One-Pot Biosynthesis of Acetone from Waste Poly(hydroxybutyrate)

The plastic waste crisis is catalyzing change across the plastics life cycle. Central to this is increased production and application of bioplastics and biodegradable plastics. In particular, poly(hydroxybutyrate) (PHB) is a biodegradable bioplastic that can be produced from various renewable and waste feedstocks and is a promising alternative to some petrochemical-derived and non-biodegradable plastics. Despite its advantages, PHB biodegradation depends on environmental conditions, and the effects of degradation into microplastics, oligomers, and the 3-hydroxybutyrate (3-HB) monomer on soil microbiomes are unknown. We hypothesized that the ease of PHB biodegradation renders this next-generation plastic an ideal feedstock for microbial recycling into platform chemicals currently produced from fossil fuels. To demonstrate this, we report the one-pot degradation and recycling of PHB into acetone using a single strain of engineered Escherichia coli. Following strain development and initial bioprocess optimization, we report maximum titers of 123 mM acetone (7 g/L) from commercial PHB granules after 24 h fermentation at 30 °C. We further report biorecycling of an authentic sample of post-consumer PHB waste at a preparative scale. This is the first demonstration of biological recycling of PHB into a second-generation chemical, and it demonstrates next-generation plastic waste as a novel feedstock for the circular bioeconomy.

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.

Photocatalytic Hydrolysis-A Sustainable Option for the Chemical Upcycling of Polylactic Acid

Plastic waste is a critical global issue, yet current strategies to avoid committing plastic waste to landfills include incineration, gasification, or pyrolysis high carbon emitting and energy consuming approaches. However, plastic waste can become a resource instead of a problem if high value products, such as fine chemicals and liquid fuel molecules, can be liberated from controlled its decomposition. This letter presents proof of concept on a low-cost, low energy approach to controlled decomposition of plastic, photocatalytic hydrolysis. This approach integrates photolysis and hydrolysis, both slow natural decomposition processes, with a photocatalytic process. The photocatalyst, α-Fe2O3, is embedded into a polylactic acid (PLA) plastic matrix. The photocatalyst/plastic composite is then immersed in water and subjected to low-energy (25 W) UV light for 90 h. The monomer lactide is produced as the major product. α-Fe2O3 (6.9 wt %) was found to accelerate the PLA degradation pathway, achieving 32% solid transformation into liquid phase products, in comparison to PLA on its own, which was found to not decompose, using the same conditions. This highlights a low energy route toward plastic waste upgrade and valorization that is less carbon intensive than pyrolysis and faster than natural degradation. By directly comparing a 25 W (0.025 kWh) UV bulb with a 13 kWh furnace, the photocatalytic reaction would directly consume 520× less energy than a conventional thermochemical pathway. Furthermore, this technology can be extended and applied to other plastics, and other photocatalysts can be used.

Electrochemical Production of Glycolate Fuelled By Polyethylene Terephthalate Plastics with Improved Techno-Economics

Electrochemical valorization of polyethylene terephthalate (PET) waste streams into commodity chemicals offers a potentially sustainable route for creating a circular plastic economy. However, PET wastes upcycling into valuable C2 product remains a huge challenge by the lack of an electrocatalyst that can steer the oxidation economically and selectively. Here, it is reported a catalyst comprising Pt nanoparticles hybridized with γ-NiOOH nanosheets supported on Ni foam (Pt/γ-NiOOH/NF) that favors electrochemical transformation of real-word PET hydrolysate into glycolate with high Faradaic efficiency (> 90%) and selectivity (> 90%) across wide reactant (ethylene glycol, EG) concentration ranges under a marginal applied voltage of 0.55 V, which can be paired with cathodic hydrogen production. Computational studies combined with experimental characterizations elucidate that the Pt/γ-NiOOH interface with substantial charge accumulation gives rise to an optimized adsorption energy of EG and a decreased energy barrier of potential determining step. A techno-economic analysis demonstrates that, with the nearly same amount of resource investment, the electroreforming strategy towards glycolate production can raise revenue by up to 2.2 times relative to conventional chemical process. This work may thus serve as a framework for PET wastes valorization process with net-zero carbon footprint and high economic viability.

