Sustainable Approach for Synthesis and Completely Recycle of Cyclic CO2-based Polycarbonates

Towards Sustainable Temperature Sensor Production through CO2-Derived Polycarbonate-Based Composites

The steep increase in carbon dioxide (CO2) emissions has created great concern due to its role in the greenhouse effect and global warming. One approach to mitigate CO2 levels involves its application in specific technologies. In this context, CO2 can be used for a more sustainable synthesis of polycarbonates (CO2-PCs). In this research, CO2-PC films and composites with multiwalled carbon nanotubes (MWCNTs, ranging from 0.2 to 7.0 wt.%) have been prepared to achieve more sustainable multifunctional sensing devices. The inclusion of the carbonaceous fillers allows for the electrical conductivity to be enhanced, reaching the percolation threshold (Pc) at 0.1 wt.% MWCNTs and a maximum electrical conductivity of 0.107 S·m-1 for the composite containing 1.5 wt.% MWCNTs. The composite containing 3.0 wt.% MWCNTs was also studied, showing a stable and linear response under temperature variations from 40 to 100 °C and from 30 to 45 °C, with a sensitivity of 1.3 × 10-4 °C-1. Thus, this investigation demonstrates the possibility of employing CO2-derived PC/MWCNT composites as thermoresistive sensing materials, allowing for the transition towards sustainable polymer-based electronics.

Closed-Loop Recycling of Mixed Plastics of Polyester and CO2-Based Polycarbonate to a Single Monomer

Physical blending is an effective strategy for tailoring polymeric materials to specific application requirements. However, physically blended mixed plastics waste adds additional barriers in mechanical or chemical recycling. This difficulty arises from the intricate requirement for meticulous sorting and separation of the various polymers in the inherent incompatibility of mixed polymers during recycling. To overcome this impediment, this work furthers the emerging single-monomer - multiple-materials approach through the design of a bifunctional monomer that can not only orthogonally polymerize into two different types of polymers - specifically lactone-based polyester and CO2-based polycarbonate - but the resultant polymers and their mixture can also be depolymerized back to the single, original monomer when facilitated by catalysis. Specifically, the lactone/epoxide hybrid bifunctional monomer (BiLO) undergoes ring-opening polymerization through the lactone manifold to produce polyester, PE(BiLO), and is also applied to ring-opening copolymerization with CO2, via the epoxide manifold, to yield polycarbonate, PC(BiLO). Remarkably, a one-pot recycling process of a BiLO-derived PE/PC blend back to the constituent monomer BiLO in >99 % selectivity was achieved with a superbase catalyst at 150 °C, thereby effectively obviating the requirement for sorting and separation typically required for recycling of mixed polymers.

High Molar Mass Polycarbonates as Closed-Loop Recyclable Thermoplastics

Using carbon dioxide (CO2) to make recyclable thermoplastics could reduce greenhouse gas emissions associated with polymer manufacturing. CO2/cyclic epoxide ring-opening copolymerization (ROCOP) allows for >30 wt % of the polycarbonate to derive from CO2; so far, the field has largely focused on oligocarbonates. In contrast, efficient catalysts for high molar mass polycarbonates are underinvestigated, and the resulting thermoplastic structure-property relationships, processing, and recycling need to be elucidated. This work describes a new organometallic Mg(II)Co(II) catalyst that combines high productivity, low loading tolerance, and the highest polymerization control to yield polycarbonates with number average molecular weight (Mn) values from 4 to 130 kg mol-1, with narrow, monomodal distributions. It is used in the ROCOP of CO2 with bicyclic epoxides to produce a series of samples, each with Mn > 100 kg mol-1, of poly(cyclohexene carbonate) (PCHC), poly(vinyl-cyclohexene carbonate) (PvCHC), poly(ethyl-cyclohexene carbonate) (PeCHC, by hydrogenation of PvCHC), and poly(cyclopentene carbonate) (PCPC). All these materials are amorphous thermoplastics, with high glass transition temperatures (85 < Tg < 126 °C, by differential scanning calorimetry) and high thermal stability (Td > 260 °C). The cyclic ring substituents mediate the materials' chain entanglements, viscosity, and glass transition temperatures. Specifically, PCPC was found to have 10× lower entanglement molecular weight (Me)n and 100× lower zero-shear viscosity compared to those of PCHC, showing potential as a future thermoplastic. All these high molecular weight polymers are fully recyclable, either by reprocessing or by using the Mg(II)Co(II) catalyst for highly selective depolymerizations to epoxides and CO2. PCPC shows the fastest depolymerization rates, achieving an activity of 2500 h-1 and >99% selectivity for cyclopentene oxide and CO2.

Depolymerization within a Circular Plastics System

The societal importance of plastics contrasts with the carelessness with which they are disposed. Their superlative properties lead to economic and environmental efficiency, but the linearity of plastics puts the climate, human health, and global ecosystems at risk. Recycling is fundamental to transitioning this linear model into a more sustainable, circular economy. Among recycling technologies, chemical depolymerization offers a route to virgin quality recycled plastics, especially when valorizing complex waste streams poorly served by mechanical methods. However, chemical depolymerization exists in a complex and interlinked system of end-of-life fates, with the complementarity of each approach key to environmental, economic, and societal sustainability. This review explores the recent progress made into the depolymerization of five commercial polymers: poly(ethylene terephthalate), polycarbonates, polyamides, aliphatic polyesters, and polyurethanes. Attention is paid not only to the catalytic technologies used to enhance depolymerization efficiencies but also to the interrelationship with other recycling technologies and to the systemic constraints imposed by a global economy. Novel polymers, designed for chemical depolymerization, are also concisely reviewed in terms of their underlying chemistry and potential for integration with current plastic systems.

