Chemical Recycling Processes of Waste Polyethylene Terephthalate Using Solid Catalysts

Optimization of PET depolymerization for enhanced terephthalic acid recovery from commercial PET and post consumer PET-bottles via low-temperature alkaline hydrolysis

The increasing demand for plastic has resulted in a surge in plastic waste production. Polyethylene terephthalate (PET), commonly used in beverage bottle manufacturing, is only partially recycled, with an estimated recycling rate of just 28.4% in 2019. This accumulation of plastic waste is harmful to the environment and living organisms, necessitating effective recycling methods for PET waste. One promising method is alkaline hydrolysis using NaOH, which can break down PET into its monomer components, terephthalic acid (TPA) and ethylene glycol (EG). This process not only recycles PET efficiently but also manages contaminants effectively, producing high-quality TPA, supporting the development of a circular economy. This study looks into PET depolymerization via alkaline hydrolysis at low temperature by investigating effects of various factors: pH levels, water to ethanol ratio, NaOH concentration, NaOH to PET ratio, reaction time, PET size, reusability of unreacted PET, air plasma pretreatment of PET, and different kinds of PET. Promisingly, PET conversion rates of over 90% and a TPA purity of 99.6% were achieved in this study highlighting the efficacy of alkaline hydrolysis in depolymerizing post-consumer PET waste. Ultimately, this research advances sustainable plastic waste management and supports the integration of PET into a circular economy framework.

PET Glycolysis to BHET Efficiently Catalyzed by Stable and Recyclable Pd-Cu/γ-Al2O3

Glycolysis of poly(ethylene terephthalate) (PET) is a prospective way for degradation of PET to its monomer bis(hydroxyethyl) terephthalate (BHET), providing the possibility for a permanent loop recycling. However, most reported glycolysis catalysts are homogeneous, making the catalyst difficult to recover and contaminating the products. Herein, we reported on the Pd-Cu/γ-Al2O3 catalyst and applied it in the glycolysis of PET as catalyst. The formed structure gave Pd-Cu/γ-Al2O3 a high active surface area, which enabled these micro-particles to work more efficiently. The PET conversion and BHET yield reached 99% and 86%, respectively, in the presence of 5 wt% of Pd-Cu/γ-Al2O3 catalyst within 80 min at 160 °C. After the reaction, the catalyst can be quickly separated by filtration, so it can be easily reused without significant loss of reactivity at least five times. Therefore, the Pd-Cu/γ-Al2O3 catalyst may contribute to an economically and environmentally improved large-scale recycling of PET fiber waste.

Value-Added Upcycling of PET to 1,4-Cyclohexanedimethanol by a Hydrogenation/Hydrogenolysis Relay Catalysis

We present an innovative process for directly transforming poly(ethylene terephthalate) (PET), a polymer extensively used in food and beverage packaging, into trans-isomer-enriched 1,4-cyclohexanedimethanol (CHDM), a key ingredient in advanced specialty polymers. Our approach leverages a dual-catalyst system featuring palladium on reduced graphene oxide (Pd/r-GO) and oxalate-gel-derived copper-zinc oxide (og-CuZn), utilizing hydrogenation/hydrogenolysis relay catalysis. This method efficiently transforms PET into polyethylene-1,4-cyclohexanedicarboxylate (PECHD), which is then converted into CHDM with an impressive overall yield of 95 % in a two-stage process. Our process effectively handles various post-consumer PET plastics, converting them into CHDM with yields between 78 % and 89 % across different substrates. Additionally, we demonstrate the applicability and scalability of this approach through a temperature-programmed three-stage relay process on a 10-gram scale, which results in purified CHDM with an isolated yield of 87 % and a notably higher trans/cis ratio of up to 4.09/1, far exceeding that of commercially available CHDM. This research not only provides a viable route for repurposing PET waste but also enhances the control of selectivity patterns in multistage relay catalysis.

Ir(triNHC)-Catalyzed Upcycling of Waste PET for Lactic Acid Production with Sustainable Isolation via Bipolar Membrane Electrodialysis

For the upcycling of waste polyethylene terephthalate (PET), encompassing both colored and fabric PET materials, we investigated the Ir(triNHC)-catalyzed dehydrogenative coupling of PET and methanol, leading to the production of sodium lactate with good yields. We proposed a sustainable method for isolating lactic acid from the catalytic reaction mixture of sodium lactate and regenerating the base using bipolar membrane electrodialysis (BMED). This isolation method demonstrated high effectiveness, achieving isolation of lactic acid while maintaining economic feasibility at $ 0.10 per kg of lactic acid, and enabling sustainable NaOH regeneration with complete resource circulation. We assessed the recyclability of the catalyst and elucidated the mechanism involving base-mediated depolymerization and catalyst-promoted dehydrogenation, highlighting the importance of triNHC ligands in enhancing catalytic activity.

