Carbon nanotubes production from real-world waste plastics and the pyrolysis behaviour

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.

Recent Progresses in Pyrolysis of Plastic Packaging Wastes and Biomass Materials for Conversion of High-Value Carbons: A Review

The recycling of plastic packaging wastes helps to alleviate the problems of white pollution and resource shortage. It is very necessary to develop high-value conversion technologies for plastic packaging wastes. To our knowledge, carbon materials with excellent properties have been widely used in energy storage, adsorption, water treatment, aerospace and functional packaging, and so on. Waste plastic packaging and biomass materials are excellent precursor materials of carbon materials due to their rich sources and high carbon content. Thus, the conversion from waste plastic packaging and biomass materials to carbon materials attracts much attention. However, closely related reviews are lacking up to now. In this work, the pyrolysis routes of the pyrolysis of plastic packaging wastes and biomass materials for conversion to high-value carbons and the influence factors were analyzed. Additionally, the applications of these obtained carbons were summarized. Furthermore, the limitations of the current pyrolysis technology are put forward and the research prospects are forecasted. Therefore, this review can provide a useful reference and guide for the research on the pyrolysis of plastic packaging wastes and biomass materials and the conversion to high-value carbon.

Plastic wastes-derived N-doped carbon nanotubes for efficient removal of sulfamethoxazole in high salinity wastewater via nonradical peroxymonosulfate activation

Peroxymonosulfate (PMS) catalytic activation is effective to eliminate organic pollutants from water, thus the development of low-cost and efficient catalysts is significant in applications. The resource conversion of plastic wastes (PWs) into carbon nanotubes (CNTs) is a promising candidate for PMS-based advanced oxidation processes (AOPs), and also a sustainable strategy to realize plastic management and reutilization. Herein, cost-effective PWs-derived N-doped CNTs (N-pCNTs) were synthesized, which displayed efficient activity for PMS activation through an electron transfer pathway (ETP) for sulfamethoxazole (SMX) degradation in high salinity water. The pyrrolic N induced the positively charged surface of N-pCNTs, favoring the electrostatic adsorption of PMS and subsequent generation of active PMS* . A galvanic oxidation process was developed to prove the electron-shuttle dominated ETP for SMX oxidation. Combined with theoretical calculations, the efficiency of ETP was determined by the potential difference between HOMO of SMX and LUMO of N-pCNTs. Such oxidation produced low-toxicity intermediates and resulted in selective degradation of specific sulfonamide antibiotics. This work reveals the feasibility of low-cost N-pCNTs catalysts from PWs serving as an appealing candidate for PMS-AOPs in water remediation, providing a new solution to alleviate environmental issues caused by PWs and also advances the understanding of ETP during PMS activation.

Simultaneous production of high-valued carbon nanotubes and hydrogen from catalytic pyrolysis of waste plastics: The role of cellulose impurity

Upcycling waste plastics into valuable carbon nanotubes (CNTs) and hydrogen via catalytic pyrolysis is a sustainable strategy to mitigate white pollution. However, real-world plastics are complex and generally contain organic impurities, such as cellulose, which have a non-negligible impact on the catalytic pyrolysis process and product distribution. In this study, cellulose was chosen as a model compound to distinguish the effects of oxygen-containing components on the CNTs and hydrogen production during the catalytic pyrolysis of waste polypropylene. Different amounts of cellulose were mixed with polypropylene to regulate the O/C mass ratio of the feedstock, and the relationship between the O/C mass ratio and the yield of products has been built quantificationally. The results revealed that the relative content of CNTs increased to over 95%, and the stability and purity of carbon deposition increased accordingly when the O/C mass ratio is 0.05. This could be ascribed to the etching effects caused by small amounts of H2O and CO2 on amorphous carbon. However, further increasing the amount of cellulose caused the deactivation of the Fe-Ni catalyst. This not only decreased the carbon yield but had an adverse impact on its morphology and graphitization, leading to the increase of amorphous carbon. This study can provide fundamental guidance for the efficient utilization of waste plastics that take advantage of organic impurities in waste plastic to promote the formation of high-purity CNTs.

Fe-Co Bimetallic Catalysts for Pyrolysis of Disposable Face Masks and Nitrile Gloves: Synthesis and Characterization of N-Doped Carbon Nanotubes

The global spread of severe acute respiratory syndrome coronavirus 2 has led to a widespread surge in the use of disposable medical face masks (DFMs) and waste nitrile gloves (WNGs). To address the immense disruption in waste management systems, the catalytic pyrolysis of DFMs and WNGs was undertaken to yield multiwalled carbon nanotubes. Two MgO-supported bimetallic catalysts, Fe-Co and Fe-Ni, were synthesized for catalytic pyrolysis. The MgO-supported Fe and Co catalysts showed a good yield of N-doped CNTs (N-CNTs) above 33 wt %, while the percentage of WNGs did not exceed 20 wt %. The pyrolysis process resulted in the formation of Fe-Co microspinels, which were subsequently encapsulated within N-CNTs, ultimately yielding FeCo-NCNTs. The synthesized FeCo-NCNTs were approximately 25 nm in diameter and were extended over several micrometers in length. Subsequent evaluations included testing several acid-washed FeCo-NCNTs as catalysts for the oxygen reduction reaction. The FeCo-NCNTs exhibited remarkable catalytic performance, with a half-wave potential at 0.831 V (vs RHE) and exceptional resistance to methanol poisoning. These remarkable findings have the potential to contribute to the sustainable recycling of waste generated during the COVID-19 pandemic and to the utilization of waste-derived materials.