Catalytic upcycling of high-density polyethylene via a processive mechanism

Highly selective upcycling of plastic mixture waste by microwave-assisted catalysis over Zn/b-ZnO

7 billion of 9.2 billion tons of plastic produced becomes waste while conventional catalytic plastic recycling methods are vulnerable with degraded performance and intensive energy input. Here, a hybrid Zn/b-ZnO catalyst, together with the specially-designed microwave reaction system, has achieved fast plastic waste upgrading under atmospheric pressure without using H2. Bifunctional ZnO acts as a microwave absorber and substrate catalyst, and in-situ formed Zn clusters promote C-C bond cleavage and nearly 100% upcycle landfilled plastic mixtures into lubricant base oil precursors and monomers. Unprecedented turnover number (250 gplastic g-1catalyst) of plastic depolymerisation and long-time stability over 50 successive cycles have been demonstrated, together with 8-time higher energy efficiency compared with conventional catalysis, indicating this strategy is an economical approach to efficient upcycling of plastics towards valuable products. Moreover, the catalyst can tolerate high contaminates, even the landfilled plastics can still be converted to lubricant base oil precursors, which has never been reported before.

Microwave-Powered Liquid Metal Degradation of Polyolefins

Upcycling waste plastics is highly promising to tackle global white pollution while achieving sustainable development. However, prevailing approaches often encounter challenges in scalable engineering practices due to either insufficient plastic upcycling capability or arduousness in the separation, recovery, and purification of catalysts, which inevitably augments the cost of plastic upcycling. Here, the microwave-powered liquid metal synergetic depolymerization is presented to facilitate low-cost plastic upcycling. By leveraging the fluidity of liquid metals and their exceptional chemical-bond activation ability under microwave field, this method efficiently converts various polyolefins into narrowband hydrocarbon oil (Oil yield: 81 wt.% for polypropylene (PP), 85.9 wt.% for polyethylene (PE)) and high-value olefin monomers (C2-4  selectivity: 50% for PE, 65.3% for PP) over 30 successive cycles, resulting in a high turnover frequency of 2.83 kgPlastic mLLiquid metal -1. These captivating advantages offered by electromagnetically-powered liquid metals are also supported by their self-separation features, thereby paving the way for large-scale engineering solutions in waste plastic upcycling.

Upcycling Polyethylene to High-Purity Hydrogen under Ambient Conditions via Mechanocatalysis

Polyethylene (PE) is the most abundant plastic waste, and its conversion to hydrogen (H2) offers a promising route for clean energy generation. However, PE decomposition typically requires high temperatures due to its strong chemical bonds, leading to significant carbon emissions and low H2 selectivity (theoretically less than 75 vol % after accounting for further steam-reforming reactions). Here, we report a mechanocatalytic strategy that upcycles PE into high-purity H2 (99.4 vol %) with an exceptional H2 recovery ratio of 98.5 % (versus 15.7 % via thermocatalysis), using manganese as a catalyst at a low temperature of 45 °C. This method achieves a reaction rate 3 orders of magnitude higher than thermocatalysis. The marked improvement in H2 recovery ratio is mainly due to metal carbides formation induced by the mechanocatalytic process, which does not catalyze hydrocarbons formation. This work is expected to advance studies of the conversion of polyolefins to high-purity H2 with net-zero carbon emissions.

Selective Hydrogenolysis Conversion of Polyethylene into Alkyl Oil Over Iridium-based Catalyst

Plastic not only brings convenience but also places a great burden on the environment. Utilizing plastic as a low-cost feed-stock for producing valuable chemicals and fuels is one of the most attractive directions. Among the huge types of plastics, polyolefins (PO), especially polyethylene (PE), were the most abundant type and the most difficult to upgrade. Hydrocracking and hydrogenolysis operate at relatively low reaction temperatures which show promising applications. Herein, Iridium-based catalysts were developed and proved to be effective in PE hydrogenolysis under relatively mild conditions. Catalysts were characterized by TEM, HRTEM, SEM, HAADF-STEM, XPS, CO chemisorption and H2 chemisorption etc. The Ir catalysts showed similar reactivity but better selectivity for liquid products than Ru under similar conditions. A highest 92.7 % percent of liquid products could be obtained under 250 °C, 3 MPa of H2 in 8 hours with Ir/γ-Al2O3 catalyst. The support could also affect the performance, including Lewis acid amount, surface areas, and morphology. And we suppose Iridium catalysts could serve as another choice for plastic hydrogenolysis under mild conditions.

A comprehensive review of recycling and reusing methods for plastic waste focusing Indian scenario

Plastics are integral to modern life but present significant environmental and economic challenges due to ineffective waste management systems. This article provides a comprehensive review of global plastic waste management (PWM) strategies, focusing on advancements in processing technologies, policy frameworks and their practical applications. It highlights the role of the World Intellectual Property Organization (WIPO) and regulatory bodies across the United States, Canada, Europe, Britain, India, Japan, Australia and China in fostering sustainable PWM practices. The study evaluates key processing techniques, including pyrolysis, gasification, supercritical water conversion, plasma-assisted processes, mechanical reprocessing and landfilling, emphasizing their technological advancements, limitations and scalability. Supercritical water conversion (operating at >374°C and 22.1 MPa) and plasma-assisted processing (using ionized gas at >3000°C) are identified as advanced methods capable of converting plastics into simpler molecules or valuable by-products. However, these technologies face challenges such as high energy requirements, operational costs and limited scalability. Persistent issues, including microplastic pollution, environmental impacts and the chemical-intensive nature of certain processes, are critically analysed. Drawing on extensive reviews of patents, case studies and real-world implementations, the study also examines the reuse potential of plastic by-products in diverse industries and evaluates state-level PWM initiatives in India. This review provides actionable insights for policymakers, researchers and industry stakeholders, highlighting critical gaps and opportunities to enhance the sustainability and scalability of PWM systems. By addressing persistent challenges, it contributes to advancing a circular economy for plastics and sustainable waste management practices globally.

