Hydroformylation of pyrolysis oils to aldehydes and alcohols from polyolefin waste

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.

Hydrolytic Degradation of Key Plastic Pollutant Model Systems by a Discrete Metal-Oxo Cluster: A Combined Theoretical and Experimental Study

Degradation of plastic materials represents one of the major challenges faced by the modern world. In this study, computational and experimental techniques have been employed to investigate the hydrolysis of most commonly used plastic materials poly(ether urethane) (PEU) and polyethylene terephthalate (PET) and their commercially available models ethyl N-phenylcarbamate (ENP) and ethylene glycol dibenzoate (EGD), respectively, by a discrete metal-oxo cluster, Zr-substituted Keggin-type polyoxometalate, (Et2NH2)8[Zr(μ-O)(H2O)(PW11O39)] (ZrK), in which the Zr(IV) catalytic site is stabilized by coordination to a robust metal-oxo core. The all-atom molecular dynamics simulations predicted that all substrates interact with ZrK through water-mediated interactions. The quantum mechanics/molecular mechanics (QM/MM) calculations showed that the lengths of scissile ester and amide bonds of PEU/ENP and the ester bond of PET/EGD are quite similar, and the hydrolysis of PEU and ENP and PET and EGD occurs with similar energetics. According to the most plausible mechanisms, the cleavage of the ester and amide bonds of PEU/ENP takes place with a barrier of 16.5/16.6 and 19.0/20.4 kcal/mol, respectively. However, the scissile ester bond of PET/EGD is hydrolyzed with a barrier of 16.7/16.5 kcal/mol. This computed difference in the rate-limiting barrier of 3.9 kcal/mol between the amide bond of ENP and the ester bond of EGD is supported by the experimentally observed sluggish hydrolysis of ENP in comparison to EGD. While both ENP and EGD were successfully hydrolyzed by ZrK in DMSO solvent at 100 °C, EGD hydrolysis has proven to be much more efficient, with 99% yield obtained within 18 h compared to 48% of ENP hydrolysis observed after 162 h. The combined theoretical and experimental results presented here contribute to the development of potent and robust all-inorganic cluster-based catalysts for the degradation of PEU and PET and suggest that ENP and EGD can be used as excellent model substrates in this endeavor.

Catalytic Hydroformylation of Alkenes to Branched Aldehydes by Triphenylphosphine-Based Porous Organic Polymer-Anchored Rhodium Cluster Catalysts

Hydroformylation of alkenes to high-value-added aldehydes is one of the most important processes in the chemical industry. The use of heterogeneous hydroformylation catalysts encounters substantial challenges including low catalyst activity and stability as well as difficulties in achieving high selectivity for branched aldehydes. In this work, a porous organic polymer (POP) system with embedded triphenylphosphine ligands was prepared, and through impregnation, reduction, and anchoring, rhodium was immobilized on the PPh3-p-Ph4 material as rhodium clusters. Triphenylphosphine exerts significant steric hindrance toward selective alkene hydroformylation, and using water as a solvent also demonstrated pronounced electronic effects, resulting in a high selectivity toward branched aldehydes with a branched-to-linear ratio of more than ten. Mechanistic studies confirmed that the reaction to the branched aldehydes follows pathways with lower reaction energy, thus achieving a high selectivity and yield (95.4%) of branched products. Importantly, the catalyst can be easily recovered and reused while maintaining its activity and selectivity over five cycles without significant losses. The utilization of triphenylphosphine ligands for the preparation of POP supports for rhodium catalysts not only enables the heterogenization of homogeneous complex catalysts but also presents novel ideas and methodologies for future research on alkene hydroformylation to produce branched aldehydes.

