Degradation of waste polycarbonate via hydrolytic strategy to recover monomer (bisphenol A) catalyzed by DBU-based ionic liquids under metal- and solvent-free conditions

Chemical upcycling of poly(bisphenol A carbonate) via sequential diamino-/methanolysis: A phosgeneless one-pot route to dimethyl dicarbamate esters

Waste poly(bisphenol A carbonate) (PC) is a potential source of harmful bisphenol A (BPA). In this study a new approach aiming to chemically valorize hazardous PC wastes is described. A one-pot process has been developed that allows to recover BPA from PC used as "phosgene equivalent" for the synthesis of dimethyl dicarbamates MeO2CNH-R-NHCO2Me. Dicarbamate esters are industrially relevant precursors of non-isocyanate polyurethanes and polyureas. The devised process is conducted stepwisely. PC is first depolymerized by reaction with basic diamines H2NRNH2 (1,6-diaminohexane (3a); 4,7,10-trioxa-1,13-tridecanediamine (4a); meta-xylylenediamine (5a); para-xylylenediamine (6a)) into BPA and oligourethanes H[-OArO(O)CNHRNHC(O)-]nOArOH (Ar = 4,4'-C6H4C(Me)2C6H4-) that, in a subsequent step, are one-pot converted into MeO2CNH-R-NHCO2Me and more BPA by transurethanization with methanol. Both the steps proceed under mild conditions and do not require any auxiliary catalyst. The process allows to recover BPA in high yield and, as an additional outstanding advantage, offers a new solution to the synthesis of MeO2CNH-R-NHCO2Me dicarbamates without using poisonous phosgene, traditionally used to this purpose. Aromatic diamines are much less reactive than aliphatic ones. Under conditions comparable with those used for 3a-6a, 4,4'-diaminodiphenylmethane reacted with PC under the assistance of a base catalyst (DBU; NaOH) to give polyurea [-NHRNHCO-]n as major product.

Halide-free ion pair organocatalyst from biobased α-hydroxy acid for cycloaddition of CO2 to epoxide

The cycloaddition of CO2 to epoxide (CCE) reactions produce valuable cyclic carbonates useful in the electrolytes of lithium-ion batteries, as organic solvents, and in polymeric materials. However, halide-containing catalysts are predominantly used in these reactions, despite halides being notoriously corrosive to steel processing equipment and residual halides also having harmful effects. To eliminate the reliance on halides as cocatalyst in most CCE reactions, halide-free catalysts are highly desirable. Herein, a series of halide-free organocatalysts composed of stoichiometric base-acid binary adducts of super strong nitrogen bases and natural α-hydroxy acids was designed. The adducts were virtually biobased ionic liquids composed of a protonated base cation and an α-hydroxy carboxylate anion. Ionic liquids from four super strong bases (two amidines and two guanidines) and four α-hydroxy acids were evaluated as halide-free organocatalysts in the CCE reactions. Combining amidine 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) and mandelic acid (HMAc) generated an optimal ion pair catalyst [DBUH][MAc], which showed good catalytic activity in the cycloaddition of CO2 to styrene oxide with a 92% yield and 99% selectivity by 2.5 mol% catalyst loading, under conditions of 120 °C, 1.0 MPa, and 12 h. A reasonable bifunctional activation mechanism was proposed in which the protonated base DBUH coordinated to the epoxide by H-bonding, and the carboxylate interacted with CO2 facilitating the formation of the acyl carbonate intermediate that attacked the epoxide. The mechanism was validated by 1H NMR titrations, by the intermediate capture, and by controlled experiments by cation and/or anion switches.

