Polyethylene Hydrogenolysis at Mild Conditions over Ruthenium on Tungstated Zirconia

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.

Efficient Upcycling of Polyolefin Waste to Light Aromatics via Coupling C─C Scission and Carbonylation

The upcycling of waste polyolefins into light aromatics has great potential to generate hundreds of millions of tons of valuable aromatic carbon feedstock. However, the conventional high-temperature radical cracking method for aromatizing polyolefins on zeolites faces challenges in aromaticity control and rapid deactivation due to coke. Here, we present a unique strategy that integrates the traditional cracking-aromatization process of PE with CO insertion, a key step of Fischer-Tropsch synthesis, achieving a rise of yield of light aromatics by four times, with an absolute value up to 67% by weight at only 280 °C. The insertion of CO into the Ru-alkyl intermediates formed during polyolefin cracking facilitates the generation of active oxygenate species, guarantees an ideal C─C chain length range, and smooths the way for subsequent efficient aromatization on Hol-ZSM-5@S1 with a short b axis. According to the technical economic analysis, this low-carbon-footprint and economic approach can reduce approximately 1/3 of carbon emissions compared to traditional naphtha cracking technologies and holds promise for reshaping the global aromatic hydrocarbon cycle of the petrochemical industry through polyolefin degradation.

Polyethylene Upcycling to Liquid Alkanes in Molten Salts under Neat and External Hydrogen Source-Free Conditions

Development of facile approaches to convert plastic waste into liquid fuels under neat conditions is highly desired but challenging, particularly without noble metal catalysts and an external hydrogen source. Herein, highly efficient and selective polyethylene-to-gasoline oil (branched C6-C12 alkanes) conversion was achieved under mild conditions (<170 °C) using commercially available AlCl3-containing molten salts as reaction media and to provide catalytic sites (no extra solvents, additives, or hydrogen feeding). The high catalytic efficiency and selectivity was ensured by the abundant active Al sites with strong Lewis acidity (comparable to the Al type in acidic zeolite) and highly ionic nature of the molten salts to stabilize the carbenium intermediates. Dynamic genesis of the Al sites was elucidated via time-resolved Al K-edge soft X-ray and 27Al NMR, confirming the tricoordinated Al3+ as active sites and its coordination with the as-generated alkene/aromatic intermediates. The carbenium formation and polyethylene chain variation was illustrated by inelastic neutron scattering (INS) and an isotope-labeling experiment. Theoretical simulations further demonstrated the successive hydride abstraction, β-scission, isomerization, and internal hydrogen transfer reaction pathway with AlCl3 as active sites. This facile catalytic system can further achieve the conversion of robust, densely assembled, and high molecular weight plastic model compounds to liquid alkane products in the diesel range.

Polyolefin Recycling with Binary Cobalt-Nickel Nanosheets

The recycling of polyolefin plastics into value-added chemicals has emerged as a new frontier regarding the current environmental concerns. In this work, it is demonstrated that binary cobalt-nickel nanosheets (Co─Ni NSs) can serve as a non-noble catalyst for recycling polyethylene and polypropylene plastics. Detailed analysis implies that the strong synergy between Co and Ni in binary Co─Ni NSs enables the electron transfer from Ni to Co and enhances adsorption abilities to H2 and C─C chain, realizing the cracking of polyethylene plastic to liquid products with a selectivity of 83.3% at a conversion of >98%. Impressively, such a catalyst can realize the successful recycling of commercial polyolefin wastes into value-added products. Given the enhanced stability, high selectivity to liquid products, and low-cost of Co─Ni NSs, this work provides a feasible strategy for recycling polyolefin plastics, which will attract extensive attention in various fields including catalysis, materials, energy, and beyond.