Controlling Reaction Pathways of Ethylene Hydroformylation Using Isolated Bimetallic Rhodium-Cobalt Sites

Designing efficient ligand-free heterogeneous catalysts for ethylene hydroformylation to produce C3 oxygenates is of importance for both fundamental research and practical applications, but it is often hindered by insufficient catalytic activity and selectivity. This work designs isolated rhodium-cobalt (Rh-Co) sites confined within a ZSM-5 zeolite to enhance ethylene hydroformylation rates and selectivity while maintaining catalyst stability. By adjusting the Co/Al ratio in Co-ZSM-5, different sizes of Co are formed; subsequent Rh introduction produces isolated Rh1Cox clusters with different Rh-Co coordination numbers (CNs). In-situ characterizations and density functional theory calculations reveal that a Rh-Co CN of 3, corresponding to an isolated Rh1Co3 site, provides optimal bindings to reaction intermediates and thus achieves the highest hydroformylation rates among supported Rh-based catalysts. This study demonstrates the role of coordination-tuning via a secondary metal in effectively controlling the reaction pathway over single Rh atom catalysts.

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.

Upcycling waste commodity polymers into high-performance polyarylate materials with direct utilization of capping agent impurities

Commodity polymers are ubiquitous in our society, having replaced many inorganic and metal-based materials due to their versatile properties. However, their functionality heavily relies on the addition of various components known as additives, making it challenging to recycle the polymer fraction of plastic materials effectively. Thus, it is crucial to develop efficient chemical recovery strategies for commodity polymers and additives to facilitate the direct utilization of recovered monomers and additives without additional purification. Here, we develop a strategy for co-upcycling two types of waste commodity polymers, polycarbonate, and polyethylene terephthalate into polyarylate, a high-performance transparent engineering plastic. By incorporating a highly active metal-free ionic liquids catalyst for methanolysis and a two-stage interface polymerization technique with variable temperature control, we successfully prepare polyacrylate film materials from real end-of-life plastics with direct utilization of capping agent impurities in recovered monomers. These materials exhibit excellent thermal performance (Tg = 192.8 °C), transmittance (reach up to 86.73%), and flame-retardant properties (V-0, UL-94), equivalent to those of commercial polyarylate (U-100, about $10000/ton), and could be further easily close-loop recycled. Demonstrated in kilogram-scale experiments and life cycle assessments, this approach offers a low-carbon, environmentally friendly, and economically feasible pathway for upcycling waste commodity polymers.

Synthesis and Properties of Isononyl-Extended Multibranched Alcohol Polyether Nonionic Surfactants

Isononanol, a branched aliphatic alcohol, is derived from isobutylene upgradation, encompassing dimerization and hydroformylation. Branched surfactants exhibit lower surface tension, superior wettability, and rapid defoaming compared to linear surfactants. Isononanol (C9-OH) with abundant methyl branching can serve as a hydrophobic tail of branched surfactants, suffering from insufficient lipophilicity due to its short effective chain length. This paper proposes a strategy to extend the hydrophobic tail by grafting one propylene oxide (P1) or butylene oxide (B1) to increase chain length and branching degree with the aim of synthesizing extended multibranched alcohols C9P1-OH and C9B1-OH with purities of 95.3 and 97.2%, respectively. Subsequently, a series of extended multibranched alcohol polyether nonionic surfactants (C9P1En and C9B1En) were synthesized by ethoxylation, with their structures confirmed by Fourier-transform infrared (FT-IR) and 1H NMR and their surfactant properties systematically investigated. The findings indicate that C9P1En and C9B1En exhibited lower γCMC values compared to the isononanol polyether surfactant (C9En), which allows for rapid wetting on a hydrophobic surface, especially C9B1E6 with an initial contact angle of only 54° compared to 80° for C9E6. Also remarkable is the rapid defoaming performance, with C9B1E6 having less than 0.1% of the initial foam volume but C9E6 having up to 50.1% foam volume after 30 s. These surfactant performances provide significant benefits for the potential application of branched nonionic surfactants in the industrial cleaning field.

