Chemical Recycling of Polyethylene by Tandem Catalytic Conversion to Propylene

Exploring biotechnology for plastic recycling, degradation and upcycling for a sustainable future

The persistent demand for plastic commodities, inadequate recycling infrastructure, and pervasive environmental contamination due to plastic waste present a formidable global challenge. Recycling, degradation and upcycling are the three most important ways to solve the problem of plastic pollution. Sequential enzymatic and microbial degradation of mechanically and chemically pre-treated plastic waste can be orchestrated, followed by microbial conversion into value-added chemicals and polymers through mixed culture systems. Furthermore, plastics-degrading enzymes can be optimized through protein engineering to enhance their specific binding capacities, stability, and catalytic efficiency across a broad spectrum of polymer substrates under challenging high salinity and temperature conditions. Also, the production and formulation of enzyme mixtures can be fine-tuned to suit specific waste compositions, facilitating their effective deployment both in vitro, in vivo and in combination with chemical technologies. Here, we emphasized the comprehensive strategy leveraging microbial processes to transform mixed plastics of fossil-derived polymers such as PP, PE, PU, PET, and PS, most notably polyesters, in conjunction with potential biodegradable alternatives such as PLA and PHA. Any residual material resistant to enzymatic degradation can be reintroduced into the process loop following appropriate physicochemical treatment.

A Broad-Spectrum Catalyst for Aliphatic Polymer Breakdown

Thermolysis of the well-defined aluminum fluoroalkoxide supported on silica (≡SiOAl(OC(CF3)3)2(O(Si≡)2), 1, 0.20 mmolAl g-1) at 200 °C forms a fluorinated amorphous silica-alumina (F-ASA) containing a distribution of Al(IV), Al(V), and Al(VI) sites that maintain relatively strong Lewis acidity. Small amounts of Brønsted sites are also present in F-ASA. Solid-state NMR studies show that a majority of the aluminum centers in F-ASA are not close to the Si-F groups that form during thermolysis. F-ASA is exceptionally reactive in cracking (or pyrolysis) reactions of neat polymer melts. Catalyst loadings as low as 2 wt % (0.017 mol % aluminum) efficiently break down isotactic polypropylene, high-density polyethylene, ethylene/1-octene copolymer, and postconsumer wastes. The major products of this reaction are hyperbranched liquid paraffins containing internal olefins and very small amounts of aromatics. Under continuous distillation of oils from the reaction mixtures, pyrolysis on 50 g reaction scales is feasible. F-ASA cokes and deactivates during this reaction but can be reactivated by calcination in air. These properties are complementary to other state-of-the-art catalysts for polymer breakdown, but unlike those catalysts F-ASA does not require an additional cofed reactant (e.g., H2, olefin, etc.) to drive the reaction.

Advances and Challenges in Low-Temperature Upcycling of Waste Polyolefins via Tandem Catalysis

Polyolefin waste is the largest polymer waste stream that could potentially serve as an advantageous hydrocarbon feedstock. Upcycling polyolefins poses significant challenges due to their inherent kinetic and thermodynamic stability. Traditional methods, such as thermal and catalytic cracking, are straightforward but require temperatures exceeding 400 °C for complete conversion because of thermodynamic constraints. We summarize and critically compare recent advances in upgrading spent polyolefins and model reactants via kinetic (and thermodynamic) coupling of the endothermic C─C bond cleavage of polyolefins with exothermic reactions including hydrogenation, hydrogenolysis, metathesis, cyclization, oxidation, and alkylation. These approaches enable complete conversion to desired products at low temperatures (<300 °C). The goal is to identify challenges and possible pathways for catalytic conversions that minimize energy and carbon footprints.

Environmental impact, economic and carbon footprint assessment of end-of-life PVC flex banners and its potential upcycling opportunities in the fashion industry

This article employs life cycle assessment (LCA) using openLCA software to compare the environmental and economic indicators of upcycled fashion accessories made from end-of-life polyvinyl chloride (PVC) flex banners with those made from conventional materials like nylon and polyester. Six bags were designed, produced from end-of-life PVC flex banners, and compared to nylon and polyester fabric bags. Data related to the manufacturing process of these bags, including material usage, transport, and production, were analysed for comparison. The LCA results revealed that upcycled bags made from end-of-life PVC flex banners are more environmentally friendly than their nylon and polyester counterparts. Out of the 16 environmental impact categories analysed in the study, U-PVC bags were shown to have a lower impact in 12 categories: 1) fossil depletion, 2) freshwater ecotoxicity, 3) freshwater eutrophication, 4) marine ecotoxicity, 5) marine eutrophication, 6) ozone depletion, 7) particulate matter formation, 8) photochemical oxidant formation, 9) terrestrial acidification, 10) terrestrial ecotoxicity, 11) urban land occupation, and 12) water depletion. Moreover, the carbon footprint of U-PVC bags was 574.89 kg CO2 eq, which is lower than the carbon footprints of C-PA bags at 612.56 kg CO2 eq and C-PES bags at 609.76 kg CO2 eq. Additionally, the average manufacturing cost of U-PVC bags was £49.86, compared to £66.80 for C-PA bags and £67.09 for C-PES bags. This indicates that U-PVC bags are not only more environmentally sustainable but also more economical compared to C-PA and C-PES bags. Our research highlights the potential to upcycle end-of-life PVC flex banners into shoulder backpack bags, demonstrating the viability of PVC upcycling to reduce environmental impact.

Probing the Catalytic Degradation of Unsaturated Polyolefin Materials via Fe-Based Lewis Acids-Initiated Carbonyl-Olefin Metathesis

Degradation and recyclability of polymeric materials, including extensively used polyolefins, are becoming increasingly necessary. Chemically stable saturated polyolefin backbones make their degradation frustratingly challenging. The current effective strategy is to create cleavable defects, e.g., C═C double bonds along the backbone, and subsequently depolymerize them via cross-metathesis reaction with olefins. High-value chemicals or reusable polymeric segments are obtained. This two-step protocol provides operable means for alleviating plastics problems. There are several approaches to introduce unsaturation into a polymer backbone, like dehydrogenation or copolymerization of olefins and conjugated dienes. However, for the second step, to conduct a cross-metathesis reaction, only noble metal catalysts can be used most of the time. Regardless of their limited availability, the fact that these organometallics are unfavorably sensitive to impurities would raise barriers in industrial practices. Herein we employed earth-abundant and inexpensive iron-based Lewis acids to initiate carbonyl-olefin metathesis reactions between ketone/aldehyde reagents and unsaturated polyolefins. After explorations in poly(diene)s and industrial thermoplastic elastomers, we extended this protocol to degrade low-density polyethylene (LDPE). Low-molecular weight PE wax-like products were obtained as useful chemicals. This catalytic degradation system is expected to enable the development of more efficient metathesis strategies to promote degradation of polyolefins and pave sustainable ways for reuse of polymeric materials.

