging the extracted knowledge to help users better access relevant information in catalysis through an entity-aware search engine and a correlation analysis system.

Bridging Plastic Recycling and Organic Catalysis: Photocatalytic Deconstruction of Polystyrene via a C–H Oxidation Pathway

Chemical recycling of synthetic polymers represents a promising strategy to deconstruct plastic waste and make valuable products. Inspired by small-molecule C–H bond activation, a visible-light-driven reaction is developed to deconstruct polystyrene (PS) into ∼40% benzoic acid as well as ∼20% other monomeric aromatic products at 50 °C and ambient pressure. The practicality of this strategy is demonstrated by deconstruction of real-world PS foam on a gram scale. The reaction is proposed to proceed via a C–H bond oxidation pathway, which is supported by theoretical calculations and experimental results. Fluorescence quenching experiments also support efficient electron transfer between the photocatalyst and the polymer substrate, providing further evidence for the proposed mechanism. This study introduces concepts from small-molecule catalysis to polymer deconstruction and provides a promising method to tackle the global crisis of plastic pollution.