Ru-Catalyzed Polyethylene Hydrogenolysis under Quasi-Supercritical Conditions

Ru/C-catalyzed polyethylene (PE) and hydrocarbon hydrogenolysis under quasi-supercritical fluid of isopentane was kinetically and mechanistically investigated. PE hydrogenolysis with C-C and C-H cleavage showed zeroth order, suggesting strong adsorption of hydrocarbons. PE yielded broad product distribution of heavy (C21-40) and diesel-range (C11-20) hydrocarbons in the primary step of hydrogenolysis due to stochastic C-C cleavage over Ru surface. Catalytic hydrogenolysis of n-hexadecane, squalane, and light hydrocarbons such as n-pentane, iso-pentane, and n-hexane further described C-C cleavage reactivity between primary and secondary carbons, i.e., 1C-2C and 2C-2C, which has an order of magnitude higher hydrogenolysis rate than that involving a tertiary carbon. The PE saturated Ru surface and lower C-C cleavage reactivity of tertiary carbon in iso-pentane, therefore, imited sovlent conversion during hydrogenolysis, whereas leading to selective PE conversion. Using hexadecane, we observed comparable hydrogenolysis rates between H2 and D2 (k H /k D ∼ 1), indicating the kinetically relevant step of C-C cleavage with facilitating C-H cleavage and rehydrogenation. However, the normal kinetic isotope effect between hexadecane and deuterated hexadecane (k C16H34 /k C16D34 ∼ 5) revealed that the dehydrogenation, i.e., C-H cleavage, can be kinetically involved in the hydrogenolysis kinetic. By considering the 8-fold lower H-D exchange rate with deuterated hexadecane compared to n-hexadecane, the lower rate for hydrogenolysis and H-D exchange with deuterated hexadecane can be attributed to the C-D bond dissociation energy being 3 kJ/mol higher than that of the C-H bond. Increasing H2 pressure favors internal C-C bond cleavage over terminal one. This minimizes the formation of lower hydrocarbons, particularly methane. However, the increase in H2 pressure increases the coverage of adsorbed hydrogen on the Ru particles due to competitive adsorption of H2 and polyethylene, which, in turn, reduces the polyethylene conversion rates.

Enhancing Waste Plastic Hydrogenolysis on Ru/CeO2 Through Concurrent Incorporation of Fe Single Atoms and FeOx Nanoclusters

Ru-based catalysts have exhibited significant promise in converting waste plastics into valuable long-carbon chain products. However, their efficiency is hindered by the uncontrollable cascade hydrogenation, which stems from their exceptional reactivity for C─C cleavage. Herein, we reported a multi-scale regulation strategy by selectively anchoring Fe single atoms (SAs) and FeOx nanoclusters (NCs) by Ru NCs-decorated CeO2 substrates. This catalyst demonstrates an extraordinary performance, achieving nearly 100% low density polyethylene (LDPE) conversion under the conditions of 250 °C and 2 MPa hydrogen after 1 h, along with remarkably-improved liquid product selectivity of 86.4% compared to that of bare Ru/CeO2 (59.8%). Through a variety of spectroscopic studies, we revealed the unique interactions between FeOx NCs and Ru NCs, which leads to an increased Ru° content. More significantly, we also confirmed the crucial role of Fe SAs in adsorbing active hydrogen species, thereby increasing the hydrogen coverage. Such precise regulations towards both the intrinsic surface state of Ru and its adjacent chemical environment successfully inhibited the cascade hydrogenation, ultimately resulting in a significant enhancement in the selectivity of liquid products.

Conversion of Compositionally Diverse Plastic Waste over Earth-Abundant Sulfides

Chemical deconstruction of polyolefin plastic wastes via hydroconversion is promising for mitigating plastic accumulation in landfills and the environment. However, hydroconversion catalysts cannot handle complex feedstocks containing multiple polymers, additives, and heteroatom impurities. Here, we report a single-step strategy using earth-abundant metal sulfide catalysts to deconstruct these wastes. We show that NiMoSx/HY catalysts deconstruct polyolefin feedstocks, achieving ∼81-94% selectivity to liquid products. Postsynthetic zeolite modification enhances the catalyst's activity by >2.5 times, achieving over 95% selectivity to liquid fuels with controllable product distribution in the naphtha, jet fuel, and diesel range. The catalyst is resilient to increasingly complex feedstocks, such as additive-containing polymers and mixed plastics composed of polyolefins and heteroatom-containing polymers, including poly(vinyl chloride). We extend the strategy to single-use polyolefin wastes that can generate toxic byproducts, such as HCl and NH3, and eliminate their emissions by integrating reaction and sorption in a one-step process.

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.

Upcycling polyolefins to methane-free liquid fuel by a Ru1-ZrO2 catalyst

Upcycling waste plastics into liquid fuels presents significant potential for advancing the circular economy but is hindered by poor selectivity and low-value methane byproduct formation. In this work, we report that atomic Ru-doped ZrO2 can selectively convert 100 grams of post-consumer polyethylene and polypropylene, yielding 85 mL of liquid in a solvent-free hydrocracking. The liquid (C5-C20) comprises ~70% jet-fuel-ranged branched hydrocarbons (C8-C16), while the gas product is liquefied-petroleum-gas (C3-C6) without methane and ethane. We found that the atomic Ru dopant in the Ru-O-Zr moiety functionalizes its neighboring O atom, originally inert, to create a Brønsted acid site. This Brønsted acid site, rather than the atomic Ru dopant itself, selectively governs the internal C-C bond cleavage in polyolefins through a carbonium ion mechanism, thereby enhancing the yield of jet-fuel-ranged hydrocarbons and suppressing methane formation. This oxide modulation strategy provides a paradigm shift in catalyst design for hydrocracking waste plastics and holds potential for a broad spectrum of applications.