Advanced Catalysts for the Chemical Recycling of Plastic Waste

Plastic products bring convenience to various aspects of the daily lives due to their lightweight, durability and versatility, but the massive accumulation of post-consumer plastic waste is posing significant environmental challenges. Catalytic methods can effectively convert plastic waste into value-added feedstocks, with catalysts playing an important role in regulating the yield and selectivity of products. This review explores the latest advancements in advanced catalysts applied in thermal catalysis, microwave-assisted catalysis, photocatalysis, electrocatalysis, and enzymatic catalysis reaction systems for the chemical recycling of plastic waste into valuable feedstocks. Specifically, the pathways and mechanisms involved in the plastics recycling process are analyzed and presented, and the strengths and weaknesses of various catalysts employed across different reaction systems are described. In addition, the structure-function relationship of these catalysts is discussed. Herein, it is provided insights into the design of novel catalysts applied for the chemical recycling of plastic waste and outline challenges and future opportunities in terms of developing advanced catalysts to tackle the "white pollution" crisis.

Polyethylene hydrogenolysis by dilute RuPt alloy to achieve H2-pressure-independent low methane selectivity

Chemical recycling of plastic waste could reduce its environmental impact and create a more sustainable society. Hydrogenolysis is a viable method for polyolefin valorization but typically requires high hydrogen pressures to minimize methane production. Here, we circumvent this stringent requirement using dilute RuPt alloy to suppress the undesired terminal C-C scission under hydrogen-lean conditions. Spectroscopic studies reveal that PE adsorption takes place on both Ru and Pt sites, yet the C-C bond cleavage proceeds faster on Ru site, which helps avoid successive terminal scission of the in situ-generated reactive intermediates due to the lack of a neighboring Ru site. Different from previous research, this method of suppressing methane generation is independent of H2 pressure, and PE can be converted to fuels and waxes/lubricant base oils with only <3.2% methane even under ambient H2 pressure. This advantage would allow the integration of distributed, low-pressure hydrogen sources into the upstream of PE hydrogenolysis and provide a feasible solution to decentralized plastic upcycling.

Review of key issues and potential strategies in bio-degradation of polyolefins

Polyolefins are the most widely used plastic product and a major contributor to white pollution. Currently, studies on polyolefin degradation systems are mainly focused on microorganisms and some redox enzymes, and there is a serious black-box phenomenon. The use of polyolefin-degrading enzymes is limited because of the small number of enzymes; in addition, the catalytic efficiency of these enzymes is poor and their catalytic mechanism is unclear, which leads to the incomplete degradation of polyolefins to produce microplastics. In this review, three questions are addressed: the generation and degradation of action targets that promote the degradation of polyolefins, the different modes by which enzymes bind substrates and their application scenarios, and possible multienzyme systems in a unified system. This review will be valuable for mining or modifying polyolefin degradation enzymes and constructing polyolefins degradation systems and may provide novel ideas and opportunities for polyolefin degradation.

Rapid Generation of Microplastics and Plastic-Derived Dissolved Organic Matter from Food Packaging Films under Simulated Aging Conditions

In this study, we show that low-density polyethylene films, a prevalent choice for food packaging in everyday life, generated high numbers of microplastics (MPs) and hundreds to thousands of plastic-derived dissolved organic matter (DOM) substances under simulated food preparation and storage conditions. Specifically, the plastic film generated 66-2034 MPs/cm2 (size range 10-5000 μm) under simulated aging conditions involving microwave irradiation, heating, steaming, UV irradiation, refrigeration, freezing, and freeze-thaw cycling alongside contact with water, which were 15-453 times that of the control (plastic film immersed in water without aging). We also noticed a substantial release of plastic-derived DOM. Using ultrahigh-resolution mass spectrometry, we identified 321-1414 analytes with molecular weights ranging from 200 to 800 Da, representing plastic-derived DOM containing C, H, and O. The DOM substances included both degradation products of polyethylene (including oxidized forms of oligomers) and toxic plastic additives. Interestingly, although no apparent oxidation was observed for the plastic film under aging conditions, plastic-derived DOM was more oxidized (average O/C increased by 27-46%) following aging with a higher state of carbon saturation and higher polarity. These findings highlight the future need to assess risks associated with MP and DOM release from plastic wraps.

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.

One-pot Hydrogenolysis of Polyethylene Terephthalate (PET) to p-xylene over CuZn/Al2O3 Catalyst

Chemical upcycling of plastic wastes into valuable chemicals is a promising strategy for resolving plastic pollution, but economically viable methods currently are still lacking. Here, we report one-pot hydrogenolysis of PET plastic into p-xylene with an excellent yield (99.8 %) over a robust non-precious Cu-based catalyst, CuZn/Al2O3, in the absence of alcohol solvents. The presence of Zn species promotes the dispersion of Cu0 and increases the ratio of Cu+/Cu0, whereas the synergistic effect of Cu0 and Cu+ leads to a superior performance in the conversion of PET. The combination of GC-MS, 13C CP MAS NMR, 2D 1H-13C CP HETCOR NMR spectroscopy and kinetic studies for the first time demonstrates 4-methyl benzyl alcohol as an important reaction intermediate in the hydrogenolysis of PET. Mechanistic studies indicate that the conversion of PET mainly follows a hydrogenolysis process, involving the cleavage of ester bonds to alcohols and the C-O bond cleavage of alcohols to alkanes. This work not only brings new insight for understanding the upgrading pathway of PET, but also provides a guidance for the design of high-performance non-precious catalysts for the chemical upcycling of plastic wastes.

Selective Upcycling of Polyolefins into High-Value Nitrogenated Chemicals

The selective upcycling of polyolefins to create products of increased value has emerged as an innovative approach to carbon resource stewardship, drawing significant scientific and industrial interest. Although recent advancements in recycling technology have facilitated the direct conversion of polyolefins to hydrocarbons or oxygenated compounds, the synthesis of nitrogenated compounds from such waste polyolefins has not yet been disclosed. Herein, we demonstrate a novel approach for the upcycling of waste polyolefins by efficiently transforming a range of postconsumer plastic products into nitriles and amides. This process leverages the catalytic properties of manganese dioxide in combination with an inexpensive nitrogen source, urea, to make it both practical and economically viable. Our approach not only opens new avenues for the creation of nitrogenated chemicals from polyolefin waste but also underscores the critical importance of recycling and valorizing carbon resources originally derived from fossil fuels. This study provides a new upcycling strategy for the sustainable conversion of waste polyolefins.