Upcycling of Waste Plastic into Hybrid Carbon Nanomaterials

Graphitic 1D and hybrid nanomaterials represent a powerful solution in composite and electronic applications due to exceptional properties, but large-scale synthesis of hybrid materials has yet to be realized. Here, a rapid, scalable method to produce graphitic 1D materials from polymers using flash Joule heating (FJH) is reported. This avoids lengthy chemical vapor deposition and uses no solvent or water. The flash 1D materials (F1DM), synthesized using a variety of earth-abundant catalysts, have controllable diameters and morphologies by parameter tuning. Furthermore, the process can be modified to form hybrid materials, with F1DM bonded to turbostratic graphene. In nanocomposites, F1DM outperform commercially available carbon nanotubes. Compared to current 1D material synthetic strategies using life cycle assessment, FJH synthesis represents an 86-92% decrease in cumulative energy demand and 92-94% decrease in global-warming potential. This work suggests that FJH affords a cost-effective and sustainable route to upcycle waste plastic into valuable 1D and hybrid nanomaterials.

Nanocomposite Foams with Balanced Mechanical Properties and Energy Return from EVA and CNT for the Midsole of Sports Footwear Application

Polymer foam that provides good support with high energy return (low energy loss) is desirable for sport footwear to improve running performance. Ethylene-vinyl acetate copolymer (EVA) foam is commonly used in the midsole of running shoes. However, EVA foam exhibits low mechanical properties. Conventional mineral fillers are usually employed to improve EVA's mechanical performance, but the energy return is sacrificed. Here, we produced nanocomposite foams from EVA and multi-walled carbon nanotubes (CNT) using a chemical foaming process. Two kinds of CNT derived from the upcycling of commodity plastics were prepared through a catalytic chemical vapor deposition process and used as reinforcing and nucleating agents. Our results show that EVA foam incorporated with oxygenated CNT (O-CNT) demonstrated a more pronounced improvement of physical, mechanical, and dynamic impact response properties than acid-purified CNT (A-CNT). When CNT with weight percentage as low as 0.5 wt% was added to the nanocomposites, the physical properties, abrasion resistance, compressive strength, dynamic stiffness, and rebound performance of the EVA foams were improved significantly. Unlike the conventional EVA formulation filled with talc mineral fillers, the incorporation of CNT does not compromise the energy return of the EVA foam. From the long-cycle dynamic fatigue test, the CNT/EVA foam displays greater properties retention as compared to the talc/EVA foam. This work demonstrates a good balanced of mechanical-energy return properties of EVA nanocomposite foam with very low CNT content, which presents promising opportunities for lightweight-high rebound midsoles for running shoes.

Upcycling of poly(ethylene terephthalate) to produce high-value bio-products

More than 70 million tons of poly(ethylene terephthalate) (PET) are manufactured worldwide every year. The accumulation of PET waste has become a global pollution concern, motivating the urgent development of technologies to valorize post-consumer PET. The development of chemocatalytic and enzymatic approaches for depolymerizing PET to its corresponding monomers opens up new opportunities for PET upcycling through biological transformation. Here, we identify Rhodococcus jostii strain PET (RPET) that can directly use PET hydrolysate as a sole carbon source. We also investigate the potential of RPET to upcycle PET into value-added chemicals, using lycopene as a proof-of-concept product. Through rational metabolic engineering, we improve lycopene production by more than 500-fold over that of the wild type. In addition, we demonstrate the production of approximately 1,300 μg/L lycopene from PET by cascading this strain with PET alkaline hydrolysis. This work highlights the great potential of biological conversion as a means of achieving PET upcycling.