A comprehensive review of PETW recycling for supercapacitor applications

The rising measure of waste produced from polyethene terephthalate (PET) and the interest in eco-accommodating energy storage arrangements have prompted escalated examination into reusing waste PET into supercapacitors. This review aims to provide a comprehensive overview of the most recent advancements in the recycling of polyethylene terephthalate waste (PETW), as a supercapacitor electrode precursor. The review looks at different methodologies for recovering PET from waste, including mechanical, chemical, enzyme, etc. It further explores the combination strategies for electrode materials produced using PET. Besides, PET-derived materials' electrochemical performance in supercapacitor application is likewise broken down, with an emphasis on key electrochemical boundaries like capacitive behaviour, cyclic stability, and electrochemical impedance spectroscopy. The need for scalable and cost-effective recycling methods, the creation of eco-friendly electrolytes, and the improvement of the electrochemical performance of recycled PET-based supercapacitors are just a few of the issues and opportunities highlighted in this expanding eco-friendly industry. Overall, the goal of this review is to provide a comprehensive understanding of the cutting-edge developments in the use of recycled PETW as a precursor for supercapacitor electrodes, highlighting the eco-friendly energy storage solution's potential and contributing to a sustainable future.

A waste-to-wealth conversion of plastic bottles into effective carbon-based adsorbents for removal of tetracycline antibiotic from water

Currently, plastic waste and antibiotic wastewater are two of the most critical environmental problems, calling for urgent measures to take. A waste-to-wealth strategy for the conversion of polyethylene terephthalate (PET) plastic bottles into value-added materials such as carbon composite is highly recommended to clean wastewater contaminated by antibiotics. Inspired by this idea, we develop a novel PET-AC-ZFO composite by incorporating PET plastic-derived KOH-activated carbon (AC) with ZnFe2O4 (ZFO) particles for adsorptive removal of tetracycline (TTC). PET-derived carbon (PET-C), KOH-activated PET-derived carbon (PET-AC), and PET-AC-ZFO were characterized using physicochemical analyses. Central composite design (CCD) was used to obtain a quadratic model by TTC concentration (K), adsorbent dosage (L), and pH (M). PET-AC-ZFO possessed micropores (d ≈ 2 nm) and exceptionally high surface area of 1110 m2 g-1. Nearly 90% TTC could be removed by PET-AC-ZFO composite. Bangham kinetic and Langmuir isotherm were two most fitted models. Theoretical maximum TTC adsorption capacity was 45.1 mg g-1. This study suggested the role of hydrogen bonds, pore-filling interactions, and π-π interactions as the main interactions of the adsorption process. Thus, a strategy for conversion of PET bottles into PET-AC-ZFO can contribute to both plastic recycling and antibiotic wastewater mitigation.

Demystifying group-4 polyolefin hydrogenolysis catalysis. Gaseous propane hydrogenolysis mechanism over the same catalysts

A kinetic/mechanistic investigation of gaseous propane hydrogenolysis over the single-site heterogeneous polyolefin depolymerization catalysts AlS/ZrNp2 and AlS/HfNp2 (AlS = sulfated alumina, Np = neopentyl), is use to probe intrinsic catalyst properties without the complexities introduced by time- and viscosity-dependent polymer medium effects. In a polymer-free automated plug-flow catalytic reactor, propane hydrogenolysis turnover frequencies approach 3,000 h-1 at 150 °C. Both catalysts exhibit approximately linear relationships between rate and [H2] at substoichiometric [H2] with rate law orders of 0.66 ± 0.09 and 0.48 ± 0.07 for Hf and Zr, respectively; at higher [H2], the rates approach zero-order in [H2]. Reaction orders in [C3H8] and [catalyst] are essentially zero-order under all conditions, with the former implying rapid, irreversible alkane binding/activation. This rate law, activation parameter, and DFT energy span analysis support a scenario in which [H2] is pivotal in one of two plausible and competing rate-determining transition states-bimolecular metal-alkyl bond hydrogenolysis vs. unimolecular β-alkyl elimination. The Zr and Hf catalyst activation parameters, ΔH‡ = 16.8 ± 0.2 kcal mol-1 and 18.2 ± 0.6 kcal mol-1, respectively, track the relative turnover frequencies, while ΔS‡ = -19.1 ± 0.8 and -16.7 ± 1.4 cal mol-1 K-1, respectively, imply highly organized transition states. These catalysts maintain activity up to 200 °C, while time-on-stream data indicate multiday activities with an extrapolated turnover number ~92,000 at 150 °C for the Zr catalyst. This methodology is attractive for depolymerization catalyst discovery and process optimization.

