Chemical recycling of PET waste into hydrophobic textile dyestuffs

Value-Added Products Derived from Poly(ethylene terephthalate) Glycolysis

Among polymer wastes, poly(ethylene terephthalate) (PET) is the most important commercial thermoplastic polyester. Less than 30% of total PET production is recycled into new products. Therefore, large amounts of waste PET need to be recycled. We describe a feasible approach for the direct application of the glycolysis products of PET (GP-PET), without further purification, for the synthesis of value-added products. It was established that GP-PET is valorized via phosphorylation with phenylphosphonic dichloride (PPD), as well as with trimethyl phosphate (TMP). When PPD is used, a condensation reaction takes place with the evolution of hydrogen chloride. During the interaction between GP-PET and TMP, the following reactions take place simultaneously: a transesterification with the participation of the hydroxyl group of GP-PET and the methoxy group of TMP and an exchange reaction between the ester group of GP-PET and the methyl ester group of TMP. The occurrence of the exchange reaction was confirmed by 1H, 31P, 13C NMR, and GPC analysis. Thermogravimetric analysis (TGA) revealed that the percentage of a carbon residual (CR) implies the possibility of using the end products as flame retardant (FR) additives, especially for polyurethanes as well as thermal stabilizers of polymer materials or Li-ion cells.

TG-FTIR-Py-GCMS analysis and catalytic pyrolysis mechanism of textile waste by red mud catalyst for liquid fuel production

The substantial generation of textile waste (TW) and red mud (RM) has resulted in significant resource wastage and environmental challenges. Co-utilization technology of solid waste is an effective approach to improve waste utilization efficiency. In this study, RM catalytic pyrolysis experiments of TW were conducted using TG-FTIR and Py-GC-MS for liquid fuel production, and TW and RM were recycled simultaneously. At the optimal experimental conditions (temperature of 600 °C and feed catalyst ratio of 2:1), the tar yield and higher heating value (HHV) of TW pyrolysis catalyzed by RM were 73.43 wt% and 32.34 kJ/g, respectively. Additionally, experiments on the pyrolysis of various TW types revealed that LDPE and PP are suitable for tar production, while cotton, nylon, and PET are more suitable as feedstock for syngas production. The RM catalytic pyrolysis mechanism of textile waste is that Fe2O3 in RM exhibits significant catalytic activity in enhancing tar and syngas yields. However, during the catalytic process, Fe2O3 undergoes reduction to Fe3O4, resulting in diminished catalytic performance of the RM. After five cycles of use, the RM essentially lost its catalytic activity due to the accumulation of char and tar. All experimental findings of this study could offer an effective guideline for TW recycle and promoting RM utilization toward the waste-to-energy circular economy.

Selective recovery of caprolactam from the thermo-catalytic conversion of textile waste over γ-Al2O3 supported metal catalysts

The massive generation of synthetic textile waste has drawn considerable attention. Landfilling/incineration of textile waste has been widely made. To abate the environmental burdensome from the conventional management processes, a thermo-catalytic conversion was used for rapid volume reduction of textile waste and simultaneous valorization by recovering textile monomer in this study. Stockings were chosen as a model feedstock. Because stockings consisted of nylon with other contents, different products (caprolactam (nylon monomer), imines, cyclic dimers, and azepines) were recovered. The yield of caprolactam from the thermal conversion at 500 °C was 53.6 wt%. To selectively enhance the caprolactam yield, catalytic pyrolysis was done using γ-Al₂O₃ supported metal catalysts (Ni, Cu, Fe, or Co). γ-Al₂O₃ itself increased the caprolactam yield up to 69.0 wt% via a based-catalyzed reaction of nylon depolymerization and intramolecular cyclization. Under the presence of metal catalysts, the caprolactam yield increased up to 73.3 wt%. To offer desired feature of green chemistry, CO₂ was adopted as reactive gas. Under the CO₂-mediated catalytic pyrolysis, caprolactam yield was enhanced up to 77.1 wt% over Cu/Al₂O₃ (basis: stocking mass). Based on the net content of nylon in the stockings, the yield of caprolactam was deemed 95.3 wt%. This study proves that textile waste (stocking) and CO₂ are useful resources for recovery of nylon monomer, which can reduce the waste generation with simultaneous recovery of value-added product.