Sustainable Diesel from Rapeseed Oil Esters by Sequential Semi-Hydrogenation, Double Bond Isomerization, and Metathesis

Rapeseed oil methyl esters (RME) have been converted to biofuel with a boiling point curve that fulfills the EN 590 specifications for modern diesel engines using a robust, three-step process. In the first step, the polyunsaturated esters of the RME were semi-hydrogenated in the presence of 20 ppm of a solvent-stabilized Pd0 colloid. The resulting mono-unsaturated fatty esters were further converted into a defined mixture of double-bond isomers by passing them over inexpensive, Brønsted-acidic Amberlyst 15 resin at high space-time yields (1.3 kg⋅L-1⋅h-1). The resulting mixture was then converted into a blend of terminally unsaturated olefins and monoesters, with <4.9 % diesters and <21 % saturated fatty esters by cross-metathesis with technical-grade ethylene. In this step, 50 ppm of a cyclic alkyl amino carbene (CAAC) Ru catalyst M1001 was used to achieve record-setting conversions (91 %) and selectivities (94 %). All three steps were conducted with neat feedstock at mild temperatures (60-100 °C). This demonstrates that sustainable diesel fuel for use in contemporary diesel engines is accessible from RME and ethylene via a short set of industrially viable reaction steps.

Ruthenium-Catalyzed Deconstruction of Polyolefins: A Strategy to Up-cycle Waste Polyethylene to Value-Added Alkene

Synthesis of value-added products from post-consumer waste polyolefins is fascinating as well as challenging. Here we report ruthenium-catalyzed up-cycling of the polyethylene to long-chain alkene derivatives. The developed methodology mainly involves two steps i.e., dehydrogenation of polyethylene through hydrogen atom transfer and its metathesis using the HG-II catalyst. The dehydrogenation of polyethylene using ruthenium catalysis derived up to 3.38 %, of double bonds; with 90 % of the recovered polyolefin material. The obtained unsaturated polyethylene was subjected to cross-metathesis with ethylene using HG-II catalytic system. This resulted in the synthesis of predominantly dodecene (C12) derivatives, with 58 % selectivity, along with other derivatives of varying chain lengths. The overall reaction produced terminal and internal olefins in the ratio 1:0.8 respectively. The dehydrogenation of polyethylene and its deconstruction was confirmed by NMR spectroscopy, Gel Permeation Chromatography (GPC) and Differential Scanning Calorimetry (DSC). The origin of C12 selectivity has been demonstrated by control experiments. The scope of the methodology was extended to post-consumer waste polyethylene which gave high conversion to value-added dodecene derivatives as a major product.

Highly adaptable oxidative upcycling of polyolefins to multifunctional chemicals containing oxygen and nitrogen

Highly adaptable upcycling of waste polyolefins was demonstrated to obtain high-value nitro-containing polycarboxylic acids in high carbon yields. This method is applicable to a wide range of polyolefins, mixed PP/PE in any ratio, as well as actual polyolefin products and their mixtures. Moreover, the obtained products are homogenized with similarity in molecular weight and functional groups, enabling direct reutilization as fine chemicals or feedstocks for preparation of recyclable high-performance/functional materials. This work provided a new universal and efficient upcycling strategy for waste polyolefins, which may reshape the model of waste plastics recycling, while providing alternative functional chemicals and materials to achieve sustainable development.

Optimization of low-temperature catalytic cracking of polyolefin waste in open-batch reactors using zeolite beta with controlled intrinsic properties

Environmental problems are worsening due to the complexity in managing plastic waste. Chemical recycling emerges as a pivotal technology that can suppress carbon introduction into the carbon cycle and provide petroleum alternatives for current petrochemical processes. The utilization of zeolites can reduce energy consumption by lowering the operation temperature for pyrolysis. Here, we demonstrate low-temperature catalytic cracking of polyethylene (PE) utilizing an open-batch reactor configuration and *BEA-type zeolite catalysts. With the optimized open-batch setup and zeolites, high PE conversion (~80%) and liquid selectivity (~70%) were achieved at 330 °C. We systematically explored the effects of aluminum (Al) site density and crystal size, revealing that zeolite crystal size is another critical factor determining the liquid production. This work not only demonstrates that an effective combination and optimization of reactor and catalysts can enhance the overall catalytic activity but also offers insights into designing catalysis systems for effective recycling of polyolefin wastes.

Emerging Biochemical Conversion for Plastic Waste Management: A Review

In recent years, vast amounts of plastic waste have been released into the environment worldwide, posing a severe threat to human health and ecosystems. Despite the partial success of traditional plastic waste management technologies, their limitations underscore the need for innovative approaches. This review provides a comprehensive overview of recent advancements in chemical and biological technologies for converting and utilizing plastic waste. Key topics include the technical parameters, characteristics, processes, and reaction mechanisms underlying these emerging technologies. Additionally, the review highlights the importance of conducting economic analyses and life cycle assessments of these emerging technologies, offering valuable insights and establishing a robust foundation for future research. By leveraging the literature from the last five years, this review explores innovative chemical approaches, such as hydrolysis, hydrogenolysis, alcoholysis, ammonolysis, pyrolysis, and photolysis, which break down high-molecular-weight macromolecules into oligomers or small molecules by cracking or depolymerizing specific chemical groups within plastic molecules. It also examines innovative biological methods, including microbial enzymatic degradation, which employs microorganisms or enzymes to convert high-molecular-weight macromolecules into oligomers or small molecules through degradation and assimilation mechanisms. The review concludes by discussing future research directions focused on addressing the technological, economic, and scalability challenges of emerging plastic waste management technologies, with a strong commitment to promoting sustainable solutions and achieving lasting environmental impact.