Solvent-free upcycling of agricultural plastic waste using in situ self-assembly metal nanoparticles co-doped microporous carbocatalyst for advanced transportation fuels

Plastic mulching film is ubiquitous in modern agriculture for its heat preservation and moisture retention functions. However, plastic mulching film waste accumulated on land results in microplastic pollution, posing potential hazards as these micro and nanoplastics can enter the food chain. Chemical upcycling of waste mulching film is an emerging strategy to realize sustainable development and circular economy. This study explored an innovative decomposition-catalysis pathway over in situ self-assembly metal nanoparticles (NPs) co-doped microporous carbonaceous catalyst (M/PCCs) to upcycle waste mulching film. M/PCCs with varying Zn and Ni co-additions were tested and found that Zn50-Ni20/CSB1 (ZnCl2: 50 %; NiCl2: 20 %) predominantly favored the formation of liquid hydrocarbons and high-purity H2 production. Importantly, Zn-Ni co-doped on pine sawdust-derived carbon catalyst (Zn-Ni/PSB) with the highest surface area (671 m2/g) and microporosity (76.05 %) exhibited the highest liquid yield (51.67 wt%), and the extremely high carbon selectivity of 89.38 C% for gasoline and 71.98 C% for jet fuel, respectively. Additionally, Zn-Ni/PSB on the time stream was in situ 3D visually evaluated to insightfully unveil the catalytic deconstruction and catalyst deactivation mechanisms. In brief, this study presented a promising solution to effectively upcycle agricultural waste mulching film and thereby mitigate micro and nanoplastics pollution.

Effective Methane Suppression in Upcycling of Polyethylene into Fuels via Alloying Platinum with Ruthenium Supported on ZSM-5 Zeolite

Ruthenium (Ru)-based catalysts are active in catalyzing polyethylene (PE) upcycling, but their tendency for methanation devalues the process. Although previous works confirmed that the regulation of the Ru structure can inhibit methane yields, the mechanism is still unclear, and the catalytic performance remains higher upside potential. Herein, we synthesized M-Ru/H-ZSM-5 (M = Pt, Pd, Rh) catalysts for PE upcycling. Pt-Ru/H-ZSM-5 had better conversion (84.36%) and liquid fuel selectivity (78.38%) and extremely low methane selectivity (8.43%), which can be ascribed to its more electron-deficient Ruδ+ species and the synergistic catalytic effect induced by Pt doping. Through density functional theory calculations, the nature of methane inhibition was uncovered and the reaction pathway was proposed. Furthermore, the Pt-Ru/H-ZSM-5 catalyst demonstrated its stability and reusability, as well as its efficacy for upcycling various PEs. This work reveals the mechanism of Ru-based catalysts in PE upcycling reactions, promoting plastic recycling development.

Remote Activation Catalysis: Interparticle Hydrogen Spillover-Assisted Cumene Synthesis from Propane and Benzene

Hydrogen spillover, particularly when involving "interparticle" hydrogen spillover, offers a unique opportunity to enhance catalytic efficiency by remote activation of surface acidity. Building on this concept, this study aims to investigate physically mixed alumina-supported platinum nanoparticles (Pt/Al2O3) and zirconia-supported tungsten oxide (WO3/ZrO2) in promoting the direct synthesis of cumene from benzene and propane at 300 °C. The reaction with Pt/Al2O3 alone afforded propylene as the only product, indicating the successive reaction route of Pt-catalyzed dehydrogenation of propane, followed by acid-catalyzed alkylation. WO3/ZrO2 with 18 wt.% WO3 loading resulted in high benzene conversion (≈5.0%) and cumene selectivity (≈87.5%), which possesses poly tungstate species on the surface that is active for the acid-catalyzed alkylation. UV-vis-near infrared spectroscopy, X-ray photoelectron spectroscopy, and in situ Fourier-transform infrared spectroscopy analyses revealed that atomic hydrogen abstracted from propane spills over from Pt/Al2O3 particles to WO3/ZrO2 particles to form Brønsted acid sites on the poly tungstate species, whose activity for alkylation between benzene and propylene is double that of the parent WO3/ZrO2.

Tandem Methanolysis and Catalytic Transfer Hydrogenolysis of Polyethylene Terephthalate to p-Xylene Over Cu/ZnZrOx Catalysts