Highly selective upcycling of plastic mixture waste by microwave-assisted catalysis over Zn/b-ZnO

7 billion of 9.2 billion tons of plastic produced becomes waste while conventional catalytic plastic recycling methods are vulnerable with degraded performance and intensive energy input. Here, a hybrid Zn/b-ZnO catalyst, together with the specially-designed microwave reaction system, has achieved fast plastic waste upgrading under atmospheric pressure without using H2. Bifunctional ZnO acts as a microwave absorber and substrate catalyst, and in-situ formed Zn clusters promote C-C bond cleavage and nearly 100% upcycle landfilled plastic mixtures into lubricant base oil precursors and monomers. Unprecedented turnover number (250 gplastic g-1catalyst) of plastic depolymerisation and long-time stability over 50 successive cycles have been demonstrated, together with 8-time higher energy efficiency compared with conventional catalysis, indicating this strategy is an economical approach to efficient upcycling of plastics towards valuable products. Moreover, the catalyst can tolerate high contaminates, even the landfilled plastics can still be converted to lubricant base oil precursors, which has never been reported before.

Microwave-Powered Liquid Metal Degradation of Polyolefins

Upcycling waste plastics is highly promising to tackle global white pollution while achieving sustainable development. However, prevailing approaches often encounter challenges in scalable engineering practices due to either insufficient plastic upcycling capability or arduousness in the separation, recovery, and purification of catalysts, which inevitably augments the cost of plastic upcycling. Here, the microwave-powered liquid metal synergetic depolymerization is presented to facilitate low-cost plastic upcycling. By leveraging the fluidity of liquid metals and their exceptional chemical-bond activation ability under microwave field, this method efficiently converts various polyolefins into narrowband hydrocarbon oil (Oil yield: 81 wt.% for polypropylene (PP), 85.9 wt.% for polyethylene (PE)) and high-value olefin monomers (C2-4  selectivity: 50% for PE, 65.3% for PP) over 30 successive cycles, resulting in a high turnover frequency of 2.83 kgPlastic mLLiquid metal -1. These captivating advantages offered by electromagnetically-powered liquid metals are also supported by their self-separation features, thereby paving the way for large-scale engineering solutions in waste plastic upcycling.

Selective Reduction of Esters to Access Aldehydes Using Fiddler Crab-Type Boranes

The partial reduction of esters to aldehydes is a fundamentally important transformation for the synthesis of numerous fine chemicals and consumer goods. However, despite the many efforts, limitations have persisted, such as competing overreduction, low reproducibility, use of exigent reaction conditions and hazardous chemicals. Here, we report a novel catalyst family with a unique steric design which promotes the catalytic partial reduction of esters with unprecedented, near-perfect selectivity and efficiency. This metal-free catalytic method is ready to be placed at the disposal of chemists to provide valuable aldehyde intermediates and products and shows promise for streamlining synthetic methods in academic and industrial settings.

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.

A Highly Sustainable Supramolecular Bioplastic Film with Superior Hydroplasticity and Biodegradability

Massive accumulation of postconsumer plastic waste in eco-system has raised growing environmental concerns. Sustainable end-of-life managements of the indispensable plastic are highly demanding and challenging in modern society. To relieve the plastic menace, herein we present a full life cycle sustainable supramolecular bioplastic made from biomass-derived polyelectrolyte (chitosan quaternary ammonium salt, QCS) and natural sodium fatty acid (sodium laurate, SL) through solid-phase molecular self-assembly (SPMSA), by which the QCS-SL complexes, precipitated from mixing the aqueous solutions, self-assemble to form bioplastic film by mildly pressing at room temperature. The QCS-SL bioplastic films display superior hydroplasticity owing to the water-activated molecular rearrangement and electrostatic bond reconstruction, which allows facile self-healing and reprocessing at room temperature to significantly extend the service lifetime of both products and raw materials. With higher water content, the dynamic electrostatic interactions and precipitation-dissolution equilibrium endow the QCS-SL bioplastic films with considerable solubility in water, which is promising to mitigate the plastic accumulation in aquatic environment. Because both QCS and SL are biocompatible and biodegradable, the dissolved QCS-SL films are nontoxic and environmentally friendly. Thus, this novel supramolecular bioplastic is highly sustainable throughout the whole life cycle, which is expected to open a new vista in sustainable plastic materials.

