Heterogeneous Diels-Alder tandem catalysis for converting cellulose and polyethylene into BTX

Chemical catalytic upgrading of polyethylene terephthalate plastic waste into value-added materials, fuels and chemicals

The substantial production of polyethylene terephthalate (PET) products, coupled with high abandonment rates, results in significant environmental pollution and resource wastage. This has prompted global attention to the development of rational strategies for PET waste treatment. In the context of renewability and sustainability, catalytic chemical technology provides an effective means to recycle and upcycle PET waste into valuable resources. In this review, we initially provide an overview of strategies employed in the thermocatalytic process to recycle PET waste into valuable carbon materials, fuels and typical refined chemicals. The effect of catalysts on the quality and quantity of specific products is highlighted. Next, we introduce the development of renewable-energy-driven electrocatalytic and photocatalytic systems for sustainable PET waste upcycling, focusing on rational catalysts, innovative catalytic system design, and corresponding underlying catalytic mechanisms. Moreover, we discuss advantages and disadvantages of three chemical catalytic strategies. Finally, existing limitations and outlook toward controllable selectivity and yield enhancement of value-added products and PET upvaluing technology for scale-up applications are proposed. This review aims to inspire the exploration of waste-to-treasure technologies for renewable-energy-driven waste management toward a circular economy.

From plastic waste to potential wealth: Upcycling technologies, process synthesis, assessment and optimization

Global plastics production has doubled since the beginning of 21st century. Efficient technology is called for plastics waste valorization. The current review provides an overview of the main waste plastic chemical upcycling technologies to produce value-added products. Various technologies including gasification and pyrolysis are under reviewed. However, several review literatures have paid attention to the details and experimental progress in these chemical upcycling techniques. In this review, we attempt to conclude the progress in a multi-scale systems-by-systems perspective. After a brief overview of the current state-of-the-art chemical upcycling techniques, larger-scale process synthesis, assessment, and optimization methodologies to address the sustainability and environmental issues are summarized. Techno-economic analysis and life cycle assessment are selected as two powerful tools for process assessment. Three particular application scenarios of optimization methodologies including experimental design, process synthesis and supply chain management are consequently introduced. Very little work on review articles have summarized the plastic waste-to-wealth process in the systems engineering perspective. Review results show that (1) gasification and pyrolysis offer promising avenues for the conversion of plastic waste into valuable products. These technologies can be integrated with other subsystems to enhance the economic and environmental performance of the overall system. (2) Response surface methodology is commonly used in experimental design and parameter optimization. It allows researchers to systematically investigate the effects of various parameters and optimize process conditions to maximize desired outputs. (3) Superstructure optimization frameworks are valuable tools for process synthesis and pathway selection in plastic waste conversion. However, the potential superstructure is pre-defined. (4) Green supply chain and multi-objective supply chain frameworks can be applied to the design of plastic waste recycling networks, taking into account both economic and environmental considerations.

Assessing the economic and ecological viability of generating electricity from oil derived from pyrolysis of plastic waste in China

The increased plastic waste generation worldwide poses ponderous issues for public health and the environment. China is the highest generator of plastic waste around the world. The current treatment process (incineration) of the increased plastic waste causes dangerous environmental consequences. Pyrolysis has recently surfaced as an ecologically friendly technique for energy and material recovery from plastic waste. The present study assesses the financial and ecological viability of power production from oil derived from the pyrolysis of mixed plastic wastes in China from 2009 to 2028. The prominent findings show that the amount of plastic waste collected in 2020 (24.16 Mt) increased by 53.19% in 2028.The pyrolysis of mixed plastic wastes during the project period yielded 359.29 Mt oil, which has a power potential of 1,060.86 GWh. The economic analysis indicated the project is viable and profitable with a positive net present value (US$8.80 million) and profitability index (1.26) greater than 1. The project has 10.6 y payback period, US$0.0752/kWh levelized cost of energy, 22.5% return on investment, and 13.0% internal rate of return. The life cycle assessment results show that conversion of mixed plastic waste to pyrolysis oil for electricity generation during the project period has a total global warming potential (GWP) of 1,311.4 kt CO2eq. The GWP is mainly from conversion of pyrolysis oil to electricity (73.42%), pyrolysis oil production (15.01%) and upgrading of pyrolysis oil (11.38%). The consumption of power from the project could avoid the combustion of 2,659.0 t coal, minimizing global warming by 11,278.8 kt CO2eq. Sensitivity analysis, which examines the influence of variation in sensitive factors on the success of the project, is presented. This paper provides scientific strategies for optimal investment and decision-making on the environmental sustainability of plastic waste-to-energy pyrolysis projects.