Chemical Recycling Processes of Waste Polyethylene Terephthalate Using Solid Catalysts

Polyethylene terephthalate (PET) is a non-degradable single-use plastic and a major component of plastic waste in landfills. Chemical recycling is one of the most widely adopted methods to transform post-consumer PET into PET's building block chemicals. Non-catalytic depolymerization of PET is very slow and requires high temperatures and/or pressures. Recent advancements in the field of material science and catalysis have delivered several innovative strategies to promote PET depolymerization under mild reaction conditions. Particularly, heterogeneous catalysts assisted depolymerization of post-consumer PET to monomers and other value-added chemicals is the most industrially compatible method. This review includes current progresses on the heterogeneously catalyzed chemical recycling of PET. It describes four key pathways for PET depolymerization including, glycolysis, pyrolysis, alcoholysis, and reductive depolymerization. The catalyst function, active sites and structure-activity correlations are briefly outlined in each section. An outlook for future development is also presented.

Solid-State Enzymatic Hydrolysis of Mixed PET/Cotton Textiles

Waste polyester textiles are not recycled due to separation challenges and partial structural degradation during use and recycling. Chemical recycling of polyethylene terephthalate (PET) textiles through depolymerization can provide a feedstock of recycled monomers to make "as-new" polymers. While enzymatic PET recycling is a more selective and more sustainable approach, methods in development, however, have thus far been limited to clean, high-quality PET feedstocks, and require an energy-intensive melt-amorphization step ahead of enzymatic treatment. Here, high-crystallinity PET in mixed PET/cotton textiles could be directly and selectively depolymerized to terephthalic acid (TPA) by using a commercial cutinase from Humicola insolens under moist-solid reaction conditions, affording up to 30±2 % yield of TPA. The process was readily combined with cotton depolymerization through simultaneous or sequential application of the cellulase enzymes CTec2®, providing up to 83±4 % yield of glucose without any negative influence on the TPA yield.

Valorizing plastic toy wastes to flammable gases through CO2-mediated pyrolysis with a Co-based catalyst

Toys are discarded due to their short life cycle. Unfortunately, development of sustainable disposal platform for toy has not gained particular concern. To establish a reliable disposal platform, this study employed a pyrolysis platform to valorize plastics into value-added fuels. To confer more environmentally resilient process, CO₂ was used as a feedstock to enhance the process efficiency from a perspective of the yield of flammable gases. To this end, waste toy brick (WTB) was used as a model compound. The exact types of plastics (polyacrylonitrile, polybutadiene, polystyrene, and polymethyl methacrylate) in WTB were experimentally determined. In pyrolysis of WTB, the complicated mixture of benzene derivatives was inevitably generated. To detoxify them by means of syngas (H₂/CO) production, catalytic pyrolysis was performed. Co catalyst effectively induced chemical bond scissions, leading to substantially enhanced H₂ formation. Also, the gas phase reactions (GPRs) between CO₂ and volatile compounds over Co catalyst expedited the production rate of CO, and such CO enhancement effectively offered a chance to mitigate toxic chemical generations. The synergistic contribution of CO₂ and Co catalyst enhanced syngas formation more than 25 times in reference to pyrolysis of WTB without Co catalyst. The GPRs also greatly prevented catalyst deactivation.

The Chemical Recycling of Polyesters for a Circular Plastics Economy: Challenges and Emerging Opportunities

Whilst plastics have played an instrumental role in human development, growing environmental concerns have led to increasing public scrutiny and demands for outright bans. This has stimulated considerable research into renewable alternatives, and more recently, the development of alternative waste management strategies. Herein, the aim was to highlight recent developments in the catalytic chemical recycling of two commercial polyesters, namely poly(lactic acid) (PLA) and poly(ethylene terephthalate) (PET). The concept of chemical recycling is first introduced, and associated opportunities/challenges are discussed within the context of the governing depolymerisation thermodynamics. Chemical recycling methods for PLA and PET are then discussed, with a particular focus on upcycling and the use of metal-based catalysts. Finally, the attention shifts to the emergence of new materials with the potential to modernise the plastics economy. Emerging opportunities and challenges are discussed within the context of industrial feasibility.

Depolymerization of poly(ethylene terephthalate) waste with biomass-waste derived recyclable heterogeneous catalyst

Poly(ethylene terephthalate) (PET) is one of the most widely used polymeric materials in chemical industry representing about 13% of the world's production. With the exponentially increasing consumption of plastics combined with its non-biodegradability, the accumulation of plastic waste in the environment rises steeply and its recycling has attracted enormous attention among researchers in recent years. In this present work, we describe bamboo leaf ash (BLA) as a bio-waste derived recyclable heterogeneous catalyst for the depolymerization of waste PET. The prepared catalyst was characterized by FT-IR, XRD, SEM, TEM, EDX, TGA and BET analyses to assess its morphology and composition. Postconsumer PET bottles were shredded and processed with 20 wt% BLA and 16 equivalents of ethylene glycol (EG) at 190 °C for 3.5 h under atmospheric pressure to give recrystallized bis(2-hydroxyethyl) terephthalate (BHET) monomer in 83% yield. The catalyst can be reused for four catalytic cycles and the residual EG was recovered for subsequent catalytic reactions. Excellent activity, cost-free, environmental-friendliness and ease of preparation, handling and reusability of the catalyst with simple work-up procedure are the notable advantages of this protocol.

