In-situ exsolution of Fe-Ni alloy catalysts for H2 and carbon nanotube production from microwave plasma-initiated decomposition of plastic wastes

Highly Efficient Recycling Waste Plastic into Hydrogen and Carbon Nanotubes through a Double Layer Microwave-Assisted Pyrolysis Method

Microwave-assisted pyrolysis of PE to hydrogen and carbon material has great potential to solve the problem of waste PE induced white pollution and provide a promising way to produce hydrogen energy. To increase the hydrogen yield, a new microwave-assisted pyrolysis procedure should be developed. In the present study, a facile double-layer microwave-assisted pyrolysis (DLMP) method is developed to pyrolyze PE. Within this method, PE can be converted to hydrogen, multiwalled carbon nanotubes with extremely high efficiency compared with the traditional methods. A high hydrogen yield of 66.4 mmol g-1 PE is achieved, which is ≈93% of the upper limit of the theoretical hydrogen yield generated from the PE pyrolysis process. The mechanism of high hydrogen yield during the microwave-assisted pyrolysis of PE using the DLMP method is also clarified in detail. The DLMP method paved the potential way for recycling plastic waste into high-value-added products.

Fabrication of Fe-Zr, Co-Zr, and Ni-Zr Catalysts to Boost CNTs Synthesis from Plastic Wastes and the Electrocatalytic Oxygen Evolution Reaction

The efficient conversion of plastic wastes to high-value carbon materials like carbon nanotubes (CNTs) is one important issue about the rational recycling, reduction, and reuse of solid wastes. Herein, Fe-, Co-, and Ni-Zr catalysts were prepared and used for CNTs synthesis from polyethylene (PE) waste via a two-stage reaction system. At the same time, the effects of the PE/catalyst ratio and reaction temperature on CNTs synthesis have been studied. Compared with Co-Zr and Ni-Zr, Fe-Zr exhibited the best activity in CNTs synthesis from PE, and it achieved the highest CNTs yield of 806.3 mg/g (per gram of Fe-Zr) at 800 °C with a PE/catalyst ratio of 4. Furthermore, the obtained Fe-Zr/CNTs composite exhibited a low overpotential of 267 mV for the electrocatalytic oxygen evolution reaction (OER) at 20 mA/cm2 in 1 M KOH electrolyte solution, which was 21 mV lower than commercial RuO2 (288 mV) and 50 mV lower than Fe-Zr (317 mV). It was deduced that the in situ growth of CNTs reduced the charge transfer resistance and improved the electron transport efficiency of the Fe-Zr/CNTs composite, leading to superior activity in the electrocatalytic OER. This work provided detailed information for the preparation of the metal/CNTs composite from plastic wastes, which contributed positively to alleviate the environment and energy crisis.

Role of the hydrocarbon molecular structure in CNT growth on Fe-Al catalysts

Upgrading plastic wastes into high-value products via the thermochemical process is one of the most attractive topics. Although carbon nanotubes (CNTs) have been successfully synthesized from plastic pyrolysis gas over Fe-, Co-, or Ni-based catalysts, a deep discussion about the reaction mechanism was seldom mentioned in the literature. Herein, this work was intended to study the growth mechanism of CNTs from hydrocarbons on Fe-Al2O3 catalysts. C5-C7 hydrocarbons were used to synthesize CNTs in a high-temperature fixed-bed reactor, and the carbon products and cracked gas were analyzed in detail. The CNT yield was in the order of cyclohexane, cyclohexene > n-hexane > n-heptane > n-pentane, 1-hexene. It was proposed that CNT growth on Fe-Al2O3 catalysts was mainly determined by the yield and structure of six-membered cyclic species, which was tailored by the carbon chain length, C-C/CC bonds, and linear/cyclic structures of C5-C7 hydrocarbons. Compared with n-hexane, the six-membered rings of cyclohexane and cyclohexene promoted six-membered cyclic species formation, increasing CNT and benzene yields; the seven-membered carbon chain of n-heptane promoted methyl-six-membered cyclic species formation, decreasing CNT and benzene yields while increasing the toluene yield; the five-membered carbon chain of n-pentane and the CC bond of 1-hexene inhibited six-membered cyclic species formation, decreasing CNT and benzene yields. This work revealed the structure-activity relationship between C5-C7 hydrocarbons and CNT growth, which may direct the process design and optimization of CNT synthesis from plastic pyrolysis gas.

Mo-Doped Ni/C Catalyst for Improved Simultaneous Production of Hydrogen and Carbon Nanotubes through Ethanol Decomposition

A Mo-Ni/C catalyst was developed and assessed in terms of the decomposition of ethanol to produce multi-wall carbon nanotubes (MWCNTs) and hydrogen. The catalyst utilized different molar ratios of Mo:Ni (1:9, 2:8, and 3:7), with Mo acting as a dopant to enhance the MWCNT yield and Ni acting as the primary active phase for MWCNT formation. Among the tested ratios, the 2:8 Mo:Ni ratio exhibited the optimal performance, yielding 86% hydrogen and high-quality MWCNTs. In addition to hydrogen, the process also generated CO, CH4, and CO2. Gas chromatography (GC) was employed to analyze the influence of the Mo:Ni ratio on gas production and selectivity, while the quality of the resulting MWCNTs was evaluated using SEM, Raman spectroscopy, and TEM analyses.

