Rapid atom-efficient polyolefin plastics hydrogenolysis mediated by a well-defined single-site electrophilic/cationic organo-zirconium catalyst

Demystifying group-4 polyolefin hydrogenolysis catalysis. Gaseous propane hydrogenolysis mechanism over the same catalysts

A kinetic/mechanistic investigation of gaseous propane hydrogenolysis over the single-site heterogeneous polyolefin depolymerization catalysts AlS/ZrNp2 and AlS/HfNp2 (AlS = sulfated alumina, Np = neopentyl), is use to probe intrinsic catalyst properties without the complexities introduced by time- and viscosity-dependent polymer medium effects. In a polymer-free automated plug-flow catalytic reactor, propane hydrogenolysis turnover frequencies approach 3,000 h-1 at 150 °C. Both catalysts exhibit approximately linear relationships between rate and [H2] at substoichiometric [H2] with rate law orders of 0.66 ± 0.09 and 0.48 ± 0.07 for Hf and Zr, respectively; at higher [H2], the rates approach zero-order in [H2]. Reaction orders in [C3H8] and [catalyst] are essentially zero-order under all conditions, with the former implying rapid, irreversible alkane binding/activation. This rate law, activation parameter, and DFT energy span analysis support a scenario in which [H2] is pivotal in one of two plausible and competing rate-determining transition states-bimolecular metal-alkyl bond hydrogenolysis vs. unimolecular β-alkyl elimination. The Zr and Hf catalyst activation parameters, ΔH‡ = 16.8 ± 0.2 kcal mol-1 and 18.2 ± 0.6 kcal mol-1, respectively, track the relative turnover frequencies, while ΔS‡ = -19.1 ± 0.8 and -16.7 ± 1.4 cal mol-1 K-1, respectively, imply highly organized transition states. These catalysts maintain activity up to 200 °C, while time-on-stream data indicate multiday activities with an extrapolated turnover number ~92,000 at 150 °C for the Zr catalyst. This methodology is attractive for depolymerization catalyst discovery and process optimization.

Mild Catalytic Degradation of Crystalline Polyethylene Units in a Solid State Assisted by Carboxylic Acid Groups

Crystalline polyethylenes bearing carboxylic acid groups in the main chain were successfully degraded with a Ce catalyst and visible light. The reaction proceeds in a crystalline solid state without swelling in acetonitrile or water at a reaction temperature as low as 60 or 80 °C, employing dioxygen in air as the only stoichiometric reactant with nearly quantitative recovery of carbon atoms. Heterogeneous features of the reaction allowed us to reveal a dynamic morphological change of polymer crystals during the degradation.

A US perspective on closing the carbon cycle to defossilize difficult-to-electrify segments of our economy

Electrification to reduce or eliminate greenhouse gas emissions is essential to mitigate climate change. However, a substantial portion of our manufacturing and transportation infrastructure will be difficult to electrify and/or will continue to use carbon as a key component, including areas in aviation, heavy-duty and marine transportation, and the chemical industry. In this Roadmap, we explore how multidisciplinary approaches will enable us to close the carbon cycle and create a circular economy by defossilizing these difficult-to-electrify areas and those that will continue to need carbon. We discuss two approaches for this: developing carbon alternatives and improving our ability to reuse carbon, enabled by separations. Furthermore, we posit that co-design and use-driven fundamental science are essential to reach aggressive greenhouse gas reduction targets.

The Overlooked Potential of Sulfated Zirconia: Reexamining Solid Superacidity Toward the Controlled Depolymerization of Polyolefins

Closed-loop recycling via an efficient chemical process can help alleviate the global plastic waste crisis. However, conventional depolymerization methods for polyolefins, which compose more than 50% of plastics, demand high temperatures and pressures, employ precious noble metals, and/or yield complex mixtures of products limited to single-use fuels or oils. Superacidic forms of sulfated zirconia (SZrO) with Hammet Acidity Functions (H0) ≤ - 12 (i.e., stronger than 100% H2SO4) are industrially deployed heterogeneous catalysts capable of activating hydrocarbons under mild conditions and are shown to decompose polyolefins at temperatures near 200 °C and ambient pressure. Additionally, confinement of active sites in porous supports is known to radically increase selectivity, coking and sintering resistance, and acid site activity, presenting a possible approach to low-energy polyolefin depolymerization. However, a critical examination of the literature on SZrO led us to a surprising conclusion: despite 40 years of catalytic study, engineering, and industrial use, the surface chemistry of SZrO is poorly understood. Ostensibly spurred by SZrO's impressive catalytic activity, the application-driven study of SZrO has resulted in deleterious ambiguity in requisite synthetic conditions for superacidity and insufficient characterization of acidity, porosity, and active site structure. This ambiguity has produced significant knowledge gaps surrounding the synthesis, structure, and mechanisms of hydrocarbon activation for optimized SZrO, stunting the potential of this catalyst in olefin cracking and other industrially relevant reactions, such as isomerization, esterification, and alkylation. Toward mitigating these long extant issues, we herein identify and highlight these current shortcomings and knowledge gaps, propose explicit guidelines for characterization of and reporting on characterization of solid acidity, and discuss the potential of pore-confined superacids in the efficient and selective depolymerization of polyolefins.