Mechanical Performance of Fiber Reinforced Cement Composites Including Fully-Recycled Plastic Fibers

The use of virgin and recycled plastic macro fibers as reinforcing elements in construction materials has recently gained increasing attention from researchers. Specifically, recycled fibers have become more attractive owing to their large-scale availability, negligible cost, and low environmental footprint. In this work, we investigate the benefits related to the use of fully-recycled synthetic fibers as dispersed reinforcement in Fiber Reinforced Cement Composites (FRCCs). In light of the reference performance of FRCCs including virgin polypropylene (PP) fibers only, the mechanical response of composites reinforced with polyolefin filaments treated with a sol-gel silica coating and polyethylene terephthalate (PET)/polyethylene (PE) cylindrical draw-wire fibers is here assessed through three-point bending tests. Remarkably, recycled polyolefins lead to a notable enhancement in terms of peak strength and post-crack energy dissipation capability. This improvement is ascribed to both the flattened shape of fibers and the surface coating, which turns out to be very effective at strengthening the fiber-to-matrix bond. On the other hand, PET/PE fibrous reinforcement generally leads to a lower toughness, if compared to the virgin fibers. However, no reduction in terms of peak stress is evidenced. Balancing the significance of mechanical performance and environmental sustainability in the framework of a circular economy approach, both fully-recycled fibers at hand can be regarded as promising candidates for innovative structural applications.

Valorization of synthetic textile waste using CO2 as a raw material in the catalytic pyrolysis process

Since an invention of synthetic fibers (textiles), our life quality has been improved. However, the cumulative production and disposal of them have perceived as significant since they are not biodegradable and hard to be upcycled/recycled. From washing textiles, microplastics are released into the environment, which are regarded as emerging contaminants. As a means for source reduction of microplastics, this study proposed a rapid disposal platform for waste textiles (WTs), converting them into value-added products. To this end, catalytic pyrolysis of WT was studied. To offer more environmentally sound process, CO₂ was used as a raw material for WT pyrolysis. Thermal cracking of WT led to the production of syngas and CH₄ under the CO₂ environment. CO₂ resulted in additional CO production via gas phase reaction with volatile compounds evolved from pyrolysis of WT. To expedite the reaction kinetics for syngas formation, catalytic pyrolysis was done over Co-based catalyst. Comparing to non-catalytic pyrolysis, CO₂-assisted catalytic pyrolysis had 3- and 8-times higher production of H₂ and CO, respectively. This process also suppressed catalyst deactivation, converting more than 80 wt% of WT into syngas and CH₄. The more generation of CO from the use of CO₂ as a raw material offers an effective means to minimize the formations of harmful chemical species, such as benzene derivatives and polycyclic aromatic hydrocarbons.

Glycolysis of Poly(Ethylene Terephthalate) Using Biomass-Waste Derived Recyclable Heterogeneous Catalyst

Plastic production has increased by almost 200-fold annually from 2 million metric tons per year in 1950s to 359 million metric tons in 2018. With this rapidly increasing production, plastic pollution has become one of the most demanding environmental issues and tremendous efforts have been initiated by the research community for its disposal. In this present study, we reported for the first time, a biomass-waste-derived heterogeneous catalyst prepared from waste orange peel for the depolymerisation of poly(ethylene terephthalate) (PET) to its monomer, bis(2-hydroxyethyl terephthalate) (BHET). The prepared orange peel ash (OPA) catalyst was well-characterised using techniques such as IR, inductively coupled plasma (ICP)-OES (Optical Emission Spectrometry), XRD, X-ray fluorescence (XRF), SEM, energy-dispersive X-ray spectroscopy (EDX), TEM, BET (Brunauer-Emmett-Teller) and TGA. The catalyst was found to be composed of basic sites, high surface area, and a notable type-IV N₂ adsorption–desorption isotherm indicating the mesoporous nature of the catalyst, which might have eventually enhanced the rate of the reaction as well as the yield of the product. The catalyst completely depolymerises PET within 90 min, producing 79% of recrystallised BHET. The ability of reusing the catalysts for 5 consecutive runs without significant depreciation in the catalytic activity and its eco- and environmental-friendliness endorses this protocol as a greener route for PET recycling.

