A reusable, impurity-tolerant and noble metal-free catalyst for hydrocracking of waste polyolefins

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.

Induction Heating for the Electrification of Catalytic Processes

The increasing availability of electrical energy generated from clean, low-carbon, renewable sources like solar and wind power is paving the way for a more sustainable future. This has resulted in a growing trend in the chemical industry to increase the share of electricity use in chemical processes, particularly catalytic ones. This shift towards electrifying catalytic processes offers significant environmental benefits. Current practices rely heavily on fossil fuel-based burners, primarily using natural gas, which contribute significantly to greenhouse gas emissions. Therefore, replacing fossil fuels with electricity can significantly reduce the carbon footprint associated with chemical production. Additionally, the energy-intensive production of metal catalysts used in these processes further exacerbates the environmental impact. This review focuses on the electrification of chemical processes, particularly using induction heating (IH), as a method to reduce the environmental impact of both catalyst production and operation. IH shows promise compared to conventional heating methods, since it offers a cleaner, more efficient, and precise way to heat catalysts in chemical processes by directly generating heat within the catalyst itself. It can potentially even enhance the reaction performance through its influence on the reaction mechanism. By exploring recent advancements in IH-driven catalytic processes, the review delves into how this method is revolutionizing catalysis by enhancing performance, selectivity, and sustainability. It highlights recent breakthroughs and discusses perspectives for further exploration in this rapidly developing field.

Hydrogen Spillover-Induced Brønsted Acidity Enables Controllable Hydrocracking of Polyolefin Waste to Liquid Fuels

Efficient upcycling of polyolefin waste into liquid fuels remains challenging due to over-cracking and the lack of sufficient acidity in non-zeolitic catalysts. Here, we report a Ni/niobium oxide nanorod (Ni/NbOx) catalyst that achieves 95% selectivity to C5-20​ alkanes at full polyethylene (PE) conversion under mild conditions (240 °C), with minimal gaseous products (4%). The catalyst reaches a high liquid fuel formation rate of 1274 gliquid​ gNi -1​ h-1, rivaling noble metal systems. Its performance is governed by the morphology and crystallinity of NbOx nanorods, which provide sufficient acidity without micropore confinement, mitigating diffusion limitations and over-cracking. Detailed operando infrared spectroscopy and computational studies reveal, for the first time, that Brønsted acid sites, generated in situ via hydrogen spillover on the (110) facet, are the key catalytic sites in niobium oxide-based catalysts. The density of these acid sites exhibits a linear correlation with hydrocracking activity. The catalyst also demonstrates high efficiency across diverse polyolefin feedstocks and excellent reusability, offering a scalable and cost-effective solution for plastic upcycling.

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.

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.

Production of Branched Alkanes by Upcycling of Waste Polyethylene over Controlled Acid Sites of SO4/ZrO2-Al2O3 Catalyst

Branched alkanes, which enhance the octane number of gasoline, can be produced from waste polyethylene. However, achieving highly selective production of branched alkanes presents a significant challenge in the upcycling of waste polyethylene. Here, we report a one-pot process to convert polyethylene into gasoline-range hydrocarbons (C4-C13) with yield of 73.3 % over SO4/ZrO2-Al2O3 catalyst at 280 °C. The proportion of branched alkanes reaches 90.1 % within the C4-C13 fraction. Incorporation of sulfate group endows the catalyst with strong Lewis acid sites and weak and moderate Brønsted acid sites. In situ X-ray absorption, in situ infrared spectroscopy, in situ small angle neutron scattering, and DFT calculations reveal that polyethylene activation occurs through the synergy between sulfate groups and strong Lewis acid sites (Zr sites). The weak and moderate Brønsted acid sites preferentially catalyze the isomerization and type A β-scission processes, which favors the formation of branched alkanes, while suppressing competing reactions that produce straight-chain alkanes.

Catalytic Hydrodeoxygenation of Mixed Plastic Wastes into Sustainable Naphthenes

The chemical upcycling of plastic wastes by converting them into valuable fuels and chemicals represents a sustainable approach as opposed to landfilling and incineration. However, it encounters challenges in dealing with mixed plastic wastes due to their complex composition and sorting/cleaning costs. Here, we present a one-pot hydrodeoxygenation (HDO) method for converting mixed plastic wastes containing poly(ethylene terephthalate) (PET), polycarbonate (PC), and poly(phenylene oxide) (PPO) into sustainable naphthenes under mild reaction conditions. To facilitate this process, we developed a cost-effective, contaminant-tolerant, and reusable Ni/HZSM-5 bifunctional catalyst through an ethylene glycol-assisted impregnation method. The metallic Ni site plays a pivotal role in catalyzing C-O and C-C cleavages as well as hydrogenation reactions, while the acidic site of HZSM-5 facilitates dehydration and isomerization reactions. The collaboration between metal and acid dual sites on Ni/HZSM-5 enabled efficient HDO of a wide range of substrates, including bottles, textile fibers, pellets, sheets, CDs/DVDs, and plastics without cleaning or pigments removal and even their various mixtures, into naphthenes with a high yield up to 99% at 250 °C and 4 MPa H2 within 4-6 h. Furthermore, the metal-acid balance of the Ni/HZSM-5 catalyst is crucial for determining both HDO activity and product distribution. This proposed one-pot HDO process utilizing earth-abundant metal catalysts provides a promising avenue toward practical valorization of mixed plastic wastes.