Selective Upcycling of Polyethylene over Ru/H-ZSM-5 Bifunctional Catalyst into High-Quality Liquid Fuel at Mild Conditions

It has been known that plastics with undegradability and long half-times have caused serious environmental and ecological issues. Considering the devastating effects, the development of efficient plastic upcycling technologies with low energy consumption is absolutely imperative. Catalytic hydrogenolysis of single-use polyethylene over Ru-based catalysts to produce high-quality liquid fuel has been one of the current top priority strategies, but it is restricted by some tough challenges, such as the tendency towards methanation resulting from terminal C-C cleavage. Herein, we introduced Ru nanoparticles supported on hollow ZSM-5 zeolite (Ru/H-ZSM-5) for hydrocracking of high-density polyethylene (HDPE) under mild reaction conditions. The implication of experimental results is that the 1Ru/H-ZSM-5 (~1 wt % Ru) acted as an effective and reusable bifunctional catalyst providing higher conversion rate (82.53 %) and liquid fuel (C5-C21) yield (62.87 %). Detailed characterization demonstrated that the optimal performance in hydrocracking of PE could be attributed to the moderate acidity and appropriate positively charged Ru species resulting from the metal-zeolite interaction. This work proposes a promising catalyst for plastic upcycling and reveals its structure-performance relationship, which has guiding significance for catalyst design to improve the yield of high-value liquid fuels.

Closed-loop recyclable polymers: from monomer and polymer design to the polymerization-depolymerization cycle

The extensive utilization of plastic, as a symbol of modern technological society, has consumed enormous amounts of finite and non-renewable fossil resources and produced huge amounts of plastic wastes in the land or ocean, and thus recycling and reuse of the plastic wastes have great ecological and economic benefits. Closed-loop recyclable polymers with inherent recyclability can be readily depolymerized into monomers with high selectivity and purity and repolymerized into polymers with the same performance. They are deemed to be the next generation of recyclable polymers and have captured great and increasing attention from academia and industry. Herein, we provide an overview of readily closed-loop recyclable polymers based on monomer and polymer design and no-other-reactant-involved reversible ring-opening and addition polymerization reactions. The state-of-the-art of circular polymers is separately summarized and discussed based on different monomers, including lactones, thiolactones, cyclic carbonates, hindered olefins, cycloolefins, thermally labile olefin comonomers, cyclic disulfides, cyclic (dithio) acetals, lactams, Diels-Alder addition monomers, Michael addition monomers, anhydride-secondary amide monomers, and cyclic anhydride-aldehyde monomers, and polymers with activatable end groups. The polymerization and depolymerization mechanisms are clearly disclosed, and the evolution of the monomer structure, the polymerization and depolymerization conditions, the corresponding polymerization yield, molecular weight, performance of the polymers, monomer recovery, and depolymerization equipment are also systematically summarized and discussed. Furthermore, the challenges and future prospects are also highlighted.

Improving Environmental Stress Cracking Resistance of High-Density Polyethylene Grades by Comonomer Addition and Nanocomposite Approach

The aim of this paper is to determine the effect of polymer density, correlated to the comonomer content, and nanosilica addition on the mechanical and Environmental Stress Cracking Resistance (ESCR) characteristics of high-density polyethylene (HDPE). In this regard, five HDPE samples with similar Melt Flow Index (MFI) and molar mass but various densities were acquired from a petrochemical plant. Two polymerization reactors work in series and differ only in the amount of 1-buene comonomer fed to the second reactor. To ascertain the microstructure of the studied samples, GPC and SSA (successive self-nucleation and annealing) analyses were accomplished. All samples resulted having similar characteristics but slightly various SCB/1000 C=7.26-9.74 (SCB=Short Chain Branching). Consequently, meanwhile studied HDPEs reveal similar notched impact and stress at yield values, the tensile modulus, stress-at-break, and elongation-at-break tend to demonstrate different results with the SCB content. More significantly, ESCR characteristic varied considerably with SCB/1000 C extent, so that higher amount of SCB acknowledged advanced ESCR. Notably, blending HDPE sample containing higher amount of SCB/1000 C, with 3 wt.% of chemically modified nanosilica enhanced ESCR characteristic by 40 %. DFT (Density Functional Theory) calculations unveiled the role of the comonomer, quantitatively by binding energies and qualitatively by Non Covalent Interaction (NCI) plots.

Closed-Loop Recyclable Poly(ester-disulfide)s for Potential Alternatives to Engineering Plastic

Facile fabrication, low material complexity and closed-loop recycling are essential for polymer plastics to alter their linear product economy towards a cradle-to-cradle one. Covalent adaptable networks (CANs) are one way to achieve that, which intrinsically exhibit decent mechanical properties like the thermosets but could also be easily recycled like the thermoplastics. In this work, we introduce rigid ester structural motifs into dynamic poly(disulfide)s to form a series of dual polymer networks. Owning to the coherence of soft/rigid segments and the reversible sacrificial crosslinking, they exhibit tailorable mechanical properties and good resistance towards different chemicals. Their closed-loop recycling is achieved via mild solvolysis, maintaining materials' mechanical integrities. It offers a solution as a sustainable replacement for engineering plastics which are massively under production but hard to be recycled.

Interfacial Reactions in Chemical Recycling and Upcycling of Plastics

Depolymerization of plastics is a leading strategy to combat the escalating global plastic waste crisis through chemical recycling, upcycling, and remediation of micro-/nanoplastics. However, critical processes necessary for polymer chain scission, occurring at the polymer-catalyst or polymer-fluid interfaces, remain largely overlooked. Herein, we spotlight the importance of understanding these interfacial chemical processes as a critical necessity for optimizing kinetics and reactivity in plastics recycling and upcycling, controlling reaction outcomes, product distributions, as well as improving the environmental sustainability of these processes. Several examples are highlighted in heterogeneous processes such as hydrogenation over solid catalysts, reaction of plastics in immiscible media, and biocatalysis. Ultimately, judicious exploitation of interfacial reactivity has practical implications in developing practical, robust, and cost-effective processes to reduce plastic waste and enable a viable post-use circular plastics economy.

Assessment of transport phenomena in catalyst effectiveness for chemical polyolefin recycling

Since the dawn of agitated brewing in the Paleolithic era, effective mixing has enabled efficient reactions. Emerging catalytic chemical polyolefin recycling processes present unique challenges, considering that the polymer melt has a viscosity three orders of magnitude higher than that of honey. The lack of protocols to achieve effective mixing may have resulted in suboptimal catalyst effectiveness. In this study, we have tackled the hydrogenolysis of commercial-grade high-density polyethylene and polypropylene to show how different stirring strategies can create differences of up to 85% and 40% in catalyst effectiveness and selectivity, respectively. The reaction develops near the H2-melt interface, with the extension of the interface and access to catalyst particles the main performance drivers. Leveraging computational fluid dynamics simulations, we have identified a power number of 15,000-40,000 to maximize the catalyst effectiveness factor and optimize stirring parameters. This temperature- and pressure-independent model holds across a viscosity range of 1-1,000 Pa s. Temperature gradients may quickly become relevant for reactor scale-up.