We demonstrate a novel approach of utilizing methanol (CH3OH) in a dual role for (1) the methanolysis of polyethylene terephthalate (PET) to form dimethyl terephthalate (DMT) at near-quantitative yields (~97 %) and (2) serving as an in situ H2 source for the catalytic transfer hydrogenolysis (CTH) of DMT to p-xylene (PX, ~63 % at 240 °C and 16 h) on a reducible ZnZrOx supported Cu catalyst (i.e., Cu/ZnZrOx). Pre- and post-reaction surface and bulk characterization, along with density functional theory (DFT) computations, explicate the dual role of the metal-support interface of Cu/ZnZrOx in activating both CH3OH and DMT and facilitating a lower free-energy pathway for both CH3OH dehydrogenation and DMT hydrogenolysis, compared to Cu supported on a redox-neutral SiO2 support. Loading studies and thermodynamic calculations showed that, under reaction conditions, CH3OH in the gas phase, rather than in the liquid phase, is critical for CTH of DMT. Interestingly, the Cu/ZnZrOx catalyst was also effective for the methanolysis and hydrogenolysis of C-C bonds (compared to C-O bonds for PET) of waste polycarbonate (PC), largely forming xylenol (~38 %) and methyl isopropyl anisole (~42 %) demonstrating the versatility of this approach toward valorizing a wide range of condensation polymers.

Hydrogen-free upcycling of polyethylene waste to methylated aromatics over Ni/ZSM-5 under mild conditions

Upcycling waste plastic into aromatics presents an attractive strategy to tackle both plastic pollution and energy challenges. However, previous studies often rely on high temperatures, precious metals, and have broad product distributions. In this study, we reported that a Ni/ZSM-5 bifunctional catalyst can directly convert polyethylene (PE) into methylated aromatics with high selectivity under mild conditions, while eliminating the requirement for hydrogen gas and solvents. The liquid yield could attain up to 70.3 %, and the aromatics yield could achieve up to 51.7 %. Over 78.4 % of the aromatics were methylated aromatics including toluene, xylene, and mesitylene. Polymer chains underwent dehydrogenation over Ni and the acid sites in ZSM-5, forming CC bonds. Certain of these bonds evolved into carbenium ions through the process of proton transfer at the acid sites. The optimization of Ni and acid sites enhanced the oligomerization, cyclization, and aromatization process. The extra mesopores created by Ni on the molecular sieve aid in the generation of aromatics. Furthermore, the Ni/ZSM-5 catalyst demonstrated the ability to convert typical commercial grades of PE plastic, such as gloves and bottles, into aromatics with a selectivity of up to 61.1 %. It offers an economically feasible and environmentally friendly upcycling avenue for the circular economy of plastics.

Selective Hydrogenolysis Conversion of Polyethylene into Alkyl Oil Over Iridium-based Catalyst

Plastic not only brings convenience but also places a great burden on the environment. Utilizing plastic as a low-cost feed-stock for producing valuable chemicals and fuels is one of the most attractive directions. Among the huge types of plastics, polyolefins (PO), especially polyethylene (PE), were the most abundant type and the most difficult to upgrade. Hydrocracking and hydrogenolysis operate at relatively low reaction temperatures which show promising applications. Herein, Iridium-based catalysts were developed and proved to be effective in PE hydrogenolysis under relatively mild conditions. Catalysts were characterized by TEM, HRTEM, SEM, HAADF-STEM, XPS, CO chemisorption and H2 chemisorption etc. The Ir catalysts showed similar reactivity but better selectivity for liquid products than Ru under similar conditions. A highest 92.7 % percent of liquid products could be obtained under 250 °C, 3 MPa of H2 in 8 hours with Ir/γ-Al2O3 catalyst. The support could also affect the performance, including Lewis acid amount, surface areas, and morphology. And we suppose Iridium catalysts could serve as another choice for plastic hydrogenolysis under mild conditions.

Biotechnology for the degradation and upcycling of traditional plastics

Traditional plastics, predominantly derived from petrochemicals, are extensively utilized in modern industry and daily life. However, inadequate management and disposal practices have resulted in widespread environmental contamination, with polyethylene, polypropylene, polyvinyl chloride, polyethylene terephthalate, and polystyrene being the most prevalent pollutants. Biological methods for plastic degradation have garnered significant attention due to their cost-effectiveness and potential for resource recovery, positioning them as promising strategies for sustainable plastic waste management. While polyethylene terephthalate, characterized by its relatively less stable C-O bonds, has been extensively studied and demonstrates significant potential for biodegradation. In contrast, the biodegradation of other plastics remains a significant challenge due to the inherent stability of their C-C backbone structures. This review comprehensively examines the state-of-the-art biotechnology for treating these traditional plastics, focusing on: (1) the roles of specific microorganisms and enzymes, their taxonomic classifications, and the metabolic pathways involved in plastic biodegradation; and (2) a proposed two-stage hybrid approach integrating physicochemical and biological processes to enhance the biodegradation or upcycling of these traditional plastics. Additionally, the review highlights the critical role of multi-omics approaches and tailored strategies in enhancing the efficiency of plastic biodegradation while examining the impact of plastic molecular structures and additives on their degradation potential. It also addresses key challenges and delineates future research directions to foster the development of innovative biological methods for the effective and sustainable management of plastic waste.

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.

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.