Ultrafast Simultaneous and Selective Depolymerization of Heterogeneous Streams of Polyethylene Terephthalate and Polycarbonate: Towards Industrially Feasible Chemical Recycling

Mixed plastic waste-streams are a main obstacle to a more extensive implementation of polymer recycling. Separating mixed-plastic waste streams demands time and effort at collection or in the recycling plant, while many products consist of multiple polymers that cannot be readily separated. Chemical recycling could provide the key to overcome this issue by targeting specific chemical bonds, enabling selective depolymerization of a single polymer class in a mixture. This work explores the depolymerization of polycarbonate (PC) and polyethylene terephthalate (PET) in separate and in mixed streams. Selective depolymerization of mixed streams composed of PET and PC and one-step separation of their constituent monomers are carried out with outstanding energy efficiency through an inexpensive KOH-in-methanol hydrolysis (KMH) process developed for instantaneous PET hydrolysis. The activation energies for depolymerization of PC and PET pellets are 68.6 and 131.4 kJ mol^-1 , respectively. Randomly mixed streams are fully depolymerized within 2 min at 120 °C using 30 mL of depolymerization solution per gram of polymer. The separation of bisphenol A and terephthalic acid is demonstrated in a one-step separation process, yielding 98 and 97 % purity without any secondary reactions detected. Simultaneous depolymerization and selective one-step separation of monomers are also demonstrated for a PET/PC polymer blend prepared by solution casting, showing that this process also works for intimately mixed PET/PC mixtures.

Catalytic methods for chemical recycling or upcycling of commercial polymers

Polymers (plastics) have transformed our lives by providing access to inexpensive and versatile materials with a variety of useful properties. While polymers have improved our lives in many ways, their longevity has created some unintended consequences. The extreme stability and durability of most commercial polymers, combined with the lack of equivalent degradable alternatives and ineffective collection and recycling policies, have led to an accumulation of polymers in landfills and oceans. This problem is reaching a critical threat to the environment, creating a demand for immediate action. Chemical recycling and upcycling involve the conversion of polymer materials into their original monomers, fuels or chemical precursors for value-added products. These approaches are the most promising for value-recovery of post-consumer polymer products; however, they are often cost-prohibitive in comparison to current recycling and disposal methods. Catalysts can be used to accelerate and improve product selectivity for chemical recycling and upcycling of polymers. This review aims to not only highlight and describe the tremendous efforts towards the development of improved catalysts for well-known chemical recycling processes, but also identify new promising methods for catalytic recycling or upcycling of the most abundant commercial polymers.

Chemical recycling of poly-(bisphenol A carbonate) by diaminolysis: A new carbon-saving synthetic entry into non-isocyanate polyureas (NIPUreas)

The present study describes an unprecedented approach to valorize potentially hazardous poly-(bisphenol A carbonate) (PC) wastes. In THF, under non-severe conditions (120 °C), the reaction of PC with long-chain diamines H₂NRNH₂ (2 equivalents) provided a tool to regenerate the monomer bisphenol A (BPA; 83-95%, isolated) and repurpose waste PC into [-NHRNHCO-]_n polyureas (PUs; 78-99%, isolated) through a non-isocyanate route. Basic diamines (1,6-diaminohexane, 4,7,10-trioxa-1,13-tridecanediamine, meta-xylylenediamine, para-xylylenediamine) reacted with PC without any auxiliary catalyst; less reactive aromatic diamines (4,4'-diaminodiphenylmethane, 2,4-diaminotoluene) required the assistance of a base catalyst (1,8-diazabicyclo[5.4.0]undec-7-ene, NaOH). The formation of [-NHRNHCO-]_n goes through a carbamation step affording BPA and carbamate intermediates H[-OArOC(O)NHRNHC(O)-]_nOArOH (Ar=4,4'-C₆H₄C(Me)₂C₆H₄-) that, in a subsequent step, convert into [-NHRNHCO-]_n and more BPA. All the PUs were characterized in the solid state by CP/MAS ¹³C NMR (δ(CO) = 152-161 ppm) and IR spectroscopy. The positions of ν(N-H) and ν(CO) absorptions are typical of "hydrogen-bonded ordered" bands suggesting the presence of H-bonded groups in network structures characterized by some degree of order or regularity. DSC and TGA analyses showed that the PUs are thermally stable (T_d,5%: 212-270 °C) and suitable for being processed since their degradation begins at temperatures about 100 °C higher than their T_g or T_m.