Depolymerization by transition metal complexes: strategic approaches to convert polymeric waste into feedstocks

At present, plastic pollution is a global environmental catastrophe and a major threat to mankind. Moreover, the increasing manufacture of various plastic products is causing rapid depletion of precious resources. Thus, transforming plastic waste into feedstock, which can maintain a circular economy, has emerged as a significant technique for waste management and carbon resource conservation. Furthermore, the urgent development of effective depolymerization methods is vital to save our planet from man-made plastic pollution. Among various chemical depolymerization techniques developed thus far, cleavage of the polymeric skeleton by transition metal complexes is a highly emerging, effective and exciting strategy. In this context, herein, we have summarized mechanistic approaches for cleaving various polymeric bonds using organometallic catalysts. The recently developed strategies, catalyst design and mechanisms for depolymerization of synthetic and natural polymers with polar (C-N, C-O, C-Cl, and Si-O) and non-polar (C-C) skeletal bonds are systematically discussed in detail.

Room Temperature Ethene to Propene (ETP) Tandem Catalysis using Single Crystalline Solid-State Molecular Pre-Catalysts

A tandem catalytic ensemble of solid-state molecular organometallic (SMOM) crystalline pre-catalysts are deployed under batch or flow conditions for the ethene to propene process (ETP). These catalysts operate at ambient temperature and low pressure, via sequential ethene dimerization, butenes isomerization and cross-metathesis. Under flow conditions the on-stream ethene conversion (55 %), initial propene selectivity (92 %), stability (71 % selectivity after 7 h) and low temperature/pressures are competitive with the best-in-class heterogeneous systems, marking a new, in crystallo, approach to ETP.

In-Situ Thermometry Reveals Fragmentation Behavior Based on Local Temperature in α-Olefin Polymerization Catalysts

Typical industrial olefin polymerization processes to produce both commodity and specialty polyolefin grades are mainly based on spherical, heterogeneous catalyst particles. During α-polymerization, heat from the exothermic reaction and pressure induced by the growing polymer chains on the catalyst particle lead to fragmentation, revealing active sites for further polymerization. To study these phenomena precisely and in-depth, we utilized a Nd-doped LaOCl-supported metallocene model system. This model catalyst can accurately display fluctuations in temperature with luminescence thermometry. During mild gas phase prepolymerization conditions, we observed a temperature difference of +43 °C and link this to the exothermicity of the ethylene polymerization reaction. In addition, the fragmentation behavior of the model catalyst was accurately monitored. The shell feature of the catalyst ruptured layer-by-layer, while the inner core fragmented via a bisectional fragmentation mechanism. We demonstrated that it is possible to probe the individual temperatures of multiple catalyst support particles within the field-of-view of the probe. This was correlated to structural changes and kinetics in an α-olefin polymerization catalyst. This powerful toolbox could be applied to different heterogeneous catalytic systems to correlate the temperature profile with morphological evolution.

Anionic Surfactants from Reactive Separation of Hydrocarbons Derived from Polyethylene Upcycling

Chemical upcycling of polyethylene (PE) to long-chain alkylaromatics through tandem hydrocracking/aromatization has potential to provide value-added chemicals. However, the liquid product is a complex mixture of alkanes, alkylbenzenes, and polyaromatics, limiting its direct usability. The most valuable component of the product mixture is the alkylbenzenes because of their potential as precursors to anionic surfactants. In this study, a one-pot reactive separation is described. Sulfonating the product mixture from PE upcycling with silica sulfuric acid followed by neutralization with sodium hydroxide yields sodium alkylbenzenesulfonates (up to 93 mol % selectivity), along with a separate phase of lubricant-range hydrocarbons as a coproduct. Compared to petroleum-based sodium dodecylbenzenesulfonates, the reported PE-derived surfactant molecules show competitive physicochemical properties, including surface tension and interfacial tension. According to life cycle assessment, the described reaction strategy demonstrates 20% lower greenhouse gas emissions, when considering uses for the coproducts of PE upcycling, compared to conventional linear alkylbenzenesulfonates (LAS) manufacturing directly from petrochemical feedstocks.

Tailoring the Properties of Chemically Recyclable Polyethylene-Like Multiblock Polymers by Modulating the Branch Structure

Developing plastics that fill the need of polyolefins yet are more easily recyclable is a critical need to address the plastic waste crisis. However, most efforts in this vein have focused on high-density polyethylene (PE), while many different types of PE exist. To create broadly sustainable PE with modular properties, we present the synthesis, characterization, and demonstration of materials applications for chemically recyclable PE-like multiblock polymers prepared from distinct hard and soft blocks using ruthenium-catalyzed dehydrogenative polymerization. By altering the branching pattern within the soft blocks, a series of PE-like multiblock polymers were synthesized with tunable glass transition temperatures (Tg) while maintaining consistent high melting temperatures (Tm). A clear U-shape trend between Tg and mechanical properties was found, showcasing their potential as sustainable materials with tailored properties spanning commercial linear low-density polyethylene (LLDPE) and low-density polyethylene (LDPE). These materials offer adjustable adhesive strength to metal and demonstrate chemical recyclability and selective depolymerization in mixed plastic streams, promoting circularity and separation.

Synthesis of Polyamides Bearing Directing Groups and Their Catalytic Depolymerization

We report a directing group (DG)-enabled strategy for polyamide depolymerization. Pyridine-based DGs selectively interact with In(III) catalysts, activating amide bonds for catalytic cleavage via alcoholysis. The process achieves efficient depolymerization of DG-introduced polyamides into recyclable monomers, providing a sustainable chemical recycling approach for robust polyamides.

Upcycling Polyethylene to High-Purity Hydrogen under Ambient Conditions via Mechanocatalysis

Polyethylene (PE) is the most abundant plastic waste, and its conversion to hydrogen (H2) offers a promising route for clean energy generation. However, PE decomposition typically requires high temperatures due to its strong chemical bonds, leading to significant carbon emissions and low H2 selectivity (theoretically less than 75 vol % after accounting for further steam-reforming reactions). Here, we report a mechanocatalytic strategy that upcycles PE into high-purity H2 (99.4 vol %) with an exceptional H2 recovery ratio of 98.5 % (versus 15.7 % via thermocatalysis), using manganese as a catalyst at a low temperature of 45 °C. This method achieves a reaction rate 3 orders of magnitude higher than thermocatalysis. The marked improvement in H2 recovery ratio is mainly due to metal carbides formation induced by the mechanocatalytic process, which does not catalyze hydrocarbons formation. This work is expected to advance studies of the conversion of polyolefins to high-purity H2 with net-zero carbon emissions.