Cross-Linked Polyolefins: Opportunities for Fostering Circularity Throughout the Materials Lifecycle

Cross-linked polyolefins (XLPOs) constitute a significant portion of the plastics commercial market, with a market size of a similar order of magnitude to those of polystyrene and polyethylene terephthalate. However, few aspects of XLPO materials circularity have been examined relative to thermoplastic polyolefins. The cross-linking of polyolefins imparts superior performance properties, such as impact strength, chemical and electrical resistance, and thermal stability vs thermoplastic analogues, but it also makes the reprocessing of XLPOs to valuable products more challenging, as XLPOs cannot be molten. Thus, most XLPOs are incinerated or landfilled at the end of the first lifecycle, even though XLPO products are commonly collected as a relatively clean waste stream-providing a unique opportunity for valorization. In this review, we discuss approaches to improve XLPO circularity throughout the entire materials lifecycle by examining biobased feedstocks as alternative olefinic monomer sources and by assessing both traditional mechanical and advanced XLPO recycling methods based on industrial feasibility and potential product value. We also consider how advancing materials longevity can reduce environmental impacts and lifecycle costs and how recyclable-by-design strategies can enable better end-of-life opportunities for future generations of XLPO materials. Throughout this review, we highlight XLPO circularity routes that have the potential to balance the performance, circularity, and scalability necessary to impart economic and environmental viability at an industrial scale.

Selective Upcycling of Polyethylene over Ru/H-ZSM-5 Bifunctional Catalyst into High-Quality Liquid Fuel at Mild Conditions

It has been known that plastics with undegradability and long half-times have caused serious environmental and ecological issues. Considering the devastating effects, the development of efficient plastic upcycling technologies with low energy consumption is absolutely imperative. Catalytic hydrogenolysis of single-use polyethylene over Ru-based catalysts to produce high-quality liquid fuel has been one of the current top priority strategies, but it is restricted by some tough challenges, such as the tendency towards methanation resulting from terminal C-C cleavage. Herein, we introduced Ru nanoparticles supported on hollow ZSM-5 zeolite (Ru/H-ZSM-5) for hydrocracking of high-density polyethylene (HDPE) under mild reaction conditions. The implication of experimental results is that the 1Ru/H-ZSM-5 (~1 wt % Ru) acted as an effective and reusable bifunctional catalyst providing higher conversion rate (82.53 %) and liquid fuel (C5-C21) yield (62.87 %). Detailed characterization demonstrated that the optimal performance in hydrocracking of PE could be attributed to the moderate acidity and appropriate positively charged Ru species resulting from the metal-zeolite interaction. This work proposes a promising catalyst for plastic upcycling and reveals its structure-performance relationship, which has guiding significance for catalyst design to improve the yield of high-value liquid fuels.

Hydrogenolysis of Poly(Ethylene-co-Vinyl Alcohol) and Related Polymer Blends over Ruthenium Heterogeneous Catalysts

The hydrogenolysis of polymers is emerging as a promising approach to deconstruct plastic waste into valuable chemicals. Yet, the complexity of plastic waste, including multilayer packaging, is a significant barrier to handling realistic waste streams. Herein, we reveal fundamental insights into a new chemical route for transforming a previously unaddressed fraction of plastic waste - poly(ethylene-co-vinyl alcohol) (EVOH) and related polymer blends - into alkane products. We report that Ru/ZrO2 is active for the concurrent hydrogenolysis, hydrogenation, and hydrodeoxygenation of EVOH and its thermal degradation products into alkanes (C1-C35) and water. Detailed reaction data, product analysis, and catalyst characterization reveal that the in-situ thermal degradation of EVOH forms aromatic intermediates that are detrimental to catalytic activity. Increased hydrogen pressure promotes hydrogenation of these aromatics, preventing catalyst deactivation and improving alkane product yields. Calculated apparent rates of C-C scission reveal that the hydrogenolysis of EVOH is slower than low-density polyethylene. We apply these findings to achieve hydrogenolysis of EVOH/polyethylene blends and elucidate the sensitivity of hydrogenolysis catalysts to such blends. Overall, we demonstrate progress towards efficient catalytic processes for the hydroconversion of waste multilayer film plastic packaging into valuable products.

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.