High versatility of polyethylene terephthalate (PET) waste for the development of batteries, biosensing and gas sensing devices

Continuously growing adoption of electronic devices in energy storage, human health and environmental monitoring systems increases demand for cost-effective, lightweight, comfortable, and highly efficient functional structures. In this regard, the recycling and reuse of polyethylene terephthalate (PET) waste in the aforementioned fields due to its excellent mechanical properties and chemical resistance is an effective solution to reduce plastic waste. Herein, we review recent advances in synthesis procedures and research studies on the integration of PET into energy storage (Li-ion batteries) and the detection of gaseous and biological species. The operating principles of such systems are described and the role of recycled PET for various types of architectures is discussed. Modifying the composition, crystallinity, surface porosity, and polar surface functional groups of PET are important factors for tuning its features as the active or substrate material in biological and gas sensors. The findings indicate that conceptually new pathways to the study are opened up for the effective application of recycled PET in the design of Li-ion batteries, as well as biochemical and catalytic detection systems. The current challenges in these fields are also presented with perspectives on the opportunities that may enable a circular economy in PET use.

Polyethylene Terephthalate (PET) Recycled by Catalytic Glycolysis: A Bridge toward Circular Economy Principles

Plastic pollution has escalated into a critical global issue, with production soaring from 2 million metric tons in 1950 to 400.3 million metric tons in 2022. The packaging industry alone accounts for nearly 44% of this production, predominantly utilizing polyethylene terephthalate (PET). Alarmingly, over 90% of the approximately 1 million PET bottles sold every minute end up in landfills or oceans, where they can persist for centuries. This highlights the urgent need for sustainable management and recycling solutions to mitigate the environmental impact of PET waste. To better understand PET's behavior and promote its management within a circular economy, we examined its chemical and physical properties, current strategies in the circular economy, and the most effective recycling methods available today. Advancing PET management within a circular economy framework by closing industrial loops has demonstrated benefits such as reduced landfill waste, minimized energy consumption, and conserved raw resources. To this end, we identified and examined various strategies based on R-imperatives (ranging from 3R to 10R), focusing on the latest approaches aimed at significantly reducing PET waste by 2040. Additionally, a comparison of PET recycling methods (including primary, secondary, tertiary, and quaternary recycling, along with the concepts of "zero-order" and biological recycling techniques) was envisaged. Particular attention was paid to the heterogeneous catalytic glycolysis, which stands out for its rapid reaction time (20-60 min), high monomer yields (>90%), ease of catalyst recovery and reuse, lower costs, and enhanced durability. Accordingly, the use of highly efficient oxide-based catalysts for PET glycolytic degradation is underscored as a promising solution for large-scale industrial applications.

Polyethylene terephthalate waste derived nanomaterials (WDNMs) and its utilization in electrochemical devices

Plastics are a vital component of our daily lives in the contemporary globalization period; they are present in all facets of modern life. Because the bulk of synthetic plastics utilized in the market are non-biodegradable by nature, the issues associated with their contamination are unavoidable in an era dominated by polymers. Polyethylene terephthalate (PET), which is extensively used in industries such as automotive, packaging, textile, food, and beverages production represents a major share of these non-biodegradable polymer productions. Given its extensive application across various sectors, PET usage results in a considerable amount of post-consumer waste, majority of which require disposal after a certain period. However, the recycling of polymeric waste materials has emerged as a prominent topic in research, driven by growing environmental consciousness. Numerous studies indicate that products derived from polymeric waste can be converted into a new polymeric resource in diverse sectors, including organic coatings and regenerative medicine. This review aims to consolidate significant scientific literatures on the recycling PET waste for electrochemical device applications. It also highlights the current challenges in scaling up these processes for industrial application.

Turning plastics/microplastics into valuable resources? Current and potential research for future applications

Plastics are a wide range of synthetic or semi-synthetic materials, mainly consisting of polymers. The use of plastics has increased to over 300 million metric tonnes in recent years, and by 2050, it is expected to grow to 800 million. Presently, a mere 10% of plastic waste is recycled, with approximately 75% ended up in landfills. Inappropriate disposal of plastic waste into the environment poses a threat to human lives and marine species. Therefore, this review article highlights potential routes for converting plastic/microplastic waste into valuable resources to promote a greener and more sustainable environment. The literature review revealed that plastics/microplastics (P/MP) could be recycled or upcycled into various products or materials via several innovative processes. For example, P/MP are recycled and utilized as anodes in lithium-ion (Li-ion) and sodium-ion (Na-ion) batteries. The anode in Na-ion batteries comprising PP carbon powder exhibits a high reversible capacity of ∼340 mAh/g at 0.01 A/g current state. In contrast, integrating Fe3O4 and PE into a Li-ion battery yielded an excellent capacity of 1123 mAh/g at 0.5 A/g current state. Additionally, recycled Nylon displayed high physical and mechanical properties necessary for excellent application as 3D printing material. Induction heating is considered a revolutionary pyrolysis technique with improved yield, efficiency, and lower energy utilization. Overall, P/MPs are highlighted as abundant resources for the sustainable production of valuable products and materials such as batteries, nanomaterials, graphene, and membranes for future applications.