Heterogeneous catalysis strategies for polyolefin plastic upcycling: co-reactant-assisted and direct transformation under mild conditions

The large-scale production and inadequate disposal of polyolefin (PO) plastics pose significant environmental challenges. Traditional recycling methods are energy-intensive and often ineffective, prompting a need for more sustainable approaches. In recent years, catalytic upcycling under mild conditions has emerged as a promising strategy to transform PO plastics into valuable products. Co-reactants such as hydrogen, short-chain alkanes or alkenes, oxygen, and CO2 play a crucial role in driving these transformations, influencing reaction mechanisms and broadening the range of possible products. This review categorizes recent advancements in PO plastic upcycling based on the type of co-reactant employed and compares these with direct, co-reactant-free processes. Despite these advances, challenges remain in improving catalytic stability, product selectivity, and overcoming diffusion limitations in viscous plastic feedstocks. This review underscores the catalytic chemistry underpinning the development of efficient PO plastic upcycling processes with co-reactants, offering insights into future directions for sustainable plastic chemical management.

Chemical transformation of polyurethane into valuable polymers

Polyurethanes are an important class of synthetic polymers, widely used in a variety of applications ranging from everyday items to advanced tools in societal infrastructure. Their inherent cross-linked structure imparts exceptional durability and flexibility, yet this also complicates their degradation and recycling. Here we report a heterogeneous catalytic process that combines methanolysis and hydrogenation with a CO2/H2 reaction medium, effectively breaking down PU waste consisting of urethane and ester bonds into valuable intermediates like aromatic diamines and lactones. These intermediates are then converted into functional polymers: polyimide (PI), noted for its exceptional thermal and electrical insulation, and polylactone (P(BL-co-CL)), a biodegradable alternative to traditional plastics. Both polymers exhibit enhanced performance compared to existing commercial products. This approach not only contributes to the valorization of plastic waste but also opens new avenues for the creation of high-performance materials.

Recent Progress in Polyolefin Plastic: Polyethylene and Polypropylene Transformation and Depolymerization Techniques

This paper highlights the complexity and urgency of addressing plastic pollution, drawing attention to the environmental challenges posed by improperly discarded plastics. Petroleum-based plastic polymers, with their remarkable range of physical properties, have revolutionized industries worldwide. Their versatility-from flexible to rigid and hydrophilic to hydrophobic-has fueled an ever-growing demand. However, their versatility has also contributed to a massive global waste problem as plastics pervade virtually every ecosystem, from the depths of oceans to the most remote terrestrial landscapes. Plastic pollution manifests not just as visible waste-such as fishing nets, bottles, and garbage bags-but also as microplastics, infiltrating food chains and freshwater sources. This crisis is exacerbated by the unsustainable linear model of plastic production and consumption, which prioritizes convenience over long-term environmental health. The mismanagement of plastic waste not only pollutes ecosystems but also releases greenhouse gases like carbon dioxide during degradation and incineration, thereby complicating efforts to achieve global climate and sustainability goals. Given that mechanical recycling only addresses a fraction of macroplastics, innovative approaches are needed to improve this process. Methods like pyrolysis and hydrogenolysis offer promising solutions by enabling the chemical transformation and depolymerization of plastics into reusable materials or valuable chemical feedstocks. These advanced recycling methods can support a circular economy by reducing waste and creating high-value products. In this article, the focus on pyrolysis and hydrogenolysis underscores the need to move beyond traditional recycling. These methods exemplify the potential for science and technology to mitigate plastic pollution while aligning with sustainability objectives. Recent advances in the pyrolysis and hydrogenolysis of polyolefins focus on their potential for advanced recycling, breaking down plastics at a molecular level to create feedstocks for new products or fuels. Pyrolysis produces pyrolysis oil and syngas, with applications in renewable energy and chemicals. However, some challenges of this process include scalability, feedstock variety, and standardization, as well as environmental concerns about emissions. Companies like Shell and ExxonMobil are investing heavily to overcome these barriers and improve recycling efficiencies. By leveraging these transformative strategies, we can reimagine the lifecycle of plastics and address one of the most pressing environmental challenges of our time. This review updates the knowledge of the fields of pyrolysis and hydrogenolysis of plastics derived from polyolefins based on the most recent works available in the literature, highlighting the techniques used, the types of products obtained, and the highest yields.

Polyethylene hydrogenolysis by dilute RuPt alloy to achieve H2-pressure-independent low methane selectivity

Chemical recycling of plastic waste could reduce its environmental impact and create a more sustainable society. Hydrogenolysis is a viable method for polyolefin valorization but typically requires high hydrogen pressures to minimize methane production. Here, we circumvent this stringent requirement using dilute RuPt alloy to suppress the undesired terminal C-C scission under hydrogen-lean conditions. Spectroscopic studies reveal that PE adsorption takes place on both Ru and Pt sites, yet the C-C bond cleavage proceeds faster on Ru site, which helps avoid successive terminal scission of the in situ-generated reactive intermediates due to the lack of a neighboring Ru site. Different from previous research, this method of suppressing methane generation is independent of H2 pressure, and PE can be converted to fuels and waxes/lubricant base oils with only <3.2% methane even under ambient H2 pressure. This advantage would allow the integration of distributed, low-pressure hydrogen sources into the upstream of PE hydrogenolysis and provide a feasible solution to decentralized plastic upcycling.

Hydroaminoalkylation for Amine Functionalization of Vinyl-Terminated Polyethylene Enables Direct Access to Responsive Functional Materials

While functionalized polyethylenes (PEs) exhibit valuable characteristics, the constraints of existing synthetic approaches limit the variety of readily incorporated functionality. New methods to generate functionalized PEs are required to afford new applications of this common material. We report 100 % atom economic tantalum-catalyzed hydroaminoalkylation of vinyl-terminated polyethylene (VTPE) as a method to produce amine-terminated PE. VTPEs with molecular weights between 2200-16800 g/mol are successfully aminated using solvent-free conditions. Our catalytic system is efficient for the installation of both aromatic and aliphatic amines, and can be carried out on multigram scale. The associating amine functional groups afford modified material properties, as measured by water contact angle, differential scanning calorimetry (DSC) and polymer rheology. The basic amine functionality offers the opportunity to convert inert PE into stimuli-responsive materials, such that the protonation of aminated PE affords the generation of functional antibacterial PE films.

