A “Polymer to Polymer” Chemical Recycling of PLA Plastics by the “DE–RE Polymerization” Strategy

Depolymerization and Re/Upcycling of Biodegradable PLA Plastics

With the escalating utilization of plastic products, global attention has been increasingly drawn to environmental pollution and recycling challenges stemming from plastic waste. Against this backdrop, biodegradable plastics have emerged as viable alternatives owing to their sustainability and capacity for biodegradation. Polylactic acid (PLA) presently commands the largest market share among biodegradable plastics, finding extensive application in products such as thin films, medical materials, and biodegradable straws. However, the widespread adoption of PLA is hindered by challenges such as high cost, low recycling rates, and complete degradation to H2O and CO2 in natural conditions. Therefore, it is imperative and time-sensitive to explore solutions for the depolymerization and re/upcycling of PLA waste plastics. This review comprehensively outlines the current landscape of PLA recycling methods, emphasizing the advantages and significance of chemical re/upcycling. The subsequent exploration encompasses recent breakthroughs and technical obstacles inherent in diverse chemical depolymerization methods. Ultimately, this review accentuates the impediments and forthcoming possibilities in the realm of PLA plastics, emphasizing the pursuit of closed-loop recycling and upcycling.

Depolymerization within a Circular Plastics System

The societal importance of plastics contrasts with the carelessness with which they are disposed. Their superlative properties lead to economic and environmental efficiency, but the linearity of plastics puts the climate, human health, and global ecosystems at risk. Recycling is fundamental to transitioning this linear model into a more sustainable, circular economy. Among recycling technologies, chemical depolymerization offers a route to virgin quality recycled plastics, especially when valorizing complex waste streams poorly served by mechanical methods. However, chemical depolymerization exists in a complex and interlinked system of end-of-life fates, with the complementarity of each approach key to environmental, economic, and societal sustainability. This review explores the recent progress made into the depolymerization of five commercial polymers: poly(ethylene terephthalate), polycarbonates, polyamides, aliphatic polyesters, and polyurethanes. Attention is paid not only to the catalytic technologies used to enhance depolymerization efficiencies but also to the interrelationship with other recycling technologies and to the systemic constraints imposed by a global economy. Novel polymers, designed for chemical depolymerization, are also concisely reviewed in terms of their underlying chemistry and potential for integration with current plastic systems.

Degradation Product-Promoted Depolymerization Strategy for Chemical Recycling of Poly(bisphenol A carbonate)

The accumulation of waste plastics has a severe impact on the environment, and therefore, the development of efficient chemical recycling methods has become an extremely important task. In this regard, a new strategy of degradation product-promoted depolymerization process was proposed. Using N,N'-dimethyl-ethylenediamine (DMEDA) as a depolymerization reagent, an efficient chemical recycling of poly(bisphenol A carbonate) (BPA-PC or PC) material was achieved under mild conditions. The degradation product 1,3-dimethyl-2-imidazolidinone (DMI) was proven to be a critical factor in facilitating the depolymerization process. This strategy does not require catalysts or auxiliary solvents, making it a truly green process. This method improves the recycling efficiency of PC and promotes the development of plastic reutilization.

Solvent-Promoted Catalyst-Free Recycling of Waste Polyester and Polycarbonate Materials

Polymeric materials are indispensable in our daily lives. However, the generation of vast amounts of waste polymers poses significant environmental and ecological challenges. Instead of resorting to landfilling or incineration, strategies for polymer recycling offer a promising approach to mitigate environmental pollution. Pioneering studies have demonstrated the alcoholysis of waste polyesters and polycarbonates; however, these processes typically require the use of catalysts. Moreover, the development of strategies for catalyst removal and recycling is crucial, particularly in some industrial applications. In contrast, we present a catalyst-free method for the alcoholysis of common polyester and polycarbonate materials into small organic molecules. Certain polar organic solvents exhibit remarkable efficiency in polymer degradation under catalyst-free conditions. Employing these polar solvents, both polymer resins and commercially available products could be effectively degraded via alcoholysis. Our design contributes a straightforward route for recycling waste polymeric materials.