Recovering Valuable Chemicals from Polypropylene Waste via a Mild Catalyst-Free Hydrothermal Process

Waste polypropylene (PP) presents a significant environmental challenge, owing to its refractory nature and inert C-C backbone. In this study, we introduce a practical chemical recovery strategy from PP waste using a mild catalyst-free hydrothermal treatment (HT). The treatment converts 64.1% of the processed PP into dissolved organic products within 2 h in an air atmosphere at 160 °C. Higher temperatures increase the PP conversion efficiency. Distinct electron absorption and emission characteristics of the products are identified by spectral analysis. Fourier transform-ion cyclotron resonance-mass spectrometry (FT-ICR-MS) reveals the oxidative cracking of PP into shorter-chain homologues (10-50 carbon atoms) containing carboxylic and carbonyl groups. Density functional theory (DFT) calculations support a reaction pathway involving thermal C-H oxidation at the tertiary carbon sites in the polymer chain. The addition of 1% H2O2 further enhances the oxidation reaction to produce valuable short-chain acetic acids, enabling gram-scale recycling of both pure PP and disposable surgical masks from the real world. Techno-economic analysis (TEA) and environmental life cycle costing (E-LCC) analysis suggest that this hydrothermal oxidation recovery technology is financially viable, which shows significant potential in tackling the ongoing plastic pollution crisis and advancing plastic treatment methodologies toward a circular economy paradigm.

Interfacial Reactions in Chemical Recycling and Upcycling of Plastics

Depolymerization of plastics is a leading strategy to combat the escalating global plastic waste crisis through chemical recycling, upcycling, and remediation of micro-/nanoplastics. However, critical processes necessary for polymer chain scission, occurring at the polymer-catalyst or polymer-fluid interfaces, remain largely overlooked. Herein, we spotlight the importance of understanding these interfacial chemical processes as a critical necessity for optimizing kinetics and reactivity in plastics recycling and upcycling, controlling reaction outcomes, product distributions, as well as improving the environmental sustainability of these processes. Several examples are highlighted in heterogeneous processes such as hydrogenation over solid catalysts, reaction of plastics in immiscible media, and biocatalysis. Ultimately, judicious exploitation of interfacial reactivity has practical implications in developing practical, robust, and cost-effective processes to reduce plastic waste and enable a viable post-use circular plastics economy.

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.

Insights into hydro thermal gasification process of microplastic polyethylene via reactive molecular dynamics simulations

Microplastics have become a pressing environmental issue due to their widespread presence in our ecosystems. Among various plastic components, polyethylene (PE) is a prevalent and persistent contaminant. Hydrothermal gasification (HTG), a promising technology for converting PE into syngas, holds great promise for mitigating the microplastic problem. In this study, we employ ReaxFF molecular dynamics simulations to investigate the HTG process of PE, shedding light on the intricate relationships between temperature, water content, carbon conversion efficiency, and product distributions. The results reveal that hydrothermal gasification of PE is a complex process involving multiple reaction pathways. Consistently with experimental findings, the calculations indicate that the gas phase exhibits a substantial hydrogen fraction, reaching up to 70%. Interestingly, our simulations reveal a dual role of water content in the HTG process. On one hand, water enhances hydrogen production by promoting the gas formation. On the other hand, it elevates the activation energy required for PE decomposition. Depending on the water content, the calculated activation energies range from 176 to 268 kJ/mol, which are significantly lower than those reported for thermal gasification (TG). This suggests that HTG may be a more efficient route for PE conversion. Furthermore, this study highlights the importance of optimizing both temperature and water content in HTG systems to achieve high yields of hydrogen-rich syngas. The results obtained from our ReaxFF MD simulations demonstrate the robustness of this computational methodology in elucidating complex chemical reactions under extreme conditions. Our findings offer critical insights into the design of advanced waste management strategies for microplastics and contribute to the development of sustainable practices for resource recovery. This work underscores the potential of HTG as a key technology for addressing the global challenge of plastic pollution.

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.

Chemical Upcycling of Polyolefin Plastics Using Structurally Well-defined Catalysts

Single-use polyolefins are widely used in our daily life and industrial production due to their light weight, low cost, superior stability, and durability. However, the rapid accumulation of plastic waste and low-profit recycling methods resulted in a global plastic crisis. Catalytic hydrogenolysis is regarded as a promising technique, which can effectively and selectively convert polyolefin plastic waste to value-added products. In this perspective, we focus on the design and synthesis of structurally well-defined hydrogenolysis catalysts across mesoscopic, nanoscopic, and atomic scales, accompanied by our insights into future directions in catalyst design for further enhancing catalytic performance. These design principles can also be applied to the depolymerization of other polymers and ultimately realize the chemical upcycling of waste plastics.

Upcycling of polyethylene to gasoline through a self-supplied hydrogen strategy in a layered self-pillared zeolite

Conversion of plastic wastes to valuable carbon resources without using noble metal catalysts or external hydrogen remains a challenging task. Here we report a layered self-pillared zeolite that enables the conversion of polyethylene to gasoline with a remarkable selectivity of 99% and yields of >80% in 4 h at 240 °C. The liquid product is primarily composed of branched alkanes (selectivity of 72%), affording a high research octane number of 88.0 that is comparable to commercial gasoline (86.6). In situ inelastic neutron scattering, small-angle neutron scattering, solid-state nuclear magnetic resonance, X-ray absorption spectroscopy and isotope-labelling experiments reveal that the activation of polyethylene is promoted by the open framework tri-coordinated Al sites of the zeolite, followed by β-scission and isomerization on Brönsted acids sites, accompanied by hydride transfer over open framework tri-coordinated Al sites through a self-supplied hydrogen pathway to yield selectivity to branched alkanes. This study shows the potential of layered zeolite materials in enabling the upcycling of plastic wastes.