Catalytic Synergy between Lewis Acidic Alumina and Pt in Hydrodechlorination for Plastic Chemical Recycling

Pyrolysis-based plastic chemical recycling has gained significant industrial attention due to its advantage of eliminating complex plastic sorting processes. However, plastic pyrolysis oil contains various components that require stringent removal before subsequent processes. In particular, Cl compounds originating from the decomposition of poly(vinyl chloride) can cause serious corrosion of reactors and catalyst deactivation in downstream processes. While extensive research has been conducted on the removal of other heteroatoms (S, N, and O) from organic compounds via hydrotreating, studies on the removal of Cl have been scarce. In this study, hydrodechlorination over Pt catalysts on various supports is comprehensively investigated using 1,2-dichloroethane as a model reactant. Our results demonstrate that Pt on γ-Al2O3 can exhibit exceptionally high catalytic activity compared to those on other supports due to a distinct bifunctional mechanism. Rigorous studies reveal that the Lewis acidic pentacoordinated Al sites of γ-Al2O3 activate C-Cl bonds, whereas Pt activates H2 and provides spillover H to remove Cl as HCl. The bifunctional mechanism enables the minimized use of precious Pt (<0.1 wt %) to achieve high activity. Pt/γ-Al2O3 also allows for efficient Cl removal (96.8%) with high stability in treating waste plastic pyrolysis oil containing 7500 ppm of Cl.

Catalytic Upcycling of Polyolefins

The large production volumes of commodity polyolefins (specifically, polyethylene, polypropylene, polystyrene, and poly(vinyl chloride)), in conjunction with their low unit values and multitude of short-term uses, have resulted in a significant and pressing waste management challenge. Only a small fraction of these polyolefins is currently mechanically recycled, with the rest being incinerated, accumulating in landfills, or leaking into the natural environment. Since polyolefins are energy-rich materials, there is considerable interest in recouping some of their chemical value while simultaneously motivating more responsible end-of-life management. An emerging strategy is catalytic depolymerization, in which a portion of the C-C bonds in the polyolefin backbone is broken with the assistance of a catalyst and, in some cases, additional small molecule reagents. When the products are small molecules or materials with higher value in their own right, or as chemical feedstocks, the process is called upcycling. This review summarizes recent progress for four major catalytic upcycling strategies: hydrogenolysis, (hydro)cracking, tandem processes involving metathesis, and selective oxidation. Key considerations include macromolecular reaction mechanisms relative to small molecule mechanisms, catalyst design for macromolecular transformations, and the effect of process conditions on product selectivity. Metrics for describing polyolefin upcycling are critically evaluated, and an outlook for future advances is described.

Oxidative Upcycling of Polyethylene to Long Chain Diacid over Co-MCM-41 Catalyst

Plastic pollution is an emerging global threat due to lack of effective methods for transforming waste plastics into useful resources. Here, we demonstrate a direct oxidative upcycling of polyethylene into high-value and high-volume saturated dicarboxylic acids in high carbon yield of 85.9 % in which the carbon yield of long chain dicarboxylic (C10-C20) acids can reach 58.9% over cobalt-doped MCM-41 molecular sieves, in the absence of any solvent or precious metal catalyst. The distribution of the dicarboxylic acids can be controllably adjusted from short-chain (C4-C10) to long-chain ones (C10-C20) through changing cobalt loading of MCM-41 under nanoconfinement. Highly and sparsely dispersed cobalt along with confined space of mesoporous structure enables complete degradation of polyethylene and high selectivity of dicarboxylic acid in mild condition. So far, this is the first report on highly selective one-step preparation of long chain dicarboxylic acids. The approach provides an attractive solution to tackle plastic pollution and a promising alternative route to long chain diacids.

Low-temperature dechlorination of polyvinyl chloride (PVC) for production of H2 and carbon materials using liquid metal catalysts

Polyvinyl chloride (PVC) is ubiquitous in everyday life; however, it is not recycled because it degrades uncontrollably into toxic products above 250°C. Therefore, it is of interest to controllably dechlorinate PVC at mild temperatures to generate narrowly distributed carbon materials. We present a catalytic route to dechlorinate PVC (~90% reduction of Cl content) at mild temperature (200°C) to produce gas H2 (with negligible coproduction of corrosive gas HCl) and carbon materials using Ga as a liquid metal (LM) catalyst. A LM was used to promote intimate contact between PVC and the catalytic sites. During dechlorination of PVC, Cl is sequestrated in the carbonaceous solid product. Later, chlorine is easily removed with an acetone wash at room temperature. The Ga LM catalyst is reusable, outperforms a traditional supported metal catalyst, and successfully converts (untreated) discarded PVC pipe.

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.

Active species in chloroaluminate ionic liquids catalyzing low-temperature polyolefin deconstruction

Chloroaluminate ionic liquids selectively transform (waste) polyolefins into gasoline-range alkanes through tandem cracking-alkylation at temperatures below 100 °C. Further improvement of this process necessitates a deep understanding of the nature of the catalytically active species and the correlated performance in the catalyzing critical reactions for the tandem polyolefin deconstruction with isoalkanes at low temperatures. Here, we address this requirement by determining the nuclearity of the chloroaluminate ions and their interactions with reaction intermediates, combining in situ 27Al magic-angle spinning nuclear magnetic resonance spectroscopy, in situ Raman spectroscopy, Al K-edge X-ray absorption near edge structure spectroscopy, and catalytic activity measurement. Cracking and alkylation are facilitated by carbenium ions initiated by AlCl3-tert-butyl chloride (TBC) adducts, which are formed by the dissociation of Al2Cl7- in the presence of TBC. The carbenium ions activate the alkane polymer strands and advance the alkylation cycle through multiple hydride transfer reactions. In situ 1H NMR and operando infrared spectroscopy demonstrate that the cracking and alkylation processes occur synchronously; alkenes formed during cracking are rapidly incorporated into the carbenium ion-mediated alkylation cycle. The conclusions are further supported by ab initio molecular dynamics simulations coupled with an enhanced sampling method, and model experiments using n-hexadecane as a feed.