Critical Review on the Progress of Plastic Bioupcycling Technology as a Potential Solution for Sustainable Plastic Waste Management

Plastic production worldwide has doubled in the last two decades and is expected to reach a four-fold increase by 2050. The durability of plastic makes them a perfect material for many applications, but it is also a key limitation to their end-of-life management. The current plastic lifecycle is far from circular, with only 13% being collected for recycling and 9% being successfully recycled, indicating the failure of current recycling technology. The remaining plastic waste streams are thus incinerated, landfilled, or worse, mismanaged, leading to them leaking into the environment. To promote plastic circularity, keeping material in the loop is a priority and represents a more sustainable solution. This can be achieved through the reuse of plastic items, or by using plastic waste as a resource for new materials, instead of discarding them as waste. As the discovery of plastic-degrading/utilizing microorganisms and enzymes has been extensively reported recently, the possibility of developing biological plastic upcycling processes is opening up. An increasing amount of studies have investigated the use of plastic as a carbon source for biotechnological processes to produce high-value compounds such as bioplastics, biochemicals, and biosurfactants. In the current review, the advancements in fossil-based plastic bio- and thermochemical upcycling technologies are presented and critically discussed. In particular, we highlight the developed (bio)depolymerization coupled with bioconversion/fermentation processes to obtain industrially valuable products. This review is expected to contribute to the future development and scale-up of effective plastic bioupcycling processes that can act as a drive to increase waste removal from the environment and valorize post-consumer plastic streams, thus accelerating the implementation of a circular (plastic) economy.

Upcycling Plastic Wastes into Value-Added Products by Heterogeneous Catalysis

Plastics are playing essential roles in the modern society. The majority of them enter environment through landfilling or discarding after turning into wastes, causing severe carbon loss and imposing high risk to ecosystem and human health. Currently, physical recycling serves as the primary method to reuse plastic waste, but this method is limited to thermoplastic recycling. The quality of recycled plastics gradually deteriorates because of the undesirable degradation in the recycling process. Under such background, catalytic upcycling, which can upgrade various plastic wastes into value-added products under mild conditions, has attracted recent attention as a promising strategy to treat plastic wastes. This Review highlights recent advances in the development of efficient heterogeneous catalysts and useful strategies for upcycling plastics into liquid hydrocarbons, arene compounds, carbon materials, hydrogen, and other value-added chemicals. The functions of catalysts and the reaction mechanisms are discussed. The key factors that influence the catalytic performance are also analyzed.

Electrochemical Activation of C-C Bonds through Mediated Hydrogen Atom Transfer Reactions

Activating inert sp³ -sp³ carbon-carbon (C-C) bonds remains a major bottleneck in the chemical upcycling of recalcitrant polyolefin waste. In this study, redox mediators are used to activate the inert C-C bonds. Specifically, N-hydroxyphthalimide (NHPI) is used as the redox mediator, which is oxidized to phthalimide-N-oxyl (PINO) radical to initiate hydrogen atom transfer (HAT) reactions with benzylic C-H bonds. The resulting carbon radical is readily captured by molecular oxygen to form a peroxide that decomposes into oxygenated C-C bond-scission fragments. This indirect approach reduces the oxidation potential by >1.2 V compared to the direct oxidation of the substrate. Studies with model compounds reveal that the selectivity of C-C bond cleavage increases with decreasing C-C bond dissociation energy. With NHPI-mediated oxidation, oligomeric styrene (OS₅₁₀ ; M_n =510 Da) and polystyrene (PS; M_n ≈10 000 Da) are converted into oxygenated monomers, dimers, and oligomers.

Waste-to-Fuels: Pyrolysis of Low-Density Polyethylene Waste in the Presence of H-ZSM-11