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.

Hydrogen Bubbles: Harmonizing Local Hydrogen Transfer for Efficient Plastic Hydro-Depolymerization

Hydro-depolymerization presents a promising avenue for transforming plastic waste into high-value hydrocarbons, offering significant potential for value-added recycling. However, a major challenge in this method arises from kinetic limitations due to insufficient hydrogen concentration near the active sites, requiring optimal catalytic performance only at higher hydrogen pressures. In this study, we address this hurdle by developing "hydrogen bubble catalysts" featuring Ru nanoparticles within mesoporous SBA-15 channels (Ru/SBA). The distinctive feature of Ru/SBA catalysts lies in their capacity for physical hydrogen storage and chemically reversible hydrogen spillover, ensuring a timely and ample hydrogen supply. Under identical reaction conditions, the catalytic activity of Ru/SBA surpassed that of Ru/SiO2 (no hydrogen storage capacity) by over 4-fold. This substantial enhancement in catalytic performance provides significant opportunities for near atmospheric pressure hydro-depolymerization of plastic waste.

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.

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.

Layered Double Hydroxide Derivatives for Polyolefin Upcycling

While Ru-catalyzed hydrogenolysis holds significant promise in converting waste polyolefins into value-added alkane fuels, a major constraint is the high cost of noble metal catalysts. In this work, we propose, for the first time, that Co-based catalysts derived from CoAl-layered double hydroxide (LDH) are alternatives for efficient polyolefin hydrogenolysis. Leveraging the chemical flexibility of the LDH platform, we reveal that metallic Co species serve as highly efficient active sites for polyolefin hydrogenolysis. Furthermore, we introduced Ni into the Co framework to tackle the issue of restricted hydrogenation ability associated with contiguous Co-Co sites. In-situ analysis indicates that the integration of Ni induces electron transfer and facilitates hydrogen spillover. This dual effect synergistically enhances the hydrogenation/desorption of olefin intermediates, resulting in a significant reduction in the yield of low-value CH4 from 27.1 to 12.6%. Through leveraging the unique properties of LDH, we have developed efficient and cost-effective catalysts for the sustainable recycling and valorization of waste polyolefin materials.

Highly Selective and Efficient Perdeuteration of n-Pentane via H/D Exchange Catalyzed by a Silica-Supported Hafnium-Iridium Bimetallic Complex

A Surface OrganoMetallic Chemistry (SOMC) approach is used to prepare a novel hafnium-iridium catalyst immobilized on silica, HfIr/SiO2, featuring well-defined [≡SiOHf(CH2 tBu)2(μ-H)3IrCp*] surface sites. Unlike the monometallic analogous materials Hf/SiO2 and Ir/SiO2, which promote n-pentane deuterogenolysis through C-C bond scission, we demonstrate that under the same experimental conditions (1 bar D2, 250 °C, 3 h, 0.5 mol %), the heterobimetallic catalyst HfIr/SiO2 is highly efficient and selective for the perdeuteration of alkanes with D2, exemplified on n-pentane, without substantial deuterogenolysis (<2 % at 95 % conversion). Furthermore this HfIr/SiO2 catalyst is robust and can be re-used several times without evidence of decomposition. This represents substantial advance in catalytic H/D isotope exchange (HIE) reactions of C(sp3)-H bonds.

Stable Interfacial Ruthenium Species for Highly Efficient Polyolefin Upcycling

The present polyolefin hydrogenolysis recycling cases acknowledge that zerovalent Ru exhibits high catalytic activity. A pivotal rationale behind this assertion lies in the propensity of the majority of Ru species to undergo reduction to zerovalent Ru within the hydrogenolysis milieu. Nonetheless, the suitability of zerovalent Ru as an optimal structural configuration for accommodating multiple elementary reactions remains ambiguous. Here, we have constructed stable Ru0-Ruδ+ complex species, even under reaction conditions, through surface ligand engineering of commercially available Ru/C catalysts. Our findings unequivocally demonstrate that surface-ligated Ru species can be stabilized in the form of a Ruδ+ state, which, in turn, engenders a perturbation of the σ bond electron distribution within the polyolefin carbon chain, ultimately boosting the rate-determining step of C-C scission. The optimized catalysts reach a solid conversion rate of 609 g·gRu-1·h-1 for polyethylene. This achievement represents a 4.18-fold enhancement relative to the pristine Ru/C catalyst while concurrently preserving a remarkable 94% selectivity toward valued liquid alkanes. Of utmost significance, this surface ligand engineering can be extended to the gentle mixing of catalysts in ligand solution at room temperature, thus rendering it amenable for swift integration into industrial processes involving polyolefin degradation.

