Catalytic hydrogenolysis of plastic to liquid hydrocarbons over a nickel-based catalyst

Conversion of Polyethylene to Low-Molecular-Weight Oil Products at Moderate Temperatures Using Nickel/Zeolite Nanocatalysts

Polyethylene (PE) is the most widely used plastic, known for its high mechanical strength and affordability, rendering it responsible for ~70% of packaging waste and contributing to microplastic pollution. The cleavage of the carbon chain can induce the conversion of PE wastes into low-molecular-weight hydrocarbons, such as petroleum oils, waxes, and natural gases, but the thermal degradation of PE is challenging and requires high temperatures exceeding 400 °C due to its lack of specific chemical groups. Herein, we prepare metal/zeolite nanocatalysts by incorporating small-sized nickel nanoparticles into zeolite to lower the degradation temperature of PE. With the use of nanocatalysts, the degradation temperature can be lowered to 350 °C under hydrogen conditions, compared to the 400 °C required for non-catalytic pyrolysis. The metal components of the catalysts facilitate hydrogen adsorption, while the zeolite components stabilize the intermediate radicals or carbocations formed during the degradation process. The successful pyrolysis of PE at low temperatures yields valuable low-molecular-weight oil products, offering a promising pathway for the upcycling of PE into higher value-added products.

Upcycling Waste Plastics with a C-C Backbone by Heterogeneous Catalysis

Plastics with an inert carbon-carbon (C-C) backbone, such as polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC), are the most widely used types of plastic in human activities. However, many of these polymers were directly discarded in nature after use, and few were appropriately recycled. This not only threatens the natural environment but also leads to the waste of carbon resources. Conventional chemical recycling of these plastics, including pyrolysis and catalytic cracking, requires a high energy input due to the chemical inertness of C-C bonds and C-H bonds and leads to complex product distribution. In recent years, significant progress has been made in the development of catalysts and the introduction of small molecules as additional coreactants, which could potentially overcome these challenges. In this Review, we summarize and highlight catalytic strategies that address these issues in upcycling C-C backbone plastics with small molecules, particularly in heterogeneous catalysis. We believe that this review will inspire the development of upcycling methods for C-C backbone plastics using small molecules and heterogeneous catalysis.

Development of reusable Ni/γ-Al2O3 catalyst for catalytic hydrolysis of waste PET bottles into terephthalic acid

In order to efficiently recycle waste polyethylene terephthalate (PET) bottles, this study aimed to enhance the hydrolysis process to convert PET bottle into valuable terephthalic acid (TPA) by developing effective and reusable Ni/γ-Al2O3 catalysts. A series of Ni/γ-Al2O3 catalyst was prepared by the impregnation method with different Ni loadings (5-15 wt%) and was characterized by various techniques including XRD, SEM-EDX, and N2 adsorption-desorption. The prepared catalysts were employed in the catalytic hydrolysis of PET under varied influencing factors, namely reaction temperature (220-280 °C), reaction time (20-60 min), and Ni loading. The response surface methodology (RSM) was used to optimize the operating condition to produce the maximum TPA yield, and the optimal values were determined as follows: reaction temperature = 267.07 °C, reaction time = 48.54 min, and Ni loading = 12.90 wt%, giving the highest TPA yield of 97.06%. The R2, F-value, and P-value of the analysis of variance (ANOVA) were 0.9982, 424.96, and <0.0001, respectively, indicating a good fit of the model. The results from XRD and FTIR measurement of the produced TPA indicated the high purity and comparable chemical structures to the TPA standard. In addition, the 12.9Ni/Al catalyst exhibited high catalytic activity in repeated cycles of hydrolysis process of PET and could be regenerated by calcination to restore its catalytic activity. This finding could be a promising alternative for an effective TPA recovery from waste plastic bottles.

Structure-Property Relationships for Nickel Aluminate Catalysts in Polyethylene Hydrogenolysis with Low Methane Selectivity

Earth-abundant metals have recently been demonstrated as cheap catalyst alternatives to scarce noble metals for polyethylene hydrogenolysis. However, high methane selectivities hinder industrial feasibility. Herein, we demonstrate that low-temperature ex-situ reduction (350 °C) of coprecipitated nickel aluminate catalysts yields a methane selectivity of <5% at moderate polymer deconstruction (25-45%). A reduction temperature up to 550 °C increases the methane selectivity nearly sevenfold. Catalyst characterization (XRD, XAS, 27Al MAS NMR, H2 TPR, XPS, and CO-IR) elucidates the complex process of Ni nanoparticle formation, and air-free XPS directly after reaction reveals tetrahedrally coordinated Ni2+ cations promote methane production. Metallic and the specific cationic Ni appear responsible for hydrogenolysis of internal and terminal C-C scissions, respectively. A structure-methane selectivity relationship is discovered to guide the design of Ni-based catalysts with low methane generation. It paves the way for discovering other structure-property relations in plastics hydrogenolysis. These catalysts are also effective for polypropylene hydrogenolysis.

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.

Ionic-Liquid-Mediated Deconstruction of Polymers for Advanced Recycling and Upcycling

Ionic liquids (ILs) are a promising medium to assist in the advanced (chemical and biological) recycling of polymers, owing to their tunable catalytic activity, tailorable chemical functionality, low vapor pressures, and thermal stability. These unique physicochemical properties, combined with ILs' capacity to solubilize plastics waste and biopolymers, offer routes to deconstruct polymers at reduced temperatures (and lower energy inputs) versus conventional bulk and solvent-based methods, while also minimizing unwanted side reactions. In this Viewpoint, we discuss the use of ILs as catalysts and mediators in advanced recycling, with an emphasis on chemical recycling, by examining the interplay between IL chemistry and deconstruction thermodynamics, deconstruction kinetics, IL recovery, and product recovery. We also consider several potential environmental benefits and concerns associated with employing ILs for advanced recycling over bulk- or solvent-mediated deconstruction techniques, such as reduced chemical escape by volatilization, decreased energy demands, toxicity, and environmental persistence. By analyzing IL-mediated polymer deconstruction across a breadth of macromolecular systems, we identify recent innovations, current challenges, and future opportunities in IL application toward circular polymer economies.

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.

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.