Synthesis of a Novel Ladder Poly(azomethine-ester) Based on PET Waste Bottles

In the present investigation, a novel ladder polymer, poly(azomethine ester), was prepared via solution polycondensation polymerization between terephthalic acid and the novel monomer. Terephthalic acid was regenerated from PET waste bottles by saponification process, whereas p-phenylenediamine was obtained via Hoffmann rearrangement method. A novel monomer, namely N,N′-bis(2,5-dihydroxy benzylidene)-1,4-diaminobenzene was prepared from the reaction of 2,5-di-hydroxybenzadehyde with p-phenylenediamine in the ratio of 2:1, respectively. For the first time a solution polycondensation method has been employed for the synthesis of a ladder polymer which is otherwise prepared commonly via Diels-Alder cycloaddition reaction. The synthesized ladder polymer was characterized by Fourier transform infrared spectroscopy (FT-IR), proton nuclear magnetic resonance spectroscopy (1H NMR), carbon nuclear magnetic resonance spectroscopy (13C NMR), elemental analysis (CHN), X-ray diffraction (XRD), differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The results revealed that the ladder polymer possess highly regular ladder like framework, and that most of the ester groups have taken part in the side-by-side polymerization reaction.

Effect of multi-walled carbon nanotubes on the physical properties and crystallisation of recycled PET/TPU composites

Thermoplastic polyurethane (TPU) was blended with recycled polyethylene terephthalate (rPET) to prepare rPET/thermoplastic polyurethane (TPU) composites. Meanwhile, multiple-walled carbon nanotubes (MWCNTs) were employed as a reinforcing filler to study the synergistic effect between CNTs and rPET/TPU composites. The effect of CNT content on the morphology and micro-structure of the composites was investigated using a scanning electron microscope (SEM) and X-ray diffraction (XRD). The thermal properties were characterized using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA) and dynamic mechanical analysis (DMA). The mechanical properties were investigated using tensile tests and hardness measurements. The results showed that TPU was compatible with rPET. The existence of rPET changed the crystalline phase and affected the glass transition and crystallisation temperature of the TPU matrix. The rPET/TPU composites displayed poor thermal stability and tensile properties when compared to pure TPU. The addition of CNTs had no effect on the crystalline phase of the rPET/TPU composites. Due to the occurrence of interfacial adhesion between the CNTs and rPET, the CNTs displayed an offset effect on the reaction of rPET and decreased the rigidity of the molecular chain in the rPET/TPU composites. The thermal stability and tensile strength of the CNTs/rPET/TPU composites improved with an increase in CNT content.

Multiple-walled carbon nanotubes (MWCNTs) were employed as a reinforcing filler to study the synergistic effect between CNTs and rPET/TPU composites.

Effect of different concentration of rapeseed oil and recycled poly (ethylene terephthalate) in polyols for rigid polyurethane foams

In this research, polyols from rapeseed oil and recycled poly(ethylene terephthalate) were synthesized by two-step continuous synthesis with a different rapeseed oil and poly(ethylene terephthalate) concentration. All rapeseed oil/poly(ethylene terephthalate) polyols showed complete compatibility with blowing agent Solkane 365/227. The resulting polyols were used to prepare rigid polyurethane foams which were characterized with various techniques for determination of their physical, mechanical and thermal insulation properties. The effect of rapeseed oil and poly(ethylene terephthalate) concentrations in polyols on the characteristics of rigid polyurethane foams was investigated. The results showed that obtained rigid polyurethane foams were suitable for thermal insulation appliance. Also, the potential use of rapeseed oil as raw material combined with poly(ethylene terephthalate) to synthesize polyols with good compatibility with blowing agent was confirmed.

Chemical scavenging of post-consumed clothes

Aiming toward the rectification of fiber grade PET waste accumulation as well as recycling and providing a technically viable route leading to preservation of the natural resources and environment, the post consumed polyester clothes were chemically recycled. Post consumed polyester clothes were recycled into bis(2-hydroxyethyl) terephthalate (BHET) monomer in the presence of ethylene glycol as depolymerising agent and zinc acetate as catalyst. Depolymerized product was characterized by chemical as well as analytical techniques. The fiber grade PET was eventually converted into BHET monomer with nearly 90% yield by employing 1% catalyst concentration and at optimum temperature of 180°C without mechanical input of stirring condition.