Population Balance Equations for Reactive Separation in Polymer Upcycling

Many polymer upcycling efforts aim to convert plastic waste into high-value liquid hydrocarbons. However, the subsequent cleavage of middle distillates to light gases can be problematic. The reactor often contains a vapor phase (light gases and middle distillates) and a liquid phase (molten polymers and waxes with a suspended or dissolved catalyst). Because the catalyst resides in the liquid phase, middle distillates that partition into the vapor phase are protected against further cleavage into light gases. In this paper, we consider a simple reactive separation strategy, in which a gas outflow removes the volatile products as they form. We combine vapor-liquid equilibrium models and population balance equations (PBEs) to describe polymer upcycling in a two-phase semibatch reactor. The results suggest that the temperature, headspace volume, and flow rate of the reactor can be used to tune selectivity toward the middle distillates, in addition to the molecular mechanism of catalysis. We anticipate that two-phase reactor models will be important in many polymer upcycling processes and that reactive separation strategies will provide ways to boost the yield of the desired products in these cases.

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

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

Characterizing the Opportunity Space for Sustainable Hydrothermal Valorization of Wet Organic Wastes

Resource recovery from wet organic wastes can support circular economies by creating financial incentives to produce renewable energy and return nutrients to agriculture. In this study, we characterize the potential for hydrothermal liquefaction (HTL)-based resource recovery systems to advance the economic and environmental sustainability of wastewater sludge, FOG (fats, oils, and grease), food waste, green waste, and animal manure management through the production of liquid biofuels (naphtha, diesel), fertilizers (struvite, ammonium sulfate), and power (heat, electricity). From the waste management perspective, median costs range from -193 $·tonne-1 (FOG) to 251 $·tonne-1 (green waste), and median carbon intensities range from 367 kg CO2 eq·tonne-1 (wastewater sludge) to 769 kg CO2 eq·tonne-1 (green waste). From the fuel production perspective, the minimum selling price of renewable diesel blendstocks are within the commercial diesel price range (2.37 to 5.81 $·gal-1) and have a lower carbon intensity than petroleum diesel (101 kg CO2 eq·MMBTU-1). Finally, through uncertainty analysis and Monte Carlo filtering, we set specific targets (i.e., achieve wastewater sludge-to-biocrude yield >0.440) for the future development of hydrothermal waste management system components. Overall, our work demonstrates the potential of HTL-based resource recovery systems to reduce the costs and carbon intensity of resource-rich organic wastes.

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

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

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

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

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

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

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

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

Entropy Confinement Promotes Hydrogenolysis Activity for Polyethylene Upcycling

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

A Supported Ziegler-Type Organohafnium Site Metabolizes Polypropylene

Cp2Hf(CH3)2 reacts with silica containing strong aluminum Lewis sites to form Cp2Hf-13CH3+ paired with aluminate anions. Solid-state NMR studies show that this reaction also forms neutral organohafnium and hafnium sites lacking methyl groups. Cp2Hf-13CH3+ reacts with isotatic polypropylene (iPP, Mn = 13.3 kDa; Đ = 2.4; mmmm = 94%; ∼110 C3H6/Hf) and H2 to form oils with moderate molecular weights (Mn = 290-1200 Da) in good yields. The aliphatic oils show characteristic 13C{1H} NMR properties consistent with complete loss of diastereoselectivity and formation of regioirregular errors under 1 atm H2. These results show that a Ziegler-Natta-type active site is compatible in a common reaction used to digest waste plastic into smaller aliphatic fragments.

Controlling the selectivity of the hydrogenolysis of polyamides catalysed by ceria-supported metal nanoparticles

Catalytic hydrogenolysis is a promising approach to transform waste plastic into valuable chemicals. However, the transformation of N-containing polymers, such as polyamides (i.e. nylon), remains under-investigated, particularly by heterogeneous catalysis. Here, we demonstrate the hydrogenolysis of various polyamides catalysed by platinum-group metal nanoparticles supported on CeO2. Ru/CeO2 and Pt/CeO2 are both highly active but display different selectivity; Ru/CeO2 is selective for the conversion of all polyamides into water, ammonia, and methane, whereas Pt/CeO2 yields hydrocarbons retaining the carbon backbone of the parent polyamide. Density functional theory computations illustrate that Pt nanoparticles require higher activation energy for carbon-carbon bond cleavage than Ru nanoparticles, rationalising the observed selectivity. The high activity and product selectivity of both catalysts was maintained when converting real-world polyamide products, such as fishing net. This study provides a mechanistic basis for heterogeneously catalysed polyamide hydrogenolysis, and a new approach to the valorisation of polyamide containing waste.

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.