Synergistic catalysis for promoting selective C-C/C-O cleavage in plastic waste: structure-activity relationship and rational design of heterogeneous catalysts for liquid hydrocarbon production

Ever-increasing consumption of plastic products and poor waste management infrastructure have resulted in a massive accumulation of plastic waste in environments, causing adverse effects on climate and living organisms. Although contributing ∼10% towards the total plastic waste management infrastructure, the chemical recycling of plastic waste is considered a viable option to valorize plastic waste into platform chemicals and liquid fuels. Among the various chemical upcycling processes, catalytic hydroprocessing has attracted interest due to its potential to offer higher selectivity than other thermal-based approaches. Heterogeneous catalytic hydroprocessing reactions offer routes for converting plastic waste into essential industrially important molecules. However, the functional group similarities in the plastic polymers frequently constrain reaction selectivity. Therefore, a fundamental understanding of metal selection for targeted bond activation and plastic interaction on solid surfaces is essential for catalyst design and reaction engineering. In this review, we critically assess the structure-activity relationship of catalysts used in the hydroprocessing of plastic waste for the selective production of liquid hydrocarbons. We discuss the significance of C-C/C-O bond activation in plastic waste through active site modulation and surface modification to elucidate reaction networks and pathways for achieving selective bond activation and cleavage. Finally, we highlight current challenges and future opportunities in catalyst design to upcycle real-life plastic waste and produce selective liquid hydrocarbons.

Selective Upcycling of Polyolefins into High-Value Nitrogenated Chemicals

The selective upcycling of polyolefins to create products of increased value has emerged as an innovative approach to carbon resource stewardship, drawing significant scientific and industrial interest. Although recent advancements in recycling technology have facilitated the direct conversion of polyolefins to hydrocarbons or oxygenated compounds, the synthesis of nitrogenated compounds from such waste polyolefins has not yet been disclosed. Herein, we demonstrate a novel approach for the upcycling of waste polyolefins by efficiently transforming a range of postconsumer plastic products into nitriles and amides. This process leverages the catalytic properties of manganese dioxide in combination with an inexpensive nitrogen source, urea, to make it both practical and economically viable. Our approach not only opens new avenues for the creation of nitrogenated chemicals from polyolefin waste but also underscores the critical importance of recycling and valorizing carbon resources originally derived from fossil fuels. This study provides a new upcycling strategy for the sustainable conversion of waste polyolefins.

Installing a Trigger to Upcycle High-Density Polyethylene

Creating C═C bonds as "weak" sites in the stable C-C chains of polyethylene (PE) is an appealing strategy to promote sustainable development of the polyolefin industry. Compared to methods, such as dehydrogenation and postpolymerization modification, the copolymerization of ethylene (E) and butadiene (BD) should be a convenient and direct approach to introduce C═C bonds in PE, whereas it encounters problems in controlling the composition and regularity of the copolymer due to the mismatched activities and mechanisms between the two monomers. Herein, we report by employing the amidinate gadolinium complex, controllable E/BD copolymerization was achieved, where BD was incorporated in the uniformly discrete 1,4 mode. The obtained copolymer possesses the same physical, mechanical, processing, and antioxygen (aging at 100 °C for 28 days) properties as commercial high-density-PE, which, strikingly, were degraded by C═C bonds into α,ω-telechelic oligomers with narrow distribution. These degraded functional products were transferred to compatibilizers via atom-transfer radical polymerization or immortal ring-opening polymerization, achieving upcycling.

Controlled degradation of chemically stable poly(aryl ethers) via directing group-assisted catalysis

To establish a sustainable society, the development of polymer materials capable of reverting into monomers on demand is crucial. Traditional methods rely on breaking labile bonds such as esters in the main chain, which limits applicability to polymers that consist of robust covalent bonds. We found that the integration of directing groups allowed the engineering of resilient polymers with built-in recyclability. Our study showcases phenylene ether-based polymers fortified with directing groups, which can be selectively disassembled under nickel catalysts via selective cleavage of carbon-oxygen bonds. Notably, these polymers exhibit exceptional chemical stability towards acids, bases, and oxidizing agents, while being degradable to well-defined, repolymerizable molecules in the presence of a catalyst. Our findings allow for the development of next-generation polymer materials that are chemically recyclable by design.

Surface-Activated Mechano-Catalysis for Ambient Conversion of Plastic Waste

Improved recycling technologies can offer sustainable end-of-life options for plastic waste. While polyolefins can be converted into small hydrocarbons over acid catalysts at high temperatures, we demonstrate an alternative mechano-catalytic strategy at ambient conditions. The mechanism is fundamentally different from classical acidity-driven high-temperature approaches, exploiting mechanochemically generated radical intermediates. Surface activation of zirconia grinding spheres creates redox active surface sites directly at the point of mechanical energy input. This allows control over mechano-radical reactivity, while powder catalysts are not active. Optimized milling parameters enable the formation of 45% C1-10 hydrocarbons from polypropylene within 1 h at ambient temperature. While mechanochemical bond scission is undesired in plastic production, we show that it can also be exploited for chemical recycling.

Polyolefin waste to light olefins with ethylene and base-metal heterogeneous catalysts

The selective conversion of polyethylene (PE), polypropylene (PP), and mixtures of these two polymers to form products with high volume demand is urgently needed because current methods suffer from low selectivity, produce large quantities of greenhouse gases, or rely on expensive, single-use catalysts. The isomerizing ethenolysis of unsaturated polyolefins could be an energetically and environmentally viable route to propylene and isobutylene; however, noble-metal homogeneous catalysts and an unsaturated polyolefin are currently required and the process has been limited to PE. We show that the simple combination of tungsten oxide on silica and sodium on gamma-alumina transforms PE, PP, or a mixture of the two, including postconsumer forms of these materials, to propylene or a mixture of propylene and isobutylene in greater than 90% yield at 320°C without the need for dehydrogenation of the starting polyolefins.