Chemical Upcycling of Polyolefin Plastics Using Structurally Well-defined Catalysts

Single-use polyolefins are widely used in our daily life and industrial production due to their light weight, low cost, superior stability, and durability. However, the rapid accumulation of plastic waste and low-profit recycling methods resulted in a global plastic crisis. Catalytic hydrogenolysis is regarded as a promising technique, which can effectively and selectively convert polyolefin plastic waste to value-added products. In this perspective, we focus on the design and synthesis of structurally well-defined hydrogenolysis catalysts across mesoscopic, nanoscopic, and atomic scales, accompanied by our insights into future directions in catalyst design for further enhancing catalytic performance. These design principles can also be applied to the depolymerization of other polymers and ultimately realize the chemical upcycling of waste plastics.

Recycling Valuable Alkylbenzenes from Polystyrene through Methanol-Assisted Depolymerization

The vast bulk of polystyrene (PS), a major type of plastic polymers, ends up in landfills, which takes up to thousands of years to decompose in nature. Chemical recycling promises to enable lower-energy pathways and minimal environmental impacts compared with traditional incineration and mechanical recycling. Herein, we demonstrated that methanol as a hydrogen supplier assisted the depolymerization of PS (denoted as PS-MAD) into alkylbenzenes over a heterogeneous catalyst composed of Ru nanoparticles on SiO2. PS-MAD achieved a high yield of liquid products which accounted for 93.2 wt % of virgin PS at 280 °C for 6 h with the production rate of 118.1 mmolcarbon gcatal. -1 h-1. The major components were valuable alkylbenzenes (monocyclic aromatics and diphenyl alkanes), the sum of which occupied 84.3 wt % of liquid products. According to mechanistic studies, methanol decomposition dominates the hydrogen supply during PS-MAD, thereby restraining PS aromatization which generates by-products of fused polycyclic arenes and polyphenylenes.

Upcycling of polyethylene to gasoline through a self-supplied hydrogen strategy in a layered self-pillared zeolite

Conversion of plastic wastes to valuable carbon resources without using noble metal catalysts or external hydrogen remains a challenging task. Here we report a layered self-pillared zeolite that enables the conversion of polyethylene to gasoline with a remarkable selectivity of 99% and yields of >80% in 4 h at 240 °C. The liquid product is primarily composed of branched alkanes (selectivity of 72%), affording a high research octane number of 88.0 that is comparable to commercial gasoline (86.6). In situ inelastic neutron scattering, small-angle neutron scattering, solid-state nuclear magnetic resonance, X-ray absorption spectroscopy and isotope-labelling experiments reveal that the activation of polyethylene is promoted by the open framework tri-coordinated Al sites of the zeolite, followed by β-scission and isomerization on Brönsted acids sites, accompanied by hydride transfer over open framework tri-coordinated Al sites through a self-supplied hydrogen pathway to yield selectivity to branched alkanes. This study shows the potential of layered zeolite materials in enabling the upcycling of plastic wastes.

Recent Progresses and Challenges in Upcycling of Plastics through Selective Catalytic Oxidation

Chemical upcycling of plastics provides an important direction for solving the challenging issues of plastic pollution and mitigating the wastage of carbon resources. Among them, catalytic oxidative cracking of plastics to produce high-value chemicals, such as catalytic oxidation of polyethylene (PE) to produce fatty dicarboxylic acids, catalytic oxidation of polystyrene (PS) to produce benzoic acid, and catalytic oxidation of polyethylene terephthalate (PET) to produce terephthalic acid under mild conditions has attracted increasing attention, and some exciting progress has been made recently. In this article, we will review recent progresses on the catalytic oxidation upcycling of plastics and provide our understanding on the current challenges in catalytic oxidation upcycling of plastics.

Parameters optimization for decontamination and fine physical regeneration pathways of polypropylene plastics from waste lunchboxes

Due to the development of the food delivery industry, a large amount of waste lunchboxes made of homo polypropylene (PP) plastic have been generated. This study developed a new technological strategy to effectively regenerate PP from waste lunchboxes. Through response surface curve analysis, it was found that under the optimal process conditions of hot alkali washing at 80 ℃, 30 min, and pH 13, the optimal contact angle was 65.55°, indicating a good oil stain removal effect. By identifying and analyzing the characteristics of impurities in waste lunchboxes, a physical sorting and granulation regeneration process was constructed. And through large-scale statistical analysis and data collection, it was further verified that recycled PP plastics maintained their physical stability and excellent processing performance. The quality stability of recycled PP plastics in terms of impurities content was also verified. By designing different formulations specifically, recycled PP was mixed with different virgin PP and antioxidants in appropriate proportions, and extruded into particles under 150-300 mesh filtration conditions to obtain modified recycled PP. Modified recycled PP was applied in textiles, clothing, and injection molded products. In conclusion, we achieve the up-cylcing of waste PP lunchboxes instead of down-cylcing.

Artificial Processive Catalytic Systems

Processive catalysts remain attached to a substrate and perform multiple rounds of catalysis. They are abundant in nature. This review highlights artificial processive catalytic systems, which can be divided into (A) catalytic rings that move along a polymer chain, (B) catalytic pores that hold polymer chains and decompose them, (C) catalysts that remain attached to and move around a cyclic substrate via supramolecular interactions, and (D) anchored catalysts that remain in contact with a substrate via multiple catalytic interactions (see frontispiece).

CO2-facilitated upcycling of polyolefin plastics to aromatics at low temperature

Plastics are one of the most produced synthetic materials and largest commodities, used in numerous sectors of human life. To upcycle waste plastics into value-added chemicals is a global challenge. Despite significant progress in pyrolysis and hydrocracking, which mainly leads to the formation of pyrolysis oil, catalytic upcycling to value-added aromatics, including benzene, toluene and xylene (BTX), in one step, is still limited by high reaction temperatures (>500°C) and a low yield. We report herein CO2-facilitated upcycling of polyolefins and their plastic products to aromatics below 300°C, enabled by a bifunctional Pt/MnOx-ZSM-5 catalyst. ZSM-5 catalyzes cracking of polyolefins and aromatization, generating hydrogen at the same time, while Pt/MnOx catalyzes the reaction of hydrogen with CO2, consequently driving the reaction towards aromatization. Isotope experiments reveal that 0.2 kg CO2 is consumed per 1.0 kg polyethylene and 90% of the consumed CO2 is incorporated into the aromatic products. Furthermore, this new process yields 0.63 kg aromatics (BTX accounting for 60%), comparing favorably with the conventional pyrolysis or hydrocracking processes, which produce only 0.33 kg aromatics. In this way, both plastic waste and the greenhouse gas CO2 are turned into carbon resources, providing a new strategy for combined waste plastics upcycling and carbon dioxide utilization.