Microwave-Assisted Catalytic Deconstruction of Plastics Waste into Nanostructured Carbon and Hydrogen Fuel Using Composite Magnetic Ferrite Catalysts

Finding new catalysts and pyrolysis technologies for efficiently recycling wasted plastics into fuels and structured solid materials of high selectivity is the need of time. Catalytic pyrolysis is a thermochemical process that cracks the feedstock in an inert gas environment into gaseous and liquid fuels and a residue. This study is conducted on microwave-assisted catalytic recycling of wasted plastics into nanostructured carbon and hydrogen fuel using composite magnetic ferrite catalysts. The composite ferrite catalysts, namely, NiZnFe2O4, NiMgFe2O4, and MgZnFe2O4 were produced through the coprecipitation method and characterized for onward use in the microwave-assisted valorization of wasted plastics. The ferrite nanoparticles worked as a catalyst and heat susceptor for uniformly distributed energy transfer from microwaves to the feedstock at a moderate temperature of 450°C. The type of catalyst and the working parameters significantly impacted the process efficiency, gas yield, and structural properties of the carbonaceous residue. The tested process took 2-8 minutes to pulverize feedstock into gas and carbon nanotubes (CNTs), depending on the catalyst type. The NiZnFe2O4-catalyzed process produced CNTs with good structural properties and fewer impurities compared to other catalysts. The NiMgFe2O4 catalyst performed better in terms of hydrogen evolution by showing 87.5% hydrogen (H2) composition in the evolved gases. Almost 90% of extractable hydrogen from the feedstock evolved during the first 2 minutes of the reaction.

Microwave-Assisted Pyrolysis-A New Way for the Sustainable Recycling and Upgrading of Plastic and Biomass: A Review

The efficient utilization of organic solid waste resources can help reducing the consumption of conventional fossil fuels, mitigating environmental pollution, and achieving green sustainable development. Due to its dual nature of being both a resource and a source of pollution, it is crucial to implement suitable recycling technologies throughout the recycling and upgrading processes for plastics and biomass, which are organic solid wastes with complex mixture of components. The conventional pyrolysis and hydropyrolysis were summarized for recycling plastics and biomass into high-value fuels, chemicals, and materials. To enhance reaction efficiency and improve product selectivity, microwave-assisted pyrolysis was introduced to the upgrading of plastics and biomass through efficient energy supply especially with the aid of catalysts and microwave absorbers. This review provides a detail summary of microwave-assisted pyrolysis for plastics and biomass from the technical, applied, and mechanistic perspectives. Based on the recent technological advances, the future directions for the development of microwave-assisted pyrolysis technologies are predicted.

CO2-mediated catalytic upcycling of plastic waste for H2-rich syngas and carbon nanomaterials

To establish a reliable disposal platform of plastic waste, this work developed a novel dual-stage CO2-medaited decomposition-catalysis route by applying multi-functional zeolite-supported bimetallic catalysts. Catalytic upcycling of plastic was first performed in Ar as a reference environment. Bimetallic Fe-Co/ZSM5 catalyst achieved the highest gas yield (53.98 mmol/g), with a H2 proportion of 62.17 vol%. It was evidenced that the Fe-Co alloy had an apparent positive synergistic effect on catalytic cracking and reforming of intermediate volatiles into H2-rich fuel gas and pure carbon nanotubes (CNTs). Regarding CO2-mediated decomposition-catalysis of plastic, there was an apparent synergistic effect between metallic Ni and Fe on gas production so that bimetallic Ni-Fe catalyst gained the maximum cumulative gas yield of 82.33 mmol/g, with a syngas purity of ∼74%. Ni-Fe/ZSM5 also achieved the maximum hydrogen efficiency (87.38%) and CO2-to-CO conversion efficiency (98.62%), implying hydrogen content in plastic and oxygen content in CO2 were essentially converted into gases. Additionally, bimetallic Ni-Fe catalyst revealed the highest carbon production (33.74 wt%), witnessing a synergistic enhancement of 43.45%; specially, approximately 257 mg/g CNTs were anchored on Ni-Fe/ZSM5, with a CNTs purity of over 76%. Overall, this study offers a superb solution in plastic waste valorization and greenhouse gas emission management.

Microwave-enhanced hydrogen production: a review

Currently, the massive use of fossil fuels, which still serve as the dominant global energy, has led to the release of large amounts of greenhouse gases. Providing abundant, clean, and safe renewable energy is one of the major technical challenges for humankind. Nowadays, hydrogen-based energy is widely considered a potentially ideal energy carrier that could provide clean energy in the fields of transportation, heat and power generation, and energy storage systems, almost without any impact on the environment after consumption. However, a smooth energy transition from fossil-fuel-based energy to hydrogen-based energy must overcome a number of key challenges that require scientific, technological, and economic support. To accelerate the hydrogen energy transition, advanced, efficient, and cost-effective methods for producing hydrogen from hydrogen-rich materials need to be developed. Therefore, in this study, a new alternative method based on the use of microwave (MW) heating technology in enhanced hydrogen production pathways from plastic, biomass, low-carbon alcohols, and methane pathways compared with conventional heating methods is discussed. Furthermore, the mechanisms of MW heating, MW-assisted catalysis, and MW plasma are also discussed. MW-assisted technology usually has the advantages of low energy consumption, easy operation, and good safety practices, which make it a promising solution to supporting the future hydrogen society.