Exposing and understanding synergistic effects in co-pyrolysis of biomass and plastic waste via machine learning

During co-pyrolysis of biomass with plastic waste, bio-oil yields (BOY) could be either induced or reduced significantly via synergistic effects (SE). However, investigating/ interpreting the SE and BOY in multidimensional domains is complicated and limited. This work applied XGBoost machine-learning and Shapley additive explanation (SHAP) to develop interpretable/ explainable models for predicting BOY and SE from co-pyrolysis of biomass and plastic waste using 26 input features. Imbalanced training datasets were improved by synthetic minority over-sampling technique. The prediction accuracy of XGBoost models was nearly 0.90 R² for BOY while greater than 0.85 R² for SE. By SHAP, individual impact and interaction of input features on the XGBoost models can be achieved. Although reaction temperature and biomass-to-plastic ratio were the top two important features, overall contributions of feedstock characteristics were more than 60 % in the system of co-pyrolysis. The finding provides a better understanding of co-pyrolysis and a way of further improvements.

Valorization of neem seeds biomass to biofuel via non-catalytic and catalytic pyrolysis process: Investigation of catalytic activity of Co-Mo/Al2O3 and Ni-Mo/Al2O3 for biofuel production

Biofuel production from neem seeds have been evaluated via non-catalytic and catalytic pyrolysis process. Co-Mo/Al₂O₃ and Ni-Mo/Al₂O₃ industrial catalysts have been applied in upgrading process of pyrolysis oil to biofuel. The catalytic activity test revealed that these catalysts succeeded in converting fatty acids content of pyrolysis oil into low oxygen content compounds such as alcohols, alkanes, cyclic compounds, and esters via deoxygenation route. Enhancement of temperature and catalyst loading lead to increase of bio-gas production yield, significantly. The highest yield of pyrolysis oil (60.2%) was obtained at 450 °C, heating rate of 40 °C.min^-1 via non-catalytic pyrolysis. Using 40% catalyst loading of Ni-Mo/Al₂O₃, the content of alcohol, cyclic and alkane compounds in the bio-oil were reached 12.65%, 21.74% and 15%, respectively. The highest selectivity using 40% catalyst loading of Co-Mo/Al₂O₃ catalyst at 450 °C was related to fatty acids (62.5%), esters (18.2%) and alkanes (6.25). It is inferred that the addition of Ni to Mo causes more progress of decarbonylation and decarboxylation reactions, and the addition of Co to Mo generates more ester compounds. Sensitivity analysis indicated that the effect of Ni-Mo/Al₂O₃ catalyst through catalytic pyrolysis process was more severe than Co-Mo/Al₂O₃ catalyst.

Fabrication of Superhydrophobic/Superoleophilic Bamboo Cellulose Foam for Oil/Water Separation

Water is an indispensable strategic resource for biological and social development. The problem of oily wastewater pollution originating from oil spillages, industrial discharge and domestic oil pollution has become an extremely serious international challenge. At present, numerous superwetting materials have been applied to effectively separate oil and water. However, most of these materials are difficult to scale and their large-scale application is limited by cost and environmental protection. Herein, a simple, environmentally friendly strategy including sol-gel, freeze-drying and surface hydrophobic modification is presented to fabricate a bamboo cellulose foam with special wetting characteristics. The bamboo cellulose foam is superhydrophobic, with a water contact angle of 160°, and it has the superoleophilic property of instantaneous oil absorption. Owing to the synergistic effect of the three-dimensional network structure of the superhydrophobic bamboo cellulose foam and its hydrophobic composition, it has an excellent oil-absorption performance of 11.5 g/g~37.5 g/g for various types of oil, as well as good recyclability, with an oil (1,2-dichloroethane) absorption capacity of up to 31.5 g/g after 10 cycles. In addition, the prepared cellulose-based foam exhibits an outstanding performance in terms of acid and alkali corrosion resistance. Importantly, owing to bamboo cellulose being a biodegradable, low-cost, natural polymer material that can be easily modified, superhydrophobic/superoleophilic bamboo cellulose foam has great application potential in the field of oily wastewater treatment.