Opportunities and challenges for plastic depolymerization by biomimetic catalysis

Plastic waste has imposed significant burdens on the environment. Chemical recycling allows for repeated regeneration of plastics without deterioration in quality, but often requires harsh reaction conditions, thus being environmentally unfriendly. Enzymatic catalysis offers a promising solution for recycling under mild conditions, but it faces inherent limitations such as poor stability, high cost, and narrow substrate applicability. Biomimetic catalysis may provide a new avenue by combining high enzyme-like activity with the stability of inorganic materials. Biomimetic catalysis has demonstrated great potential in biomass conversion and has recently shown promising progress in plastic degradation. This perspective discusses biomimetic catalysis for plastic degradation from two perspectives: the imitation of the active centers and the imitation of the substrate-binding clefts. Given the chemical similarity between biomass and plastics, relevant work is also included in the discussion to draw inspiration. We conclude this perspective by highlighting the challenges and opportunities in achieving sustainable plastic recycling via a biomimetic approach.

Hydrogen Bubbles: Harmonizing Local Hydrogen Transfer for Efficient Plastic Hydro-Depolymerization

Hydro-depolymerization presents a promising avenue for transforming plastic waste into high-value hydrocarbons, offering significant potential for value-added recycling. However, a major challenge in this method arises from kinetic limitations due to insufficient hydrogen concentration near the active sites, requiring optimal catalytic performance only at higher hydrogen pressures. In this study, we address this hurdle by developing "hydrogen bubble catalysts" featuring Ru nanoparticles within mesoporous SBA-15 channels (Ru/SBA). The distinctive feature of Ru/SBA catalysts lies in their capacity for physical hydrogen storage and chemically reversible hydrogen spillover, ensuring a timely and ample hydrogen supply. Under identical reaction conditions, the catalytic activity of Ru/SBA surpassed that of Ru/SiO2 (no hydrogen storage capacity) by over 4-fold. This substantial enhancement in catalytic performance provides significant opportunities for near atmospheric pressure hydro-depolymerization of plastic waste.

Conversion of Polyethylene to Low-Molecular-Weight Oil Products at Moderate Temperatures Using Nickel/Zeolite Nanocatalysts

Polyethylene (PE) is the most widely used plastic, known for its high mechanical strength and affordability, rendering it responsible for ~70% of packaging waste and contributing to microplastic pollution. The cleavage of the carbon chain can induce the conversion of PE wastes into low-molecular-weight hydrocarbons, such as petroleum oils, waxes, and natural gases, but the thermal degradation of PE is challenging and requires high temperatures exceeding 400 °C due to its lack of specific chemical groups. Herein, we prepare metal/zeolite nanocatalysts by incorporating small-sized nickel nanoparticles into zeolite to lower the degradation temperature of PE. With the use of nanocatalysts, the degradation temperature can be lowered to 350 °C under hydrogen conditions, compared to the 400 °C required for non-catalytic pyrolysis. The metal components of the catalysts facilitate hydrogen adsorption, while the zeolite components stabilize the intermediate radicals or carbocations formed during the degradation process. The successful pyrolysis of PE at low temperatures yields valuable low-molecular-weight oil products, offering a promising pathway for the upcycling of PE into higher value-added products.

Layered Double Hydroxide Derivatives for Polyolefin Upcycling

While Ru-catalyzed hydrogenolysis holds significant promise in converting waste polyolefins into value-added alkane fuels, a major constraint is the high cost of noble metal catalysts. In this work, we propose, for the first time, that Co-based catalysts derived from CoAl-layered double hydroxide (LDH) are alternatives for efficient polyolefin hydrogenolysis. Leveraging the chemical flexibility of the LDH platform, we reveal that metallic Co species serve as highly efficient active sites for polyolefin hydrogenolysis. Furthermore, we introduced Ni into the Co framework to tackle the issue of restricted hydrogenation ability associated with contiguous Co-Co sites. In-situ analysis indicates that the integration of Ni induces electron transfer and facilitates hydrogen spillover. This dual effect synergistically enhances the hydrogenation/desorption of olefin intermediates, resulting in a significant reduction in the yield of low-value CH4 from 27.1 to 12.6%. Through leveraging the unique properties of LDH, we have developed efficient and cost-effective catalysts for the sustainable recycling and valorization of waste polyolefin materials.

Coupled conversion of polyethylene and carbon dioxide catalyzed by a zeolite-metal oxide system

Zeolite-catalyzed polyethylene (PE) aromatization achieves reduction of the aromatic yield via hydrogenation and hydrogenolysis reactions. The hydrogen required for CO2 hydrogenation can be provided by H radicals formed during aromatization. In this study, we efficiently convert PE and CO2 into aromatics and CO using a zeolite-metal oxide catalyst (HZSM-5 + CuZnZrOx) at 380°C and under hydrogen- and solvent-free reaction conditions. Hydrogen, derived from the aromatization of PE over HZSM-5, diffuses through the Brønsted acidic sites of the zeolite to the adjacent CuZnZrOx, where it is captured in situ by CO2 to produce bicarbonate and further hydrogenated to CO. This favors aromatization while inhibiting hydrogenation and secondary hydrogenolysis reactions. An aromatic yield of 62.5 wt % is achieved, of which 60% consisted of benzene, toluene, and xylene (BTX). The conversion of CO2 reaches values as high as 0.55 mmol gPE-1. This aromatization-hydrogen capture pathway provides a feasible scheme for the comprehensive utilization of waste plastics and CO2.

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.