Multi-Catalytic Metal-Based Homogeneous-Heterogeneous Systems in Organic Chemistry

The combination of metal-based homogeneous and heterogeneous catalysts in the same reaction media is a powerful, yet relatively unexplored approach in organic chemistry. This strategy can address important limitations associated with purely homogeneous or heterogeneous catalysis such as the incompatibility of different catalytic species in solution, or the limited tunability of solid catalysts, respectively. Moreover, the facile reusability of the solid catalyst, contributes to increase the overall sustainability of the process. As a result, this semi-heterogeneous multi-catalytic approach has unlocked significant advances in organic chemistry, improving existing reactions and even enabling the discovery of novel transformations, exemplified by the formal alkane metathesis. This concept article aims to showcase the benefits of this strategy through the exploration of diverse relevant examples from the literature, hoping to spur research on new metal-based homogeneous-heterogeneous catalyst combinations that will result in reactivity challenging to achieve by conventional homogeneous or heterogeneous catalysis alone.

Catalytic Upcycling of Polyolefins

The large production volumes of commodity polyolefins (specifically, polyethylene, polypropylene, polystyrene, and poly(vinyl chloride)), in conjunction with their low unit values and multitude of short-term uses, have resulted in a significant and pressing waste management challenge. Only a small fraction of these polyolefins is currently mechanically recycled, with the rest being incinerated, accumulating in landfills, or leaking into the natural environment. Since polyolefins are energy-rich materials, there is considerable interest in recouping some of their chemical value while simultaneously motivating more responsible end-of-life management. An emerging strategy is catalytic depolymerization, in which a portion of the C-C bonds in the polyolefin backbone is broken with the assistance of a catalyst and, in some cases, additional small molecule reagents. When the products are small molecules or materials with higher value in their own right, or as chemical feedstocks, the process is called upcycling. This review summarizes recent progress for four major catalytic upcycling strategies: hydrogenolysis, (hydro)cracking, tandem processes involving metathesis, and selective oxidation. Key considerations include macromolecular reaction mechanisms relative to small molecule mechanisms, catalyst design for macromolecular transformations, and the effect of process conditions on product selectivity. Metrics for describing polyolefin upcycling are critically evaluated, and an outlook for future advances is described.

A Merger of Relay Catalysis with Dynamic Kinetic Resolution Enables Enantioselective β-C(sp3)-H Arylation of Alcohols

The conceptual merger of relay catalysis with dynamic kinetic resolution strategy is reported to enable regio- and enantioselective C(sp3)-H bond arylation of aliphatic alcohols, forming enantioenriched β-aryl alcohols typically with >90 : 10 enantiomeric ratios (up to 98 : 2 er) and 36-74 % yields. The starting materials bearing neighbouring stereogenic centres can be converted to either diastereomer of the β-aryl alcohol products, with >85 : 15 diastereomeric ratios determined by the catalysts. The reactions occur under mild conditions, ensuring broad compatibility, and involve readily available aryl bromides, an inorganic base, and commercial Ru- and Pd-complexes. Mechanistic experiments support the envisioned mechanism of the transformation occurring through a network of regio- and stereoselective processes operated by a coherent Ru/Pd-dual catalytic system.

Industrial and Laboratory Technologies for the Chemical Recycling of Plastic Waste

Synthetic polymers play an indispensable role in modern society, finding applications across various sectors ranging from packaging, textiles, and consumer products to construction, electronics, and industrial machinery. Commodity plastics are cheap to produce, widely available, and versatile to meet diverse application needs. As a result, millions of metric tons of plastics are manufactured annually. However, current approaches for the chemical recycling of postconsumer plastic waste, primarily based on pyrolysis, lag in efficiency compared to their production methods. In recent years, significant research has focused on developing milder, economically viable methods for the chemical recycling of commodity plastics, which involves converting plastic waste back into monomers or transforming it into other valuable chemicals. This Perspective examines both industrial and cutting-edge laboratory-scale methods contributing to recent advancements in the field of chemical recycling.

Oxidative Upcycling of Polyethylene to Long Chain Diacid over Co-MCM-41 Catalyst

Plastic pollution is an emerging global threat due to lack of effective methods for transforming waste plastics into useful resources. Here, we demonstrate a direct oxidative upcycling of polyethylene into high-value and high-volume saturated dicarboxylic acids in high carbon yield of 85.9 % in which the carbon yield of long chain dicarboxylic (C10-C20) acids can reach 58.9% over cobalt-doped MCM-41 molecular sieves, in the absence of any solvent or precious metal catalyst. The distribution of the dicarboxylic acids can be controllably adjusted from short-chain (C4-C10) to long-chain ones (C10-C20) through changing cobalt loading of MCM-41 under nanoconfinement. Highly and sparsely dispersed cobalt along with confined space of mesoporous structure enables complete degradation of polyethylene and high selectivity of dicarboxylic acid in mild condition. So far, this is the first report on highly selective one-step preparation of long chain dicarboxylic acids. The approach provides an attractive solution to tackle plastic pollution and a promising alternative route to long chain diacids.

Circular Melt-Spun Textile Fibers from Polyethylene-like Long-Chain Polyesters

As textiles contribute considerably to overall anthropogenic pollution and resource consumption, increasing their circularity is essential. We report the melt-spinning of long-chain polyesters, materials recently shown to be fully chemically recyclable under mild conditions, as well as biodegradable. High-quality uniform fibers are enabled by the polymers' favorable combination of thermal stability, crystallization ability, melt strength, and homogeneity. The polyethylene-like crystalline structure endows these fibers with mechanical strength, which is further enhanced by its orientation upon drawing (tensile strength of up to 270 MPa). In vitro depolymerization by high concentrations of Humicola insolens cutinase underlines the accessibility of the fibers for enzymatic degradation, which can proceed from the surface and through the entire fiber within days, depending on the choice of the fiber material. Fibers and knitted fabrics withstand stress, as encountered in machine washing.