Herein, the pyrolysis of low-density polyethylene (LDPE) scrap in the presence of a H-ZSM-11 zeolite was conducted as an effort to valorize plastic waste to fuel-range chemicals. The LDPE-derived pyrolytic gas was composed of low-molecular-weight aliphatic hydrocarbons (e.g., methane, ethane, propane, ethylene, and propylene) and hydrogen. An increase in pyrolysis temperature led to increasing the gaseous hydrocarbon yields for the pyrolysis of LDPE. Using the H-ZSM-11 catalyst in the pyrolysis of LDPE greatly enhanced the content of propylene in the pyrolytic gas because of promoted dehydrogenation of propane formed during the pyrolysis. Apart from the light aliphatic hydrocarbons, jet fuel-, diesel-, and motor oil-range hydrocarbons were found in the pyrolytic liquid for the non-catalytic and catalytic pyrolysis. The change in pyrolysis temperature for the catalytic pyrolysis affected the hydrocarbon compositions of the pyrolytic liquid more materially than for the non-catalytic pyrolysis. This study experimentally showed that H-ZSM-11 can be effective at producing fuel-range hydrocarbons from LDPE waste through pyrolysis. The results would contribute to the development of waste valorization process via plastic upcycling.

Conversion of Polyolefin Waste to Liquid Alkanes with Ru-Based Catalysts under Mild Conditions

Chemical upcycling of waste polyolefins via hydrogenolysis offers unique opportunities for selective depolymerization compared to high temperature thermal deconstruction. Here, we demonstrate the hydrogenolysis of polyethylene into liquid alkanes under mild conditions using ruthenium nanoparticles supported on carbon (Ru/C). Reactivity studies on a model n-octadecane substrate showed that Ru/C catalysts are highly active and selective for the hydrogenolysis of C(sp³)-C(sp³) bonds at temperatures ranging from 200 to 250 °C. Under optimal conditions of 200 °C in 20 bar H₂, polyethylene (average M _w ∼ 4000 Da) was converted into liquid n-alkanes with yields of up to 45% by mass after 16 h using a 5 wt % Ru/C catalyst with the remaining products comprising light alkane gases (C₁-C₆). At 250 °C, nearly stoichiometric yields of CH₄ were obtained from polyethylene over the catalyst. The hydrogenolysis of long chain, low-density polyethylene (LDPE) and a postconsumer LDPE plastic bottle to produce C₇-C₄₅ alkanes was also achieved over Ru/C, demonstrating the feasibility of this reaction for the valorization of realistic postconsumer plastic waste. By identifying Ru-based catalysts as a class of active materials for the hydrogenolysis of polyethylene, this study elucidates promising avenues for the valorization of plastic waste under mild conditions.

Unraveling 1,4-Butanediol Metabolism in Pseudomonas putida KT2440

Plastics, in all forms, are a ubiquitous cornerstone of modern civilization. Although humanity undoubtedly benefits from the versatility and durability of plastics, they also cause a tremendous burden for the environment. Bio-upcycling is a promising approach to reduce this burden, especially for polymers that are currently not amenable to mechanical recycling. Wildtype P. putida KT2440 is able to grow on 1,4-butanediol as sole carbon source, but only very slowly. Adaptive laboratory evolution (ALE) led to the isolation of several strains with significantly enhanced growth rate and yield. Genome re-sequencing and proteomic analysis were applied to characterize the genomic and metabolic basis of efficient 1,4-butanediol metabolism. Initially, 1,4-butanediol is oxidized to 4-hydroxybutyrate, in which the highly expressed dehydrogenase enzymes encoded within the PP_2674-2680 ped gene cluster play an essential role. The resulting 4-hydroxybutyrate can be metabolized through three possible pathways: (i) oxidation to succinate, (ii) CoA activation and subsequent oxidation to succinyl-CoA, and (iii) beta oxidation to glycolyl-CoA and acetyl-CoA. The evolved strains were both mutated in a transcriptional regulator (PP_2046) of an operon encoding both beta-oxidation related genes and an alcohol dehydrogenase. When either the regulator or the alcohol dehydrogenase is deleted, no 1,4-butanediol uptake or growth could be detected. Using a reverse engineering approach, PP_2046 was replaced by a synthetic promotor (14g) to overexpress the downstream operon (PP_2047-2051), thereby enhancing growth on 1,4-butanediol. This work provides a deeper understanding of microbial 1,4-butanediol metabolism in P. putida, which is also expandable to other aliphatic alpha-omega diols. It enables the more efficient metabolism of these diols, thereby enabling biotechnological valorization of plastic monomers in a bio-upcycling approach.