Physical and thermal properties of poly(ethylene terephthalate) fabric coated with electrospun polyimide fibers

Two analogous polyimides (PIs) containing flexible isopropylidene units were prepared. One was based on 4,4′-oxydiphthalic anhydride and 4,4′-(4,4′-isopropylidenediphenyl-1,1′-diyldioxy) dianiline and the other was based on 4,4′-(4,4′-isopropylidenediphenoxy) bis(phthalic anhydride) and bis(3-aminophenyl) methyl phosphine oxide. The ability of these two PIs to form uniform nanoscaled fibers was investigated by electrospinning technique. At optimal spinning conditions, PI fibers were electrospun onto the surface of woven poly(ethylene terephthalate) (PET) support to form a bilayer composite structure. These new fabric systems were analyzed regarding morphology, air permeability, wetting properties, and thermal stability. It was expected that the new PET/PI mats would possess enhanced properties compared with the initial woven PET fibers due to the excellent properties of PIs. Experimental results showed that PET woven substrate coated with electrospun PI fibers had improved values of air permeability, water contact angle and thermal stability when compared with the initial woven PET fibers.

Preparation of 1,4-cyclohexanedimethanol by selective hydrogenation of a waste PET monomer bis(2-hydroxyethylene terephthalate)

A new approach is developed for the preparation of 1,4-cyclohexanedimethanol (CHDM) by hydrogenation of bis(2-hydroxyethylene terephthalate) (BHET) obtained from waste poly(ethylene terephthalate) (PET), and the 100% conversion of BHET and 78% yield of CHDM were achieved.

High performance alkyd resins synthesized from postconsumer PET bottles

A new perspective for mass production of alkyd resins from multifunctional glycolyzates obtained from waste PET – a step up to greener production and excellent applicative properties.

Recycling of Waste PET into Useful Alkyd Resin Synthesis by Microwave Irradiation and Applied in Textile Printing

Modified alkyd resins with different amounts of vegetable oil contents (sunflower oil) and different catalysts are synthesized with the incorporation of post-consumer polyethylene terephthalate (PET) as a partial substitute for phthalic anhydride. It is found that the properties of the products obtained are directly related to the oil content. The polymerization reactions are followed by the acid value. The modified binder contains 50% oil and 10% PET in the presence of LiOH as the catalyst by using microwave irradiation. The AV value is attained in a short amount of time; it is found that the glass Transition Temperature (Tg) of the modified binder is -1.7 °C. The stiffness and roughness of the printed fabrics by using the modified binder are better than those of the commercial binder for both cotton and cotton/polyester fabrics. Moreover, it is clear that the overall fastness properties of the fabrics printed by using the modified binder in the formulation of printing pastes are higher or comparable to those that use commercial binders.

Recycling and recovery routes of plastic solid waste (PSW): a review

Plastic solid waste (PSW) presents challenges and opportunities to societies regardless of their sustainability awareness and technological advances. In this paper, recent progress in the recycling and recovery of PSW is reviewed. A special emphasis is paid on waste generated from polyolefinic sources, which makes up a great percentage of our daily single-life cycle plastic products. The four routes of PSW treatment are detailed and discussed covering primary (re-extrusion), secondary (mechanical), tertiary (chemical) and quaternary (energy recovery) schemes and technologies. Primary recycling, which involves the re-introduction of clean scrap of single polymer to the extrusion cycle in order to produce products of the similar material, is commonly applied in the processing line itself but rarely applied among recyclers, as recycling materials rarely possess the required quality. The various waste products, consisting of either end-of-life or production (scrap) waste, are the feedstock of secondary techniques, thereby generally reduced in size to a more desirable shape and form, such as pellets, flakes or powders, depending on the source, shape and usability. Tertiary treatment schemes have contributed greatly to the recycling status of PSW in recent years. Advanced thermo-chemical treatment methods cover a wide range of technologies and produce either fuels or petrochemical feedstock. Nowadays, non-catalytic thermal cracking (thermolysis) is receiving renewed attention, due to the fact of added value on a crude oil barrel and its very valuable yielded products. But a fact remains that advanced thermo-chemical recycling of PSW (namely polyolefins) still lacks the proper design and kinetic background to target certain desired products and/or chemicals. Energy recovery was found to be an attainable solution to PSW in general and municipal solid waste (MSW) in particular. The amount of energy produced in kilns and reactors applied in this route is sufficiently investigated up to the point of operation, but not in terms of integration with either petrochemical or converting plants. Although primary and secondary recycling schemes are well established and widely applied, it is concluded that many of the PSW tertiary and quaternary treatment schemes appear to be robust and worthy of additional investigation.