Exploring the Morphological Effect of Zeolite Beta on Catalytic Cracking of Polyethylene

Two types of zeolite catalysts, namely, nanosized Beta-N and micrometer-sized Beta-M, were used to crack low-density polyethylene (LDPE) with three different molecular weights: 4000, 200,000, and 3,000,000. The structural and acidic properties were analyzed by N2 physisorption, transmission electron microscopy, X-ray diffraction, temperature-programmed desorption of isopropylamine (IPA-TPD), and pyridine-adsorbed FTIR. The catalytic activity was tested at 623 K and 3.5 N2 MPa in an autoclave batch reactor for PE cracking. High Mw PE required higher decomposition activation energy due to transfer limitation. Beta-N showed better activity in PE cracking than Beta-M, with PE conversion of 82.7 and 62.0% for Beta-N and Beta-M, respectively. In addition, the nanosized Beta-N exhibited quite lower activation energy of catalytic PE decomposition than Beta-M, obtained by the Kissinger method in TGA measurement. The characterization results demonstrated that the Beta-N has abundant interparticulate mesopores to provide better dispersion for the catalysts into PE melt and the proximity of the cracking active sites. These results revealed that the Beta-N catalyst shows superior activity for the cracking of polyolefins.

Pyrolytic Depolymerization of Polyolefins Catalysed by Zirconium-based UiO-66 Metal-Organic Frameworks

Polyolefins such as polyethylenes and polypropylenes are the most-produced plastic waste globally, yet are difficult to convert into useful products due to their unreactivity. Pyrolysis is a practical method for large-scale treatment of mixed, contaminated plastic, allowing for their conversion into industrially-relevant petrochemicals. Metal-organic frameworks (MOFs), despite their tremendous utility in heterogeneous catalysis, have been overlooked for polyolefin depolymerization due to their perceived thermal instabilities and inability of polyethylenes and polypropylenes to penetrate their pores. Herein, we demonstrate the viability of UiO-66 MOFs containing coordinatively-unsaturated zirconium nodes, as effective catalysts for pyrolysis that significantly enhances the yields of valuable liquid and gas hydrocarbons, whilst halving the amounts of residual solids produced. Reactions occur on the Lewis-acidic UiO-66 nodes, without the need for noble metals, and yield aliphatic product distributions distinctly different from the aromatic-rich hydrocarbons that can be obtained from zeolite catalysis. We also demonstrate the first unambiguous characterization of polyolefin penetration into UiO-66 pores at pyrolytic temperatures, allowing access to the abundant Zr-oxo nodes within the MOF interior for efficient C-C cleavage. Our work highlights the potential of MOFs as highly-designable heterogeneous catalysts for depolymerisation of plastics, which can complement conventional catalysts in reactivity.

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.

Complete Degradation of Polyolefin Plastic Wastes to High-Value Products

Plastic wastes continuously accumulate, causing critical environmental issues. It is urgent to develop efficient strategies to convert them to valuable products. Very recently, two novel approaches for plastic recycling were reported by Huber et al. (Science, 2023, 381, 660-666) and Liu et al. (Science, 2023, 381, 666-671), where polyethylene (PE) and polypropylene (PP) plastics were converted into potentially valuable products, such as alcohols, aldehydes, surfactants, and detergents. The two processes achieved complete degradation, high selectivity of target products, as well as high values of products, showing economic feasibility for industrial scale-up. These breakthroughs for plastic recycling are highlighted in this article.

Grave-to-cradle dry reforming of plastics via Joule heating

Both plastics and CO2 are waste carbon resources, and their accumulation in nature has led to severe environmental pollution. However, simultaneously converting plastic waste and CO2 into value-added chemicals remains a challenge. Here we demonstrate a catalytic reforming process that converts plastics and CO2 into syngas over an electrified FeCrAl heating wire. The temperature of the electrified heating wire can quickly exceed 800 °C, facilitating the decomposition of polyethylene into gaseous hydrocarbons. The high-temperature heating wire promote the CO2 deoxygenation, resulting in the generation of CO, as well as the dehydrogenation of gaseous hydrocarbons. Significantly, the additional O species from CO2 and the carbon species from hydrocarbons can react to form CO, maintaining the high catalytic activity of the electrified heating wire. This novel approach is of paramount to achieving a circular economy in addressing the ongoing environmental crisis caused by the accumulation of plastic waste and excessive CO2 emissions.