Anchoring Effect of Organosilanes on Hierarchical ZSM-5 Zeolite for Catalytic Fast Pyrolysis of Cellulose to Aromatics

As an essential chemical feedstock, aromatics can be obtained from biomass by catalytic fast pyrolysis (CFP) technology, in which diffusion limitation is still a problem. In this study, several ZSM-5 zeolites with intercrystal stacking macropores were synthesized by adding organosilanes (OSAs) with different alkyl chain groups. Due to the structure-directing effect of the OSA, the prepared ZSM-5 zeolites possess a larger external surface area and pore volume than Blank-Z5. Moreover, the pore size is related to the extent of anchoring of the OSA and silicon-aluminum species in the zeolite precursor. Pyridine Fourier transform infrared (Py-FTIR) and NH₃-temperature-programmed desorption (TPD) analyses show that the obtained ZSM-5 zeolites have a higher Brønsted acidity and total number of acid sites. In addition, excessive addition of OSA is not conducive to the growth of ZSM-5 zeolites. The catalytic performance of the synthesized ZSM-5 zeolites was evaluated by Py-GC/MS. The larger external surface area and pore volume improve the accessibility of the acid sites and thus promote the conversion of biomass into aromatics.

Biochar-advanced thermocatalytic salvaging of the waste disposable mask with the production of hydrogen and mono-aromatic hydrocarbons

The salvaging of the waste disposable mask was conducted in this study through catalytic pyrolysis over corn stover derived biochar catalyst combined with the boosted generation of hydrogen and mono-aromatic hydrocarbons for the first time. In the absence of biochar, up to 53 wt% of wax was observed at 550 ºC, whereas at the biochar/mask ratio of 2, around 41 wt% of liquid oil was produced without the formation of wax. The hydrogen content in the gas stream was about 26 vol% at 600 ºC for non-catalytic pyrolysis, which increased to around 55 vol% at the expense of light hydrocarbons such as methane and C_2-4 for the catalytic process with the biochar/mask ratio of 3. In resulting liquid oil, the content of mono-aromatics, especially toluene, xylenes, and ethylbenzene was about 55% for catalytic runs, which was far greater than that of 38% from the non-catalytic run. Interestingly, the dyes released from mask pyrolysis could be completely captured/adsorbed by biochar, leading to a much cleaner oil. After 10 cycles of reuse at 600 ºC without regeneration, the biochar still held a good selectivity toward hydrogen and mono-aromatic hydrocarbons. This study exemplified a readily accessible concept and pathway of 'waste against waste' targeted to upcycle waste disposable masks over biochar from biomass waste.

Microwave catalytic co-pyrolysis of waste cooking oil and low-density polyethylene to produce monocyclic aromatic hydrocarbons: Effect of different catalysts and pyrolysis parameters

It is promising to convert waste oil and plastics to renewable fuels and chemicals by microwave catalytic co-pyrolysis, enabling pollution reduction and resource recovery. The purpose of this study was to evaluate the effect of catalysts on the product selectivity of microwave-assisted co-pyrolysis of waste cooking oil and low-density polyethylene and optimize the pyrolysis process, including pyrolysis temperature, catalytic temperature, waste cooking oil to low-density polyethylene ratio, and catalyst to feedstocks ratio. The results indicated that catalysts had a great influence on the product distribution, and the yield of BTX (benzene, toluene, and xylenes), which increased in the following order: SAPO-34 < Hβ < HY < HZSM-5. HZSM-5 was more active for the formation of light aromatic hydrocarbons as compared to others, where the concentrations of toluene, benzene and xylenes reached 252.59 mg/mL, 114.7 mg/mL and 132.91 mg/mL, respectively. The optimum pyrolysis temperature, catalytic temperature, waste cooking oil to low-density polyethylene ratio and catalyst to feedstocks ratio could be 550 °C, 450 °C, 1:1 and 1:2, respectively, to maximize the formation of BTX and inhibit the formation of polycyclic aromatic hydrocarbons.

Catalytic co-pyrolysis of LDPE and PET with HZSM-5, H-beta, and HY: experiments and kinetic modelling

This study determines interaction effects and conducts kinetic modeling for catalytic co-pyrolysis of LDPE and PET with multiple zeolite frameworks.