Polyoxymethylene Upcycling into Methanol and Methyl Groups Catalyzed by a Manganese Pincer Complex

Polyoxymethylene (POM) is a commonly used engineering thermoplastic, but its recycling by conventional means, i.e., mechanical recycling, is not practiced to any meaningful extent, due to technical limitations. Instead, waste POM is typically incinerated or disposed in landfills, where it becomes a persistent environmental pollutant. An attractive alternative to mechanical recycling is upcycling, namely, the conversion of waste POM into value-added chemicals, but this has received very little attention. Herein, we report the upcycling of POM into useful chemicals through three different reactions, all of which are efficiently catalyzed by a single pincer complex of earth-abundant manganese. One method involves hydrogenation of POM into methanol using H2 gas as the only reagent, whereas another method converts POM into methanol and CO2 through a one-pot process comprising acidolysis followed by Mn-catalyzed disproportionation. The third method utilizes POM as a reagent for the methylation of ketones and amines.

Lifecycle Management for Sustainable Plastics: Recent Progress from Synthesis, Processing to Upcycling

Plastics, renowned for their outstanding properties and extensive applications, assume an indispensable and irreplaceable role in modern society. However, the ubiquitous consumption of plastic items has led to a growing accumulation of plastic waste. Unreasonable practices in the production, utilization, and recycling of plastics have led to substantial energy resource depletion and environmental pollution. Herein, the state-of-the-art advancements in the lifecycle management of plastics are timely reviewed. Unlike typical reviews focused on plastic recycling, this work presents an in-depth analysis of the entire lifecycle of plastics, covering the whole process from synthesis, processing, to ultimate disposal. The primary emphasis lies on selecting judicious strategies and methodologies at each lifecycle stage to mitigate the adverse environmental impact of waste plastics. Specifically, the article delineates the rationale, methods, and advancements realized in various lifecycle stages through both physical and chemical recycling pathways. The focal point is the attainment of optimal recycling rates for waste plastics, thereby alleviating the ecological burden of plastic pollution. By scrutinizing the entire lifecycle of plastics, the article aims to furnish comprehensive solutions for reducing plastic pollution and fostering sustainability across all facets of plastic production, utilization, and disposal.

Mild Catalytic Degradation of Crystalline Polyethylene Units in a Solid State Assisted by Carboxylic Acid Groups

Crystalline polyethylenes bearing carboxylic acid groups in the main chain were successfully degraded with a Ce catalyst and visible light. The reaction proceeds in a crystalline solid state without swelling in acetonitrile or water at a reaction temperature as low as 60 or 80 °C, employing dioxygen in air as the only stoichiometric reactant with nearly quantitative recovery of carbon atoms. Heterogeneous features of the reaction allowed us to reveal a dynamic morphological change of polymer crystals during the degradation.

Active species in chloroaluminate ionic liquids catalyzing low-temperature polyolefin deconstruction

Chloroaluminate ionic liquids selectively transform (waste) polyolefins into gasoline-range alkanes through tandem cracking-alkylation at temperatures below 100 °C. Further improvement of this process necessitates a deep understanding of the nature of the catalytically active species and the correlated performance in the catalyzing critical reactions for the tandem polyolefin deconstruction with isoalkanes at low temperatures. Here, we address this requirement by determining the nuclearity of the chloroaluminate ions and their interactions with reaction intermediates, combining in situ 27Al magic-angle spinning nuclear magnetic resonance spectroscopy, in situ Raman spectroscopy, Al K-edge X-ray absorption near edge structure spectroscopy, and catalytic activity measurement. Cracking and alkylation are facilitated by carbenium ions initiated by AlCl3-tert-butyl chloride (TBC) adducts, which are formed by the dissociation of Al2Cl7- in the presence of TBC. The carbenium ions activate the alkane polymer strands and advance the alkylation cycle through multiple hydride transfer reactions. In situ 1H NMR and operando infrared spectroscopy demonstrate that the cracking and alkylation processes occur synchronously; alkenes formed during cracking are rapidly incorporated into the carbenium ion-mediated alkylation cycle. The conclusions are further supported by ab initio molecular dynamics simulations coupled with an enhanced sampling method, and model experiments using n-hexadecane as a feed.

Recycling polyolefin plastic waste at short contact times via rapid joule heating

The chemical deconstruction of polyolefins to fuels, lubricants, and waxes offers a promising strategy for mitigating their accumulation in landfills and the environment. Yet, achieving true recyclability of polyolefins into C2-C4 monomers with high yields, low energy demand, and low carbon dioxide emissions under realistic polymer-to-catalyst ratios remains elusive. Here, we demonstrate a single-step electrified approach utilizing Rapid Joule Heating over an H-ZSM-5 catalyst to efficiently deconstruct polyolefin plastic waste into light olefins (C2-C4) in milliseconds, with high productivity at much higher polymer-to-catalyst ratio than prior work. The catalyst is essential in producing a narrow distribution of light olefins. Pulsed operation and steam co-feeding enable highly selective deconstruction (product fraction of >90% towards C2-C4 hydrocarbons) with minimal catalyst deactivation compared to Continuous Joule Heating. This laboratory-scale approach demonstrates effective deconstruction of real-life waste materials, resilience to additives and impurities, and versatility for circular polyolefin plastic waste management.

Deconstruction of Polymers through Olefin Metathesis

The consumption of synthetic polymers has ballooned; so has the amount of post-consumer waste generated. The current polymer economy, however, is largely linear with most of the post-consumer waste being either landfilled or incinerated. The lack of recycling, together with the sizable carbon footprint of the polymer industry, has led to major negative environmental impacts. Over the past few years, chemical recycling technologies have gained significant traction as a possible technological route to tackle these challenges. In this regard, olefin metathesis, with its versatility and ease of operation, has emerged as an attractive tool. Here, we discuss the developments in olefin-metathesis-based chemical recycling technologies, including the development of new materials and the application of olefin metathesis to the recycling of commercial materials. We delve into structure-reactivity relationships in the context of polymerization-depolymerization behavior, how experimental conditions influence deconstruction outcomes, and the reaction pathways underlying these approaches. We also look at the current hurdles in adopting these technologies and relevant future directions for the field.