Selective and Controllable Cracking of Polyethylene Waste by Beta Zeolites with Different Mesoporosity and Crystallinity

Waste plastics bring about increasingly serious environmental challenges, which can be partly addressed by their interconversion into valuable compounds. It is hypothesized that the porosity and acidity of a zeolite-based catalyst will affect the selectivity and effectiveness, enabling a controllable and selective conversion of polyethylene (PE) into gas-diesel or lubricating base oil. A series of embryonic, partial- and well-crystalline zeolites beta with adjustable porosity and acidity are prepared from mesoporous SBA-15. The catalysts and catalytic systems are studied with nuclear magnetic resonance (NMR), X-ray diffraction (XRD), and adsorption kinetics and catalytic reactions. The adjustable porosity and acidity of zeolite-beta-based catalysts achieve a controllable selectivity toward gas-diesel or lubricating base oil for PE cracking. With a catalyst with mesopores and appropriate acid sites, a fast escape and reduced production of cracking of intermediates are observed, leading to a significant fraction (88.7%) of lubricating base oil. With more micropores, a high acid density, and strong acid strength, PE is multiply cracked into low carbon number hydrocarbons. The strong acid center of the zeolite is confirmed to facilitate significantly the activation of hydrogen (H2), and, an in situ ammonia poisoning strategy can significantly inhibit hydrogen transfer and effectively regulate the product distribution.

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.

Catalytic Approaches to Tackle Mixed Plastic Waste Challenges: A Review

Plastics are widely used materials in our daily lives and various industries due to their affordability and versatility. The massive production of plastic waste, however, has recently emerged as a pressing environmental concern across all media. To address this, emerging technologies are being explored for the sustainable valorization of postconsumer plastic wastes including thermochemical, physical, and catalytic processes aimed at transforming them into higher value-added products. However, the chemical recycling of mixed plastic wastes poses a formidable challenge due to the diverse array of monomers and catalyst systems involved, each employing distinct mechanisms. Complicating matters further is that contaminants reduce catalytic efficacy, requiring rigorous and labor-intensive separation and purification processes to extract individual plastic streams from practical plastic waste mixtures. Consequently, the majority of such mixtures often end up in incineration and landfills, perpetuating environmental and societal challenges, such as leachate, carbon dioxide emissions, and other air pollutants. This review will introduce current technical developments available for recycling practical plastic waste mixtures through catalytic processes. The current challenges in process performance, low selectivity of the desired products, and catalyst deactivation from the catalysis of plastic waste mixtures are also discussed. Promising approaches to overcome the problems are suggested in future research directions.

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.

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.

Self-evolutionary recycling of flame-retardant polyurethane foam enabled by controllable catalytic cleavage

Polyurethane (PU) foams, pivotal in modern life, face challenges suh as fire hazards and environmental waste burdens. The current reliance of PU on potentially ecotoxic halogen-/phosphorus-based flame retardants impedes large-scale material recycling. Here, our demonstrated controllable catalytic cracking strategy, using cesium salts, enables self-evolving recycling of flame-retardant PU. The incorporation of cesium citrates facilitates efficient urethane bond cleavage at low temperatures (160 °C), promoting effective recycling, while encouraging pyrolytic rearrangement of isocyanates into char at high temperatures (300 °C) for enhanced PU fire safety. Even in the absence of halogen/phosphorus components, this foam exhibits a substantial increase in ignition time (+258.8%) and a significant reduction in total smoke release (-79%). This flame-retardant foam can be easily recycled into high-quality polyol under mild conditions, 60 °C lower than that for the pure foam. Notably, the trace amounts of cesium gathered in recycled polyols stimulate the regenerated PU to undergo self-evolution, improving both flame-retardancy and mechanical properties. Our controllable catalytic cracking strategy paves the way for the self-evolutionary recycling of high-performance firefighting materials.