Chemical Recycling of Commercial Poly(l-lactic acid) to l-Lactide Using a High-Performance Sn(II)/Alcohol Catalyst System

Poly(l-lactic acid) (PLLA) is a leading commercial polymer produced from biomass, showing useful properties for plastics and fiber applications; after use, it is compostable. One area for improvement is postconsumer waste PLLA chemical recycling to monomer (CRM), i.e., the formation of l-lactide (l-LA) from waste plastic. This process is currently feasible at high reaction temperatures and shows low catalytic activity accompanied, in some cases, by side reactions, including epimerization. Here, a commercial Sn(II) catalyst, applied with nonvolatile commercial alcohol, enables highly efficient CRM of PLLA to yield l-LA in excellent yield and purity (92% yield, >99% l-LA from theoretical max.). The depolymerization is performed using neat polymer films at low temperatures (160 °C) under a nitrogen flow or vacuum. The chemical recycling operates with outstanding activity, achieving turnover frequencies which are up to 3000× higher than previously excellent catalysts and applied at loadings up to 6000× lower than previously leading catalysts. The catalyst system achieves a TOF = 3000 h-1 at 0.01 mol % or 1:10,000 catalyst:PLLA loading. The depolymerization of waste PLLA plastic packaging (coffee cup lids) produces pure l-LA in excellent yield and selectivity. The new catalyst system (Sn + alcohol) can itself be recycled four times in different PLLA "batch degradations" and maintains its high catalytic productivity, activity, and selectivity.

A Versatile Step-Growth Polymerization Route to Functional Polyesters from an Activated Diester Monomer

This work describes a versatile and efficient condensation polymerization route to aliphatic polyesters by organo-catalyzed (4-dimethylaminopyridine) transesterification reactions between an activated pentafluorophenyl-diester of adipic acid and structurally different diols. By introducing "monofunctional impurity" or "stoichiometric imbalance," this methodology can afford well-defined end-functionalized polyesters with predictable molecular weights and narrow dispersity under mild conditions without any necessity for the removal of the byproducts to accelerate the polymerization reaction, which remains a major challenge in conventional polyester synthesis with non-activated diesters. Wide substrate scope with structurally different monomers and the synthesis of block copolymers by chain extension following either ring-opening polymerization or controlled radical polymerization have been successfully demonstrated. Some of the polyesters synthesized by this newly introduced approach show high thermal stability, crystallinity, and enzymatic degradation in aqueous environments.

Repurposing of waste PET by microbial biotransformation to functionalized materials for additive manufacturing

Plastic waste is an outstanding environmental thread. Poly(ethylene terephthalate) (PET) is one of the most abundantly produced single-use plastics worldwide, but its recycling rates are low. In parallel, additive manufacturing is a rapidly evolving technology with wide-ranging applications. Thus, there is a need for a broad spectrum of polymers to meet the demands of this growing industry and address post-use waste materials. This perspective article highlights the potential of designing microbial cell factories to upcycle PET into functionalized chemical building blocks for additive manufacturing. We present the leveraging of PET hydrolyzing enzymes and rewiring the bacterial C2 and aromatic catabolic pathways to obtain high-value chemicals and polymers. Since PET mechanical recycling back to original materials is cost-prohibitive, the biochemical technology is a viable alternative to upcycle PET into novel 3D printing materials, such as replacements for acrylonitrile butadiene styrene. The presented hybrid chemo-bio approaches potentially enable the manufacturing of environmentally friendly degradable or higher-value high-performance polymers and composites and their reuse for a circular economy.

ONE-SENTENCE SUMMARY

Biotransformation of waste PET to high-value platform chemicals for additive manufacturing.

Antimicrobial and Gas Barrier Crustaceans and Fungal Chitin-Based Coatings on Biodegradable Bioplastic Films

Chitin nanofibrils (CN) can be obtained from crustaceans and fungal sources and can be used for preparing coatings for bioplastic films, that are fundamental for developing a safe and sustainable biodegradable food packaging. Coatings with different concentrations of CN from shrimps were applied on different bioplastic substrates, like Poly (butylene succinate-co-adipate)/Poly(3-hydroxybutyrate-co-3-hydroxyvalerate (PBSA/PHBV) blend, Polybutylene succinate (PBS), and Polybutylene adipate terephthalate/Poly(lactic acid) (PBAT/PLA) blend, but the adhesion to the substrates was scarce. On the contrary, the fungal-based CN showed a better adhesion. Additionally, it was found that the use of an additive based on oligomeric lactic acid was useful to prepare a coating with an improved adhesion to bioplastics. The gas barrier properties to oxygen and water vapour of coated and un-coated films were measured, revealing an improvement of these properties thanks to applied coatings, especially towards the oxygen. Antimicrobial properties and biodegradation capacity were also evaluated revealing an antibacterial effect of the coatings that did not significantly interfere with their biodegradability. The results are discussed and interpreted considering the correlation between composition and macromolecular structures with the observed functional properties.