Dynamic Chemistry Toolbox for Advanced Sustainable Materials

Developing dynamic chemistry for polymeric materials offers chemical solutions to solve key problems associated with current plastics. Mechanical performance and dynamic function are equally important in material design because the former determines the application scope and the latter enables chemical recycling and hence sustainability. However, it is a long-term challenge to balance the subtle trade-off between mechanical robustness and dynamic properties in a single material. The rise of dynamic chemistry, including supramolecular and dynamic covalent chemistry, provides many opportunities and versatile molecular tools for designing constitutionally dynamic materials that can adapt, repair, and recycle. Facing the growing social need for developing advanced sustainable materials without compromising properties, recent progress showing how the toolbox of dynamic chemistry can be explored to enable high-performance sustainable materials by molecular engineering strategies is discussed here. The state of the art and recent milestones are summarized and discussed, followed by an outlook toward future opportunities and challenges present in this field.

Catalytic Strategies for the Upcycling of Polyolefin Plastic Waste

Chemical upgrading of waste plastics is currently one of the most important methods for addressing plastic pollution. In comparison to the current methods of incineration or landfill, chemical upgrading enables the utilization of carbon and hydrogen elements in waste plastics as resources. This process strongly relies on efficient catalysts and reaction systems. Through catalyst design, waste plastics can be converted into fuels or chemicals under the optimized reaction conditions, extending their life cycles. In this review, we systematically discuss various chemical conversion methods for polyolefin waste plastics, which account for a large proportion of waste plastics. We further explore the remaining challenges and future development trends in this field, including improving product value through product engineering and shifting research perspectives to exploring the tolerance of catalysts toward impurities in practical waste plastic waste rather than using pure plastic feedstock.

Circular olefin copolymers made de novo from ethylene and α-olefins

Ethylene/α-olefin copolymers are produced in huge scale and widely used, but their after-use disposal has caused plastic pollution problems. Their chemical inertness made chemical re/upcycling difficult. Ideally, PE materials should be made de novo to have a circular closed-loop lifecycle. However, synthesis of circular ethylene/α-olefin copolymers, including high-volume, linear low-density PE as well as high-value olefin elastomers and block copolymers, presents a particular challenge due to difficulties in introducing branches while simultaneously installing chemical recyclability and directly using industrial ethylene and α-olefin feedstocks. Here we show that coupling of industrial coordination copolymerization of ethylene and α-olefins with a designed functionalized chain-transfer agent, followed by modular assembly of the resulting AB telechelic polyolefin building blocks by polycondensation, affords a series of ester-linked PE-based copolymers. These new materials not only retain thermomechanical properties of PE-based materials but also exhibit full chemical circularity via simple transesterification and markedly enhanced adhesion to polar surfaces.

Isoreticular Metal-Organic Frameworks Confined Mononuclear Ru-Hydrides Enable Highly Efficient Shape-Selective Hydrogenolysis of Polyolefins

Upcycling nonbiodegradable plastics such as polyolefins is paramount due to their ever-increasing demand and landfills after usage. Catalytic hydrogenolysis is highly appealing to convert polyolefins into targeted value-added products under mild reaction conditions compared with other methods, such as high-temperature incineration and pyrolysis. We have developed three isoreticular zirconium UiO-metal-organic frameworks (UiO-MOFs) node-supported ruthenium dihydrides (UiO-RuH2), which are efficient heterogeneous catalysts for hydrogenolysis of polyethylene at 200 °C, affording liquid hydrocarbons with a narrow distribution and excellent selectivity via shape-selective catalysis. UiO-66-RuH2 catalyzed hydrogenolysis of single-use low-density polyethylene (LDPE) produced a C12 centered narrow bell-shaped distribution of C8-C16 alkanes in >80% yield and 90% selectivity in the liquid phase. By tuning the pore sizes of the isoreticular UiO-RuH2 MOF catalysts, the distribution of the products could be systematically altered, affording different fuel-grade liquid hydrocarbons from LDPE in high yields. Our spectroscopic and theoretical studies and control experiments reveal that UiO-RuH2 catalysts enable highly efficient upcycling of plastic wastes under mild conditions owing to their unique combination of coordinatively unsaturated single-site Ru-active sites, uniform and tunable pores, well-defined porous structure, and superior stability. The kinetics and theoretical calculations also identify the C-C bond scission involving β-alkyl transfer as the turnover-limiting step.