The catalytic performance of (ZrO)n (n = 1-4, 12) clusters for Suzuki-Miyaura cross-coupling: a DFT study

Superatoms are special clusters with similar physicochemical properties to individual atoms in the periodic table, which open up new avenues for exploring inexpensive catalysts. Given that the ZrO superatom possesses the same number of valence electrons as a Pd atom, the mechanisms of the Suzuki-Miyaura reaction catalyzed by (ZrO)n (n = 1-4) clusters have been investigated and compared with the corresponding Pdn (n = 1-4) species to explore superatom-based catalysts for the formation of C-C bonds via a density functional theory (DFT) study. It was interesting to find that the catalytic activities of (ZrO)n (n = 1-4) towards the Suzuki-Miyaura reaction gradually improved as the cluster size increased. Therefore, to obtain more efficient catalysts, the catalytic activity of a well-designed (ZrO)12 nanocage towards this cross-coupling reaction has been further evaluated. Gratifyingly, this nanocage shows excellent catalytic performance for the considered coupling reaction, which is even comparable to that of the commonly used Pd catalyst and outperforms the corresponding Pd12 cluster. We hope this study can not only provide valuable guidance for the development of noble metal-like catalysts for C-C bond formation, but also expand the application of superatoms in the catalysis of organic reactions.

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.

Micelles Cascade Assembly to Tandem Porous Catalyst for Waste Plastics Upcycling

Catalytic upcycling of polyolefins into high-value chemicals represents the direction in end-of-life plastics valorization, but poses great challenges. Here, we report the synthesis of a tandem porous catalyst via a micelle cascade assembly strategy for selectively catalytic cracking of polyethylene into olefins at a low temperature. A hierarchically porous silica layer from mesopore to macropore is constructed on the surface of microporous ZSM-5 nanosheets through cascade assembly of dynamic micelles. The outer macropore arrays can adsorb bulky polyolefins quickly by the capillary and hydrophobic effects, enhancing the diffusion and access to active sites. The middle mesopores present a nanoconfinement space, pre-cracking polyolefins into intermediates by weak acid sites, which then transport into zeolites micropores for further cracking by strong Brønsted acid sites. The hierarchically porous and acidic structures, mimicking biomimetic protease catalytic clefts, ideally match the tandem cracking steps of polyolefins, thus suppressing coke formation and facilitating product escape. As a result, light hydrocarbons (C1-C7) are produced with a yield of 443 mmol gZSM-5 -1, where 74.3 % of them are C3-C6 olefins, much superior to ZSM-5 and porous silica catalysts. This tandem porous catalyst exemplifies a superstructure design of catalytic cracking catalysts for industrial and economical upcycling of plastic wastes.

Ni-based catalysts supported on Hbeta zeolite for the hydrocracking of waste polyolefins

Polyolefin plastics are the most popular polymer materials worldwide, and the catalytic degradation of post-consumer polyolefins has attracted increased attention as a viable process. In this study, two types of Ni-based catalysts supported on Hbeta zeolite, Ni-Hbeta and NiS2-Hbeta, have been successfully synthesized for the hydrocracking of waste polyolefin. The experimental results indicated that the synergistic effect between Ni or NiS2 and the acidic sites of Hbeta zeolites can significantly enhance the tandem cracking and hydrogenation of polyolefin plastics, which suppresses the formation of gas products and coke. Ni-Hbeta employed as a catalyst can effectively degrade HDPE into high value liquid and gas products with high yield of 94% under 523 K and 3 MPa H2, while also exhibiting excellent cycle stability. In particular, Ni-Hbeta shows better catalytic performance than NiS2-Hbeta during the hydrocracking of HDPE at a relatively low temperature of 523 K. Furthermore, Ni-Hbeta catalyst also exhibits a remarkable capability for efficient depolymerization of unsorted post-consumer polyolefin plastics (HDPE, LDPE, PP) containing various additives and pollutants. These findings underscore the application potential of employing noble metal-free and recyclable catalysts for hydrocracking plastic waste, thereby facilitating the realization of a circular economy for plastics.

Coupled conversion of polyethylene and carbon dioxide catalyzed by a zeolite-metal oxide system

Zeolite-catalyzed polyethylene (PE) aromatization achieves reduction of the aromatic yield via hydrogenation and hydrogenolysis reactions. The hydrogen required for CO2 hydrogenation can be provided by H radicals formed during aromatization. In this study, we efficiently convert PE and CO2 into aromatics and CO using a zeolite-metal oxide catalyst (HZSM-5 + CuZnZrOx) at 380°C and under hydrogen- and solvent-free reaction conditions. Hydrogen, derived from the aromatization of PE over HZSM-5, diffuses through the Brønsted acidic sites of the zeolite to the adjacent CuZnZrOx, where it is captured in situ by CO2 to produce bicarbonate and further hydrogenated to CO. This favors aromatization while inhibiting hydrogenation and secondary hydrogenolysis reactions. An aromatic yield of 62.5 wt % is achieved, of which 60% consisted of benzene, toluene, and xylene (BTX). The conversion of CO2 reaches values as high as 0.55 mmol gPE-1. This aromatization-hydrogen capture pathway provides a feasible scheme for the comprehensive utilization of waste plastics and CO2.