Stapler Strategies for Upcycling Mixed Plastics

Mechanical recycling is one of the simplest and most economical strategies to address ever-increasing plastic pollution, but it cannot be applied to immiscible mixed plastics and suffers from property deterioration after each cycle. By combining the amphiphilic block copolymer strategy and reactive compatibilization strategy, we designed a series of stapler strategies for compatibilizing/upcycling mixed plastics. First, various functionalized graft copolymers were accessed via different synthetic routes. Subsequently, the addition of a very small amount of stapler molecules induced a synergistic effect with the graft copolymers that improved the compatibility and mechanical properties of mixed plastics. These strategies were highly effective for various binary/ternary plastic systems and can be directly applied to postconsumer waste plastics, which can increase the toughness of mixed postconsumer waste plastics by 162 times. Most importantly, it also effectively improved the impact resistance, adhesion performance, and three-dimensional (3D) printing performance of mixed plastics, and permitted the recycling of plastic blends 20 times with minimal degradation in their mechanical properties.

Recent advances in oxidative degradation of plastics

Oxidative degradation is a powerful method to degrade plastics into oligomers and small oxidized products. While thermal energy has been conventionally employed as an external stimulus, recent advances in photochemistry have enabled photocatalytic oxidative degradation of polymers under mild conditions. This tutorial review presents an overview of oxidative degradation, from its earliest examples to emerging strategies. This review briefly discusses the motivation and the development of thermal oxidative degradation of polymers with a focus on underlying mechanisms. Then, we will examine modern studies primarily relevant to catalytic thermal oxidative degradation and photocatalytic oxidative degradation. Lastly, we highlight some unique studies using unconventional approaches for oxidative polymer degradation, such as electrochemistry.

Driving selective upcycling of mixed polyethylene waste with table salt

Advanced recycling offers a unique opportunity for the circular economy, especially for mixed and contaminated plastics that are difficult to recycle mechanically. However, advanced recycling has barriers such as poor selectivity, contaminant sensitivity, and the need for expensive catalysts. Reported herein is a simple yet scalable methodology for converting mixed polyethylene (high-density and low-density polyethylene recycled polyethylene) into upcycled waxes with up to 94% yield. This high yield was possible by performing the reaction at a mild temperature and was enabled by using inexpensive and reusable table salt. Without table salt, in otherwise identical conditions, the plastic remained essentially undegraded. These upcycled waxes were used as prototypes for applications such as water- and oil-resistant paper, as well as rheology modifiers for plastics. Their performance is similar to that of commercial wax as well as rheology modifiers. A preliminary economic analysis shows that the upcycled waxes obtained by this table salt-catalyzed approach offer three times more revenue than those reported in the literature. This pioneering discovery opens the door for a circular economy of plastics in general and polyolefins in particular.

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.

Mapping Plastic and Plastic Additive Cycles in Coastal Countries: A Norwegian Case Study

The growing environmental consequences caused by plastic pollution highlight the need for a better understanding of plastic polymer cycles and their associated additives. We present a novel, comprehensive top-down method using inflow-driven dynamic probabilistic material flow analysis (DPMFA) to map the plastic cycle in coastal countries. For the first time, we covered the progressive leaching of microplastics to the environment during the use phase of products and modeled the presence of 232 plastic additives. We applied this methodology to Norway and proposed initial release pathways to different environmental compartments. 758 kt of plastics distributed among 13 different polymers was introduced to the Norwegian economy in 2020, 4.4 Mt was present in in-use stocks, and 632 kt was wasted, of which 15.2 kt (2.4%) was released to the environment with a similar share of macro- and microplastics and 4.8 kt ended up in the ocean. Our study shows tire wear rubber as a highly pollutive microplastic source, while most macroplastics originated from consumer packaging with LDPE, PP, and PET as dominant polymers. Additionally, 75 kt of plastic additives was potentially released to the environment alongside these polymers. We emphasize that upstream measures, such as consumption reduction and changes in product design, would result in the most positive impact for limiting plastic pollution.