Rapid Polyolefin Hydrogenolysis by a Single-Site Organo-Tantalum Catalyst on a Super-Acidic Support: Structure and Mechanism

The novel electrophilic organo-tantalum catalyst AlS/TaNpx (1) (Np=neopentyl) is prepared by chemisorption of the alkylidene Np3 Ta=CHt Bu onto highly Brønsted acidic sulfated alumina (AlS). The proposed catalyst structure is supported by EXAFS, XANES, ICP, DRIFTS, elemental analysis, and SSNMR measurements and is in good agreement with DFT analysis. Catalyst 1 is highly effective for the hydrogenolysis of diverse linear and branched hydrocarbons, ranging from C2 to polyolefins. To the best of our knowledge, 1 exhibits one of the highest polyolefin hydrogenolysis activities (9,800 (CH2 units) ⋅ mol(Ta)-1  ⋅ h-1 at 200 °C/17 atm H2 ) reported to date in the peer-reviewed literature. Unlike the AlS/ZrNp2 analog, the Ta catalyst is more thermally stable and offers multiple potential C-C bond activation pathways. For hydrogenolysis, AlS/TaNpx is effective for a wide variety of pre- and post-consumer polyolefin plastics and is not significantly deactivated by standard polyolefin additives at typical industrial concentrations.

A Supported Ziegler-Type Organohafnium Site Metabolizes Polypropylene

Cp2Hf(CH3)2 reacts with silica containing strong aluminum Lewis sites to form Cp2Hf-13CH3+ paired with aluminate anions. Solid-state NMR studies show that this reaction also forms neutral organohafnium and hafnium sites lacking methyl groups. Cp2Hf-13CH3+ reacts with isotatic polypropylene (iPP, Mn = 13.3 kDa; Đ = 2.4; mmmm = 94%; ∼110 C3H6/Hf) and H2 to form oils with moderate molecular weights (Mn = 290-1200 Da) in good yields. The aliphatic oils show characteristic 13C{1H} NMR properties consistent with complete loss of diastereoselectivity and formation of regioirregular errors under 1 atm H2. These results show that a Ziegler-Natta-type active site is compatible in a common reaction used to digest waste plastic into smaller aliphatic fragments.

Chemically recyclable polyolefin-like multiblock polymers

Polyolefins are the most important and largest volume plastics produced. Unfortunately, the enormous use of plastics and lack of effective disposal or recycling options have created a plastic waste catastrophe. In this work, we report an approach to create chemically recyclable polyolefin-like materials with diverse mechanical properties through the construction of multiblock polymers from hard and soft oligomeric building blocks synthesized with ruthenium-mediated ring-opening metathesis polymerization of cyclooctenes. The multiblock polymers exhibit broad mechanical properties, spanning elastomers to plastomers to thermoplastics, while integrating a high melting transition temperature (Tm) and low glass transition temperature (Tg), making them suitable for use across diverse applications (Tm as high as 128°C and Tg as low as -60°C). After use, the different plastics can be combined and efficiently deconstructed back to the fundamental hard and soft building blocks for separation and repolymerization to realize a closed-loop recycling process.

Molecular Alumo- and Gallosilicate Hydrides Functionalized with Terminal M(NR2)3 and Bridging M(NR2)2 (M = Ti, Zr, Hf; R = Me, Et) Moieties