The Effective Fragment Molecular Orbital Method: Achieving High Scalability and Accuracy for Large Systems

The effective fragment molecular orbital (EFMO) method has been developed to predict the total energy of a very large molecular system accurately (with respect to the underlying quantum mechanical method) and efficiently by taking advantage of the locality of strong chemical interactions and employing a two-level hierarchical parallelism. The accuracy of the EFMO method is partly attributed to the accurate and robust intermolecular interaction prediction between distant fragments, in particular, the many-body polarization and dispersion effects, which require the generation of static and dynamic polarizability tensors by solving the coupled perturbed Hartree-Fock (CPHF) and time-dependent HF (TDHF) equations, respectively. Solving the CPHF and TDHF equations is the main EFMO computational bottleneck due to the inefficient (serial) and I/O-intensive implementation of the CPHF and TDHF solvers. In this work, the efficiency and scalability of the EFMO method are significantly improved with a new CPU memory-based implementation for solving the CPHF and TDHF equations that are parallelized by either message passing interface (MPI) or hybrid MPI/OpenMP. The accuracy of the EFMO method is demonstrated for both covalently bonded systems and noncovalently bound molecular clusters by systematically examining the effects of basis sets and a key distance-related cutoff parameter, Rcut. Rcut determines whether a fragment pair (dimer) is treated by the chosen ab initio method or calculated using the effective fragment potential (EFP) method (separated dimers). Decreasing the value of Rcut increases the number of separated (EFP) dimers, thereby decreasing the computational effort. It is demonstrated that excellent accuracy (<1 kcal/mol error per fragment) can be achieved when using a sufficiently large basis set with diffuse functions coupled with a small Rcut value. With the new parallel implementation, the total EFMO wall time is substantially reduced, especially with a high number of MPI ranks. Given a sufficient workload, nearly ideal strong scaling is achieved for the CPHF and TDHF parts of the calculation. For the first time, EFMO calculations with the inclusion of long-range polarization and dispersion interactions on a hydrated mesoporous silica nanoparticle with explicit water solvent molecules (more than 15k atoms) are achieved on a massively parallel supercomputer using nearly 1000 physical nodes. In addition, EFMO calculations on the carbinolamine formation step of an amine-catalyzed aldol reaction at the nanoscale with explicit solvent effects are presented.

Synthesis and Deconstruction of Polyethylene-type Materials

Polyethylene deconstruction to reusable smaller molecules is hindered by the chemical inertness of its hydrocarbon chains. Pyrolysis and related approaches commonly require high temperatures, are energy-intensive, and yield mixtures of multiple classes of compounds. Selective cleavage reactions under mild conditions ( Collapse

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Grants

• H2020 European Research Council

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Affiliation(s)

Simon T. Schwab Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany
Maximilian Baur Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany
Taylor F. Nelson Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany
Stefan Mecking Chair of Chemical Materials Science, Department of Chemistry, University of Konstanz, Universitätsstraße 10, 78464 Konstanz, Germany

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Stable Interfacial Ruthenium Species for Highly Efficient Polyolefin Upcycling

The present polyolefin hydrogenolysis recycling cases acknowledge that zerovalent Ru exhibits high catalytic activity. A pivotal rationale behind this assertion lies in the propensity of the majority of Ru species to undergo reduction to zerovalent Ru within the hydrogenolysis milieu. Nonetheless, the suitability of zerovalent Ru as an optimal structural configuration for accommodating multiple elementary reactions remains ambiguous. Here, we have constructed stable Ru0-Ruδ+ complex species, even under reaction conditions, through surface ligand engineering of commercially available Ru/C catalysts. Our findings unequivocally demonstrate that surface-ligated Ru species can be stabilized in the form of a Ruδ+ state, which, in turn, engenders a perturbation of the σ bond electron distribution within the polyolefin carbon chain, ultimately boosting the rate-determining step of C-C scission. The optimized catalysts reach a solid conversion rate of 609 g·gRu-1·h-1 for polyethylene. This achievement represents a 4.18-fold enhancement relative to the pristine Ru/C catalyst while concurrently preserving a remarkable 94% selectivity toward valued liquid alkanes. Of utmost significance, this surface ligand engineering can be extended to the gentle mixing of catalysts in ligand solution at room temperature, thus rendering it amenable for swift integration into industrial processes involving polyolefin degradation.

Upcycling Waste Plastics with a C-C Backbone by Heterogeneous Catalysis

Plastics with an inert carbon-carbon (C-C) backbone, such as polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC), are the most widely used types of plastic in human activities. However, many of these polymers were directly discarded in nature after use, and few were appropriately recycled. This not only threatens the natural environment but also leads to the waste of carbon resources. Conventional chemical recycling of these plastics, including pyrolysis and catalytic cracking, requires a high energy input due to the chemical inertness of C-C bonds and C-H bonds and leads to complex product distribution. In recent years, significant progress has been made in the development of catalysts and the introduction of small molecules as additional coreactants, which could potentially overcome these challenges. In this Review, we summarize and highlight catalytic strategies that address these issues in upcycling C-C backbone plastics with small molecules, particularly in heterogeneous catalysis. We believe that this review will inspire the development of upcycling methods for C-C backbone plastics using small molecules and heterogeneous catalysis.

Consumer Grade Polyethylene Recycling via Hydrogenolysis on Ultrafine Supported Ruthenium Nanoparticles

Catalytic hydrogenolysis has the potential to convert high-density polyethylene (HDPE), which comprises about 30 % of plastic waste, into valuable alkanes. Most investigations have focused on increasing activity for lab grade HDPEs displaying low molecular weight, with limited mechanistic understanding of the product distribution. No efficient catalyst is available for consumer grades due to their lower reactivity. This study targets HDPE used in bottle caps, a waste form generated globally at a rate of approximately one million units per hour. Ultrafine ruthenium particles (1 nm) supported on titania (anatase) achieved up to 80 % conversion into light alkanes (C1 -C45 ) under mild conditions (498 K, 20 bar H2 , 4 h) and were reused for three cycles. Small ruthenium nanoparticles were critical to achieving relevant conversions, as activity sharply decreased with particle size. Selectivity commonalities and peculiarities across HDPE grades were disclosed by a reaction modelling approach applied to products. Isomerization cedes to backbone scission as the reaction progresses. Within this trend, low molecular weight favor isomerization whilst high molecular weight favor cleavage. Commercial caps obeyed this trend with decreased activity, anticipating the influence of additives in realistic processing. This study demonstrates effective hydrogenolysis of consumer grade polyethylene and provides selectivity patterns for product control.