Selective Upcycling of Polyethylene Terephthalate towards High-valued Oxygenated Chemical Methyl p-Methyl Benzoate using a Cu/ZrO2 Catalyst

Upgrading of polyethylene terephthalate (PET) waste into valuable oxygenated molecules is a fascinating process, yet it remains challenging. Herein, we developed a two-step strategy involving methanolysis of PET to dimethyl terephthalate (DMT), followed by hydrogenation of DMT to produce the high-valued chemical methyl p-methyl benzoate (MMB) using a fixed-bed reactor and a Cu/ZrO2 catalyst. Interestingly, we discovered the phase structure of ZrO2 significantly regulates the selectivity of products. Cu supported on monoclinic ZrO2 (5 %Cu/m-ZrO2 ) exhibits an exceptional selectivity of 86 % for conversion of DMT to MMB, while Cu supported on tetragonal ZrO2 (5 %Cu/t-ZrO2 ) predominantly produces p-xylene (PX) with selectivity of 75 %. The superior selectivity of MMB over Cu/m-ZrO2 can be attributed to the weaker acid sites present on m-ZrO2 compared to t-ZrO2 . This weak acidity of m-ZrO2 leads to a moderate adsorption capability of MMB, and facilitating its desorption. Furthermore, DFT calculations reveal Cu/m-ZrO2 catalyst shows a higher effective energy barrier for cleavage of second C-O bond compared to Cu/t-ZrO2 catalyst; this distinction ensures the high selectivity of MMB. This catalyst not only presents an approach for upgrading of PET waste into fine chemicals but also offers a strategy for controlling the primary product in a multistep hydrogenation reaction.

Advances in solar-driven, electro/photoelectrochemical, and microwave-assisted upcycling of waste polyesters

Plastic waste in the environment causes significant environmental pollution. The potential of using chemical methods for upcycling plastic waste offers a dual solution to ensure resource sustainability and environmental restoration. This article provides a comprehensive overview of the latest technologies driven by solar-driven, electro/photoelectrochemical-catalytic, and microwave-assisted methods for the conversion of plastics into various valuable chemicals. It emphasizes selective conversion during the plastic transformation process, elucidates reaction pathways, and optimizes product selectivity. Finally, the article offers insights into the future developments of chemical upcycling of polyesters.

Eco-Friendly Blends of Recycled PET Copolymers with PLLA and Their Composites with Chopped Flax Fibres

The structure and properties of blends of a novel polyethylene terephthalate copolymer (COPET) obtained by chemical recycling of commercial PET with high-molar-mass poly-L-lactide (PLLA) are investigated and compared to corresponding composites with chopped flax fibres. The focus is on the morphology at nano- and micro-scales, on the thermal characteristics and on the mechanical behaviour. The blends are immiscible, as evidenced by virtually unchanged glass transition temperatures of the blend components compared to the neat polymers (49 °C for COPET and 63 °C for PLLA by DSC). At low PLLA content, the blends display a sea-island morphology with sub-micron to micron droplet sizes. As the composition approaches 50/50, the morphology transitions to a coarser co-continuous elongated structure. The blends and composites show strongly improved stiffness compared to COPET above its glass transition temperature, e.g., from melt behaviour at 60 °C for COPET alone to almost 600 MPa for the 50/50 blend and 500 MPa for the 20% flax composite of the 80/20 COPET/PLLA blend. The flax fibres increase the crystallisation rate of PLLA in blends with dispersed PLLA morphology. The evidence of cavitation on the fracture surfaces of blends shows that despite the immiscibility of the components, the interfacial adhesion between the phases is excellent. This is attributed to the presence of aliphatic ester spacers in COPET. The tensile strength of the 80/20 blend is around 50 MPa with a Young's modulus of 2250 MPa. The corresponding 20% flax composite has similar tensile strength but a high Young's modulus equal to 6400 MPa, which results from the individual dispersion and strong adhesion of the flax fibres and leads close to the maximum possible reinforcement of the composite, as demonstrated by tensile tests and nano-indentation. The Ashby approach to eco-selection relying on the embodied energy (EE) further clarifies the eco-friendliness of the blends and their composites, which are even better positioned than PLLA in a stiffness versus EE chart.