Competitive Mechanism of Stereocomplexes and Homocrystals in High-Performance Symmetric and Asymmetric Poly(lactic acid) Enantiomers: Qualitative Methods

To systematically explore the critical contributions of both molecular weights and crystallization temperature and chain length and molar ratios to the formation of stereocomplexes (SCs), our group quantitatively prepared a wide MW range of symmetric and asymmetric poly(lactic acid) (PLA) racemic blends, which contains L-MW PLLA with M _n > 6k g/mol. The crystallinity and relative fraction of SCs increase with T _c, and the SCs are exclusively formed at T _c > 180 °C in M/H-MW racemic blends. When MWs of one of the enantiomers are over 6k and less than 41k, multiple stereocomplexation is clear in the asymmetric racemic blends and more ordered SCs form with less entanglement or the amorphous region compared to those for the MW of the enantiomers over 41k in the symmetric/asymmetric enantiomers. When the MW of the blends is more than 41k, SCs and homocrystals (HCs) coexist in the symmetric enantiomers and the multicomplexation can restrict the asymmetric enantiomers. This study provides a deep comprehensive insight into the stereocomplex crystallization mechanism of polymers and provides a reference value for future research attempting to prepare stereocomplex materials.

Chemical Upcycling of Poly(ε-caprolactone) to Valuable Chemical via TBD-Catalyzed Efficient Methanolysis Strategy

As a petroleum-derived polyester material, poly(ε-caprolactone) (PCL) plays an essential role in biomedical field due to its excellent biocompatibility and non-toxicity. With the increasing use of PCL in recent years, its waste disposal has become a significant challenge. To address this challenge, we demonstrate a high-efficiency organocatalysis strategy for the chemical upcycling of PCL to valuable chemical. Among organocatalysts explored in this article, 1,5,7-triazabicyclo[4,4,0]dec-5-ene (TBD) shows superior performance for transforming end-of-life poly(ε-caprolactone) into highly value-added methyl 6-hydroxyhexanoate with quantitative conversion in a short time. The endwise unzipping depolymerization mechanism is corroborated by monitoring molecular weight during depolymerization process and 1 H NMR control experiments. Furthermore, this approach is also practicable for large-scale depolymerization for commercial PCL plastics, providing idea for promoting the sustainable development of PCL plastics.

“Like Recycles Like”: Selective Ring‐Closing Depolymerization of Poly(L‐Lactic Acid) to L‐Lactide

Chemical recycling of poly(L‐lactic acid) to the cyclic monomer L‐lactide is hampered by low selectivity and by epimerization and elimination reactions, impeding its use on a large scale. The high number of side reactions originates from the high ceiling temperature (T_c) of L‐lactide, which necessitates high temperatures or multistep reactions to achieve recycling to L‐lactide. To circumvent this issue, we utilized the impact of solvent interactions on the monomer–polymer equilibrium to decrease the T_c of L‐lactide. Analyzing the observed T_c in different solvents in relation to their Hildebrand solubility parameter revealed a “like recycles like” relationship. The decreased T_c, obtained by selecting solvents that interact strongly with the monomer (dimethyl formamide or the green solvent γ‐valerolactone), allowed chemical recycling of high‐molecular‐weight poly(L‐lactic acid) directly to L‐lactide, within 1–4 h at 140 °C, with >95 % conversion and 98–99 % selectivity. Recycled L‐lactide was isolated and repolymerized with high control over molecular weight and dispersity, closing the polymer loop.

Flame-Retardant Properties and Mechanism of Polylactic Acid-Conjugated Flame-Retardant Composites

The DOPO derivative-conjugated flame retardant 4, 4'-{1'', 4'' - phenylene - bis [amino - (10‴ - oxy -10‴-hydro-9‴-hydrogen-10‴ λ⁵ -phosphaphenanthrene-10''-yl)-methyl]}-diphenol (P-PPD-Ph) with two hydroxyl groups was synthesized. Polylactic acid conjugated flame-retardant composites with P-PPD-Ph were papered by using a twin-screw extruder. The flame-retardant properties of polylactic acid-conjugated flame-retardant composites were investigated. The flame-retardant properties of PLA-conjugated flame-retardant composites were characterized by the limiting oxygen index (LOI) and the vertical burning test (UL94). The results showed that the PLA-conjugated flame-retardant composites achieved a V-0 rating (UL-94, 3.2 mm) when the conjugated flame retardant was added at 5 wt%, and increase in LOI value from 22.5% to 31.4% relative to composites without added conjugated flame retardant. The flame-retardant mechanism of PLA-conjugated flame-retardant composites were further studied by TG-FTIR, the results showed that the P-PPD-Ph promoted the PLA-conjugated flame-retardant composites to decompose and also released fragments with quenching and dilution, which suggests that P-PPD-Ph for PLA-conjugated flame-retardant composites mainly play a role of the gas-phase flame retardant.