Using a natural chlorite as catalyst in chemical recycling of waste plastics: Hydrolytic depolymerization of poly-[bisphenol A carbonate] promoted by clinochlore

The present study describes the first example of utilization of a natural clay mineral as catalyst in a process addressed to chemical valorization of poly-[bisphenol A carbonate] (PC; (1)) wastes. A natural clinochlore was investigated for the first time as the catalyst of the hydrolysis reaction of 1, a potential route to chemical recycling of wastes of this polymeric material. At 473 K, in tetrahydrofuran (THF) as the solvent, the mineral promoted effectively the depolymerization (up to 99%, after 6 h) of 1 by H₂O and the selective (~99%) regeneration of the monomer bisphenol A (BPA, (2)). Temperature, catalyst loading, reaction time, H₂O/PC weight ratio affected markedly the productivity of the process. The role of the catalyst was also focused: the experimental data showed that the exposed brucite-like sheets of clinochlore are involved in the hydrolysis reaction and take active part in promoting the depolymerization process.

100th Anniversary of Macromolecular Science Viewpoint: Toward Catalytic Chemical Recycling of Waste (and Future) Plastics

The current global materials economy has long been inefficient due to unproductive reuse and recycling efforts. Within the wider materials portfolio, plastics have been revolutionary to many industries but they have been treated as disposable commodities leading to their increasing accumulation in the environment as waste. The field of chemistry has had significant bearing in ushering in the current plastics industry and will undoubtedly have a hand in transforming it to become more sustainable. Existing approaches include the development of synthetic biodegradable plastics and turning to renewable raw materials in order to produce plastics similar to our current petrol-based materials or to create new polymers. Additionally, chemists are confronting the environmental crisis by developing alternative recycling methods to deal with the legacy of plastic waste. Important emergent technologies, such as catalytic chemical recycling or upcycling, have the potential to alleviate numerous issues related to our current and future refuse and, in doing so, help pivot our materials economy from linearity to circularity.

Hydrogenative Depolymerization of End-of-Life Polycarbonates by an Iron Pincer Complex

Chemical recycling processes can contribute to a resource-efficient plastic economy. Herein, a procedure for the iron-catalyzed hydrogenation of the carbonate function of end-of-life polycarbonates under simultaneous depolymerization is presented. The use of a straightforward iron pincer complex leads to high rate of depolymerization of poly(bisphenol A carbonate) and poly(propylene carbonate) yielding the monomers bisphenol A and 1,2-propanediol, respectively, as products under mild reaction conditions. Furthermore, the iron complex was able to depolymerize polycarbonates containing goods and mixture of plastics containing polycarbonates.

Chemical recycling of poly(bisphenol A carbonate)

This review covers the current status of chemical recycling and upcycling of poly(bisphenol A carbonate), a leading engineering plastic of great economic and environmental interest.

Hydrogenative Depolymerization of End-of-Life Poly-(Bisphenol A Carbonate) Catalyzed by a Ruthenium-MACHO-Complex

The valorization of waste to valuable chemicals can contribute to a more resource-efficient and circular chemistry. In this regard, the selective degradation of end-of-life polymers/plastics to produce useful chemical building blocks can be a promising target. We have investigated the hydrogenative depolymerization of end-of-life poly(bisphenol A carbonate). Applying catalytic amounts of the commercial available Ruthenium-MACHO-BH complex the end-of-life polycarbonate was converted to bisphenol A and methanol. Importantly, bisphenol A can be reprocessed for the manufacture of new poly-(bisphenol A carbonate) and methanol can be utilized as energy storage material.

Recycling of End-of-Life Poly(bisphenol A carbonate) via Alkali Metal Halide-Catalyzed Phenolysis

The chemical recycling of end-of-life plastic waste streams can contribute to a resource-conserving and sustainable society. This matter of recycling is composed of a sequence of depolymerization and subsequent polymerization reactions. In this regard, we have studied the chemical recycling of end-of-life poly(bisphenol A carbonate) applying phenol as depolymerization reagent. In the presence of catalytic amounts of alkali metal halides as products bisphenol A and diphenyl carbonate were obtained in excellent turnover frequencies of up to 1392 h-1 and short reaction times. These depolymerization products offer the straightforward possibility to close the cycle by producing new poly(bisphenol A carbonate) and as second product phenol, which can be reused for further depolymerizations.