Structural Design of Single-Atom Catalysts for Enhancing Petrochemical Catalytic Reaction Process

Petroleum, as the "lifeblood" of industrial development, is the important energy source and raw material. The selective transformation of petroleum into high-end chemicals is of great significance, but still exists enormous challenges. Single-atom catalysts (SACs) with 100% atom utilization and homogeneous active sites, promise a broad application in petrochemical processes. Herein, the research systematically summarizes the recent research progress of SACs in petrochemical catalytic reaction, proposes the role of structural design of SACs in enhancing catalytic performance, elucidates the catalytic reaction mechanisms of SACs in the conversion of petrochemical processes, and reveals the high activity origins of SACs at the atomic scale. Finally, the key challenges are summarized and an outlook on the design, identification of active sites, and the appropriate application of artificial intelligence technology is provided for achieving scale-up application of SACs in petrochemical process.

Recent Progresses and Challenges in Upcycling of Plastics through Selective Catalytic Oxidation

Chemical upcycling of plastics provides an important direction for solving the challenging issues of plastic pollution and mitigating the wastage of carbon resources. Among them, catalytic oxidative cracking of plastics to produce high-value chemicals, such as catalytic oxidation of polyethylene (PE) to produce fatty dicarboxylic acids, catalytic oxidation of polystyrene (PS) to produce benzoic acid, and catalytic oxidation of polyethylene terephthalate (PET) to produce terephthalic acid under mild conditions has attracted increasing attention, and some exciting progress has been made recently. In this article, we will review recent progresses on the catalytic oxidation upcycling of plastics and provide our understanding on the current challenges in catalytic oxidation upcycling of plastics.

iPP/HDPE blends compatibilized by a polyester: An unconventional concept to valuable products

Polyolefins are the most widely used plastics accounting for a large fraction of the polymer waste stream. Although reusing polyolefins seems to be a logical choice, their recycling level remains disappointingly low. This is mainly due to the lack of large-scale availability of efficient and inexpensive compatibilizers for mixed polyolefin waste, typically consisting of high-density polyethylene (HDPE) and isotactic polypropylene (iPP) that, despite their similar chemical hydrocarbon structure, are immiscible. Here, we describe an unconventional approach of using polypentadecalactone, a straightforward and simple-to-produce aliphatic polyester, as a compatibilizer for iPP/HDPE blends, especially the brittle iPP-rich ones. The unexpectedly effective compatibilizer transforms brittle iPP/HDPE blends into unexpectedly tough materials that even outperform the reference HDPE and iPP materials. This simple approach creates opportunities for upcycling polymer waste into valuable products.

Artificial Processive Catalytic Systems

Processive catalysts remain attached to a substrate and perform multiple rounds of catalysis. They are abundant in nature. This review highlights artificial processive catalytic systems, which can be divided into (A) catalytic rings that move along a polymer chain, (B) catalytic pores that hold polymer chains and decompose them, (C) catalysts that remain attached to and move around a cyclic substrate via supramolecular interactions, and (D) anchored catalysts that remain in contact with a substrate via multiple catalytic interactions (see frontispiece).

"Inverted" Cyclic(Alkyl)(Amino)Carbene (CAAC) Ruthenium Complex Catalyzed Isomerization Metathesis (ISOMET) of Long Chain Olefins to Propylene at Low Ethylene Pressure

Isomerization Metathesis (ISOMET) reaction is an emerging tool for "open loop" chemical recycling of polyethylene to propylene. Novel, latent N-Alkyl substituted Cyclic(Alkyl)(Amino)Carbene (CAAC)-ruthenium catalysts (5a-Ru, 3b-Ru - 6c-Ru) are developed rendering "inverted" chemical structure while showing enhanced ISOMET activity in combination with (RuHCl)(CO)(PPh3)3 (RuH) double bond isomerization co-catalyst. Systematic investigations reveal that the steric hindrance of the substituents on nitrogen and carbon atom adjacent to carbene moiety in the CAAC ligand have significantly improved the catalytic activity and robustness. In contrast to the NHC-Ru and CAAC-Ru catalyst systems known so far, these systems show higher isomerization metathesis (ISOMET) activity (TON: 7400) on the model compound 1-octadecene at as low as 3.0 bar optimized pressure, using technical grade (3.0) ethylene. The propylene content formed in the gas phase can reach up to 20% by volume.

Chloride and Hydride Transfer as Keys to Catalytic Upcycling of Polyethylene into Liquid Alkanes

Transforming polyolefin waste into liquid alkanes through tandem cracking-alkylation reactions catalyzed by Lewis-acid chlorides offers an efficient route for single-step plastic upcycling. Lewis acids in dichloromethane establish a polar environment that stabilizes carbenium ion intermediates and catalyzes hydride transfer, enabling breaking of polyethylene C-C bonds and forming C-C bonds in alkylation. Here, we show that efficient and selective deconstruction of low-density polyethylene (LDPE) to liquid alkanes is achieved with anhydrous aluminum chloride (AlCl3) and gallium chloride (GaCl3). Already at 60 °C, complete LDPE conversion was achieved, while maintaining the selectivity for gasoline-range liquid alkanes over 70 %. AlCl3 showed an exceptional conversion rate of 5000g L D P E m o l c a t - 1 h - 1 ${{{\rm g}}_{{\rm L}{\rm D}{\rm P}{\rm E}}{{\rm \ }{\rm m}{\rm o}{\rm l}}_{{\rm c}{\rm a}{\rm t}}^{-1}{{\rm \ }{\rm h}}^{-1}}$ , surpassing other Lewis acid catalysts by two orders of magnitude. Through kinetic and mechanistic studies, we show that the rates of LDPE conversion do not correlate directly with the intrinsic strength of the Lewis acids or steric constraints that may limit the polymer to access the Lewis acid sites. Instead, the rates for the tandem processes of cracking and alkylation are primarily governed by the rates of initiation of carbenium ions and the subsequent intermolecular hydride transfer. Both jointly control the relative rates of cracking and alkylation, thereby determining the overall conversion and selectivity.

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.

Synthesis and Deconstruction of Polyethylene-type Materials

Polyethylene deconstruction to reusable smaller molecules is hindered by the chemical inertness of its hydrocarbon chains. Pyrolysis and related approaches commonly require high temperatures, are energy-intensive, and yield mixtures of multiple classes of compounds. Selective cleavage reactions under mild conditions ( Collapse

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Grants

• H2020 European Research Council

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Affiliation(s)

Simon T. Schwab Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany
Maximilian Baur Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany
Taylor F. Nelson Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany
Stefan Mecking Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany

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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.

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.