A general synthetic strategy for the systematic synthesis of group 4 MIV heterometallic complexes LMIII(H)(μ-O)Si(μ-O)(OtBu)2}nMIV(NR2)4-n (L = {[HC{C(Me)N(2,6-iPr2C6H3)}2; MIII = Al or Ga; n = 1 or 2; MIV = Ti, Zr, Hf; R = Me, Et), based on alumo- or gallosilicate hydride ligands bearing a Si-OH moiety, is presented. The challenging isolation of these metalloligands involved two strategies. On the one hand, the acid-base reaction of LAlH2 with (HO)2Si(OtBu)2 yielded LAlH(μ-O)Si(OH)(OtBu)2 (1), while on the other hand, the oxidative addition of (HO)2Si(OtBu)2 to LGa produced the gallium analog (2). These metalloligands successfully stabilized two hydrogen atoms with different acid-base properties (MIII-H and SiO-H) in the same molecule. Reactivity studies between 1 and 2 and group 4 amides MIV(NR2)4 (MIV = Ti, Zr, Hf; R = Me, Et) and tuning the reactions conditions and stoichiometry led to isolation and structural characterization of heterometallic complexes 3-11 with a 1:1 or 2:1 metalloligand/MIV ratio. Notably, some of these molecular heterometallic silicate complexes stabilize for the first time terminal (O3Si-O-)MIV(NR2)3 moieties known from single-site silica-grafted species. Furthermore, the aluminum-containing heterometallic complexes possess Al-H vibrational energies similar to those reported for modified alumina surfaces, which makes them potentially suitable models for the proposed MIV species grafted onto silica/alumina surfaces with hydride and dihydride architectures.

Structure-Property Relationships for Nickel Aluminate Catalysts in Polyethylene Hydrogenolysis with Low Methane Selectivity

Earth-abundant metals have recently been demonstrated as cheap catalyst alternatives to scarce noble metals for polyethylene hydrogenolysis. However, high methane selectivities hinder industrial feasibility. Herein, we demonstrate that low-temperature ex-situ reduction (350 °C) of coprecipitated nickel aluminate catalysts yields a methane selectivity of <5% at moderate polymer deconstruction (25-45%). A reduction temperature up to 550 °C increases the methane selectivity nearly sevenfold. Catalyst characterization (XRD, XAS, 27Al MAS NMR, H2 TPR, XPS, and CO-IR) elucidates the complex process of Ni nanoparticle formation, and air-free XPS directly after reaction reveals tetrahedrally coordinated Ni2+ cations promote methane production. Metallic and the specific cationic Ni appear responsible for hydrogenolysis of internal and terminal C-C scissions, respectively. A structure-methane selectivity relationship is discovered to guide the design of Ni-based catalysts with low methane generation. It paves the way for discovering other structure-property relations in plastics hydrogenolysis. These catalysts are also effective for polypropylene hydrogenolysis.

MAO- and Borate-Free Activating Supports for Group 4 Metallocene and Post-Metallocene Catalysts of α-Olefin Polymerization and Oligomerization

Modern industry of advanced polyolefins extensively uses Group 4 metallocene and post-metallocene catalysts. High-throughput polyolefin technologies demand the use of heterogeneous catalysts with a given particle size and morphology, high thermal stability, and controlled productivity. Conventional Group 4 metal single-site heterogeneous catalysts require the use of high-cost methylalumoxane (MAO) or perfluoroaryl borate activators. However, a number of inorganic phases, containing highly acidic Lewis and Brønsted sites, are able to activate Group 4 metal pre-catalysts using low-cost and affordable alkylaluminums. In the present review, we gathered comprehensive information on MAO- and borate-free activating supports of different types and discussed the surface nature and chemistry of these phases, examples of their use in the polymerization of ethylene and α-olefins, and prospects of the further development for applications in the polyolefin industry.

Cationic Tantalum Hydrides Catalyze Hydrogenolysis and Alkane Metathesis Reactions of Paraffins and Polyethylene

Sulfated aluminum oxide (SAO), a high surface area material containing sulfate anions that behave like weakly coordinating anions, reacts with Ta(═CH^tBu)(CH₂^tBu)₃ to form [Ta(CH₂^tBu)₂(O-)₂][SAO] (1). Subsequent treatment with H₂ forms Ta-H⁺ sites supported on SAO that are active in hydrogenolysis and alkane metathesis reactions. In both reactions Ta-H⁺ is more active than related neutral Ta-H sites supported on silica. This reaction chemistry extends to melts of high-density polyethylene (HDPE), where Ta-H⁺ converts 30% of a low molecular weight HDPE (M_n = 2.5 kg mol^-1; Đ = 3.6) to low molecular weight paraffins under hydrogenolysis conditions. Under alkane metathesis conditions Ta-H⁺ converts this HDPE to a high MW fraction (M_n = 6.2 kDa; Đ = 2.3) and low molecular weight alkane products (C₁₃-C₃₂). These results show that incorporating charge as a design element in supported d⁰ metal hydrides is a viable strategy to increase the reaction rate in challenging reactions involving reorganization of C-C bonds in alkanes.