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.

Polyurethane with β-Selenocarbonyl Structure Enabling the Combination of Plastic Degradation and Waste Upcycling

Degradable polymers offer a promising solution to mitigate global plastic pollution, but the degraded products often suffer from diminished value. Upcycling is a more sustainable approach to upgrade polymer waste into value-added products. Herein, we report a β-selenocarbonyl-containing polyurethane (SePU), which can be directly degraded under mild conditions into valuable selenium fertilizers for selenium-rich vegetable cultivation globally, enabling both plastic degradation and waste upcycling. Under oxidation condition, this polymer can be easily and selectively degraded via selenoxide elimination reaction from mixed plastic waste. The degraded product can serve as effective selenium fertilizers to increase selenium content in radish and pak choi. The SePU exhibits excellent mechanical properties. Additionally, we observed the formation of spherulites-like selenium particles within the materials during degradation for the first time. Our research offers a successful application of selenoxide elimination reaction in the field of plastic degradation for the first time, endowing plastics with both degradability and high reusable value. This strategy provides a promising solution to reduce pollution and improve economy and sustainability of plastics.

Upcycling Polyolefin Blends into High-Performance Materials by Exploiting Azidotriazine Chemistry Using Reactive Extrusion

The revalorization of incompatible polymer blends is a key obstacle in realizing a circular economy in the plastics industry. Polyolefin waste is particularly challenging because it is difficult to sort into its constituent components. Untreated blends of polyethylene and polypropylene typically exhibit poor mechanical properties that are suitable only for low-value applications. Herein, we disclose a simple azidotriazine-based grafting agent that enables polyolefin blends to be directly upcycled into high-performance materials by using reactive extrusion at industrially relevant processing temperatures. Based on a series of model experiments, the azidotriazine thermally decomposes to form a triplet nitrene species, which subsequently undergoes a complex mixture of grafting, oligomerization, and cross-linking reactions; strikingly, the oligomerization and cross-linking reactions proceed through the formation of nitrogen-nitrogen bonds. When applied to polyolefin blends during reactive extrusion, this combination of reactions leads to the generation of amorphous, phase-separated nanostructures that tend to exist at polymer-polymer interfaces. These nanostructures act as multivalent cross-linkers that reinforce the resulting material, leading to dramatically improved ductility compared with the untreated blends, along with high dimensional stability at high temperatures and excellent mechanical recyclability. We propose that this unique behavior is derived from the thermomechanically activated reversibility of the nitrogen-nitrogen bonds that make up the cross-linking structures. Finally, the scope of this chemistry is demonstrated by applying it to ternary polyolefin blends as well as postconsumer polyolefin feedstocks.

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.

Thermally Robust yet Deconstructable and Chemically Recyclable High-Density Polyethylene (HDPE)-Like Materials Based on Si-O Bonds

Polyethylene (PE) is the most widely produced synthetic polymer. By installing chemically cleavable bonds into the backbone of PE, it is possible to produce chemically deconstructable PE derivatives; to date, however, such designs have primarily relied on carbonyl- and olefin-related functional groups. Bifunctional silyl ethers (BSEs; SiR2 (OR'2 )) could expand the functional scope of PE mimics as they possess strong Si-O bonds and facile chemical tunability. Here, we report BSE-containing high-density polyethylene (HDPE)-like materials synthesized through a one-pot catalytic ring-opening metathesis polymerization (ROMP) and hydrogenation sequence. The crystallinity of these materials can be adjusted by varying the BSE concentration or the steric bulk of the Si-substituents, providing handles to control thermomechanical properties. Two methods for chemical recycling of HDPE mimics are introduced, including a circular approach that leverages acid-catalyzed Si-O bond exchange with 1-propanol. Additionally, despite the fact that the starting HDPE mimics were synthesized by chain-growth polymerization (ROMP), we show that it is possible to recover the molar mass and dispersity of recycled HDPE products using step-growth Si-O bond formation or exchange, generating high molecular weight recycled HDPE products with mechanical properties similar to commercial HDPE.