Supported Platinum Nanoparticles Catalyzed Carbon-Carbon Bond Cleavage of Polyolefins: Role of the Oxide Support Acidity

Supported platinum nanoparticle catalysts are known to convert polyolefins to high-quality liquid hydrocarbons using hydrogen under relatively mild conditions. To date, few studies using platinum grafted onto various metal oxide (MxOy) supports have been undertaken to understand the role of the acidity of the oxide support in the carbon-carbon bond cleavage of polyethylene under consistent catalytic conditions. Specifically, two Pt/MxOy catalysts (MxOy = SrTiO3 and SiO2-Al2O3; Al = 3.0 wt %, target Pt loading 2 wt % Pt ∼1.5 nm), under identical catalytic polyethylene hydrogenolysis conditions (T = 300 °C, P(H2) = 170 psi, t = 24 h; Mw = ∼3,800 g/mol, Mn = ∼1,100 g/mol, Đ = 3.45, Nbranch/100C = 1.0), yielded a narrow distribution of hydrocarbons with molecular weights in the range of lubricants (Mw = < 600 g/mol; Mn < 400 g/mol; Đ = 1.5). While Pt/SrTiO3 formed saturated hydrocarbons with negligible branching, Pt/SiO2-Al2O3 formed partially unsaturated hydrocarbons (<1 mol % alkenes and ∼4 mol % alkyl aromatics) with increased branch density (Nbranch/100C = 5.5). Further investigations suggest evidence for a competitive hydrocracking mechanism occurring alongside hydrogenolysis, stemming from the increased acidity of Pt/SiO2-Al2O3 compared to Pt/SrTiO3. Additionally, the products of these polymer deconstruction reactions were found to be independent of the polyethylene feedstock, allowing the potential to upcycle polyethylenes with various properties into a value-added product.

Catalytic conversion of mixed polyolefins under mild atmospheric pressure

The chemical recycling of polyolefin presents a considerable challenge, especially as upcycling methods struggle with the reality that plastic wastes typically consist of mixtures of polyethylene (PE), polystyrene (PS), and polypropylene (PP). We report a catalytic aerobic oxidative approach for polyolefins upcycling with the corresponding carboxylic acids as the product. This method encompasses three key innovations. First, it operates under atmospheric pressure and mild conditions, using O2 or air as the oxidant. Second, it is compatible with high-density polyethylene, low-density polyethylene, PS, PP, and their blends. Third, it uses an economical and recoverable metal catalyst. It has been demonstrated that this approach can efficiently degrade mixed wastes of plastic bags, bottles, masks, and foam boxes.

Population Balance Equations for Reactive Separation in Polymer Upcycling

Many polymer upcycling efforts aim to convert plastic waste into high-value liquid hydrocarbons. However, the subsequent cleavage of middle distillates to light gases can be problematic. The reactor often contains a vapor phase (light gases and middle distillates) and a liquid phase (molten polymers and waxes with a suspended or dissolved catalyst). Because the catalyst resides in the liquid phase, middle distillates that partition into the vapor phase are protected against further cleavage into light gases. In this paper, we consider a simple reactive separation strategy, in which a gas outflow removes the volatile products as they form. We combine vapor-liquid equilibrium models and population balance equations (PBEs) to describe polymer upcycling in a two-phase semibatch reactor. The results suggest that the temperature, headspace volume, and flow rate of the reactor can be used to tune selectivity toward the middle distillates, in addition to the molecular mechanism of catalysis. We anticipate that two-phase reactor models will be important in many polymer upcycling processes and that reactive separation strategies will provide ways to boost the yield of the desired products in these cases.

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.

Controlling Product Distribution of Polyethylene Hydrogenolysis Using Bimetallic RuM3 (M = Fe, Co, Ni) Catalysts

Plastic hydrogenolysis is an attractive approach for producing value-added chemicals due to its mild reaction conditions, but controlling product distribution is challenging due to the formation of undesired CH4. This work reports several bimetallic RuM3/CeO2 (M = Fe, Co, Ni) catalysts that shift the product of low-density polyethylene hydrogenolysis toward longer-chain hydrocarbons. These catalysts were characterized by using X-ray absorption fine structure spectroscopy, electron microscopy imaging, and H2 temperature-programmed reduction. The combined catalytic evaluation and characterization results revealed that the product distribution was regulated by the formation of bimetallic alloys. A model compound, n-hexadecane, was selected to further understand the differences in hydrogenolysis over the Ru-based catalysts. Although a longer reaction time shifted the product toward smaller molecules, the bimetallic (RuCo3/CeO2) catalyst limited the further conversion of C2-C5 into CH4. This work highlights the role of bimetallic alloys in tailoring the interaction with hydrocarbons, thereby controlling the product distribution of polymer hydrogenolysis.

Polyethylene Upgrading to Liquid Fuels Boosted by Atomic Ce Promoters

Hydrocracking catalysis is a key route to plastic waste upgrading, but the acid site-driven C-C cleavage step is relatively sluggish in conventional bifunctional catalysts, dramatically effecting the overall efficiency. We demonstrate here a facile and efficient way to boost the reactivity of acid sites by introducing Ce promoters into Pt/HY catalysts, thus achieving a better metal-acid balance. Remarkably, 100 % of low-density polyethylene (LDPE) can be converted with 80.9 % selectivity of liquid fuels over the obtained Pt/5Ce-HY catalysts at 300 °C in 2 h. For comparison, Pt/HY only gives 38.8 % of LDPE conversion with 21.3 % selectivity of liquid fuels. Through multiple experimental studies on the structure-performance relationship, the Ce species occupied in the supercage are identified as the actual active sites, which possess remarkably-improved adsorption capability towards short-chain intermediates.

Visualizing the Structure, Composition and Activity of Single Catalyst Particles for Olefin Polymerization and Polyolefin Decomposition

The structural and morphological characterization of individual catalyst particles for olefin polymerization, as well as for the reverse process of polyolefin decomposition, can provide an improved understanding for how these catalyst materials operate under relevant reaction conditions. In this review, we discuss an emerging analytical toolbox of 2D and 3D chemical imaging techniques that is suitable for investigating the chemistry and reactivity of related catalyst systems. While synchrotron-based X-ray microscopy still provides unparalleled spatial resolutions in 2D and 3D, a number of laboratory-based techniques, most notably focused ion beam-scanning electron microscopy, confocal fluorescence microscopy, infrared photoinduced force microscopy and laboratory-based X-ray nano-computed tomography, have helped to significantly expand the arsenal of analytical tools available to scientists in heterogeneous catalysis and polymer science. In terms of future research, the review outlines the role and impact of in situ and operando (spectro-)microscopy experiments, involving sophisticated reactors as well as online reactant and product analysis, to obtain real-time information on the formation, decomposition, and mobility of polymer phases within single catalyst particles. Furthermore, the potential of fluorescence microscopy, X-ray microscopy and optical microscopy is highlighted for the high-throughput characterization of olefin polymerization and polyolefin decomposition catalysts. By combining these chemical imaging techniques with, for example, chemical staining methodologies, selective probe molecules as well as particle sorting approaches, representative structure-activity relationships can be derived at the level of single catalyst particles.