Evaluating Heterodinuclear Mg(II)M(II) (M = Mn, Fe, Ni, Cu, and Zn) Catalysts for the Chemical Recycling of Poly(cyclohexene carbonate)

Polymer chemical recycling to monomers (CRM) is important to help achieve a circular plastic economy, but the "rules" governing catalyst design for such processes remain unclear. Here, carbon dioxide-derived polycarbonates undergo CRM to produce epoxides and carbon dioxide. A series of dinuclear catalysts, Mg(II)M(II) where M(II) = Mg, Mn, Fe, Co, Ni, Cu, and Zn, are compared for poly(cyclohexene carbonate) depolymerizations. The recycling is conducted in the solid state, at 140 °C monitored using thermal gravimetric analyses, or performed at larger-scale using laboratory glassware. The most active catalysts are, in order of decreasing rate, Mg(II)Co(II), Mg(II)Ni(II), and Mg(II)Zn(II), with the highest activity reaching 8100 h-1 and with >99% selectivity for cyclohexene oxide. Both the activity and selectivity values are the highest yet reported in this field, and the catalysts operate at low loadings and moderate temperatures (from 1:300 to 1:5000, 140 °C). For the best heterodinuclear catalysts, the depolymerization kinetics and activation barriers are determined. The rates in both reverse depolymerization and forward CHO/CO2 polymerization catalysis show broadly similar trends, but the processes feature different intermediates; forward polymerization depends upon a metal-carbonate intermediate, while reverse depolymerization depends upon a metal-alkoxide intermediate. These dinuclear catalysts are attractive for the chemical recycling of carbon dioxide-derived plastics and should be prioritized for recycling of other oxygenated polymers and copolymers, including polyesters and polyethers. This work provides insights into the factors controlling depolymerization catalysis and steers future recycling catalyst design toward exploitation of lightweight and abundant s-block metals, such as Mg(II).

Insights into substitution strategy towards thermodynamic and property regulation of chemically recyclable polymers

The development of chemically recyclable polymers serves as an attractive approach to address the global plastic pollution crisis. Monomer design principle is the key to achieving chemical recycling to monomer. Herein, we provide a systematic investigation to evaluate a range of substitution effects and structure-property relationships in the ɛ-caprolactone (CL) system. Thermodynamic and recyclability studies reveal that the substituent size and position could regulate their ceiling temperatures (T_c). Impressively, M4 equipped with a tert-butyl group displays a T_c of 241 °C. A series of spirocyclic acetal-functionalized CLs prepared by a facile two-step reaction undergo efficient ring-opening polymerization and subsequent depolymerization. The resulting polymers demonstrate various thermal properties and a transformation of the mechanical performance from brittleness to ductility. Notably, the toughness and ductility of P(M13) is comparable to the commodity plastic isotactic polypropylene. This comprehensive study is aimed to provide a guideline to the future monomer design towards chemically recyclable polymers.

Advances in the Synthesis of Chemically Recyclable Polymers

The development of modern society is closely related to polymer materials. However, the accumulation of polymer materials and their evolution in the environment causes not only serious environmental problems, but also waste of resources. Although physical processing can be used to reuse polymers, the properties of the resulting polymers are significantly degraded. Chemically recyclable polymers, a type of polymer that degrades into monomers, can be an effective solution to the degradation of polymer properties caused by physical recycling of polymers. The ideal chemical recycling of polymers, i. e., quantitative conversion of the polymer to monomers at low energy consumption and repolymerization of the formed monomers into polymers with comparable properties to the original, is an attractive research goal. In recent years, significant progress has been made in the design of recyclable polymers, enabling the regulation of the "polymerization-depolymerization" equilibrium and closed-loop recycling under mild conditions. This review will focus on the following aspects of closed-loop recycling of poly(sulfur) esters, polycarbonates, polyacetals, polyolefins, and poly(disulfide) polymer, illustrate the challenges in this area, and provide an outlook on future directions.

CO2 Fixation and PCHC Depolymerization by a Dinuclear β-Diketiminato Zinc Complex

The production of cyclic carbonates and (or) polycarbonates from the coupling of carbon dioxide (CO₂ ) with epoxides is a practical strategy for CO₂ fixation. Chemically recycling of the polycarbonates is also urgently needed for sustainable development of plastics. Here a dinuclear β-diketiminato (BDI) methyl zinc complex((BDI-ZnMe)₂ , 1) is reported to achieve not only selective cyclic carbonates from cycloaddition of CO₂ to meso-CHO in the presence of cocatalyst, but also effective depolymerization of PCHC into trans-CHC. The trans-CHC can be further transformed into cis-CHC, thus demonstrating great application potentials of this strategy in CO₂ fixation and chemical recycling of plastics.

Solid-State Chemical Recycling of Polycarbonates to Epoxides and Carbon Dioxide Using a Heterodinuclear Mg(II)Co(II) Catalyst

Polymer chemical recycling to monomers (CRM) could help improve polymer sustainability, but its implementation requires much better understanding of depolymerization catalysis, ensuring high rates and selectivity. Here, a heterodinuclear [Mg(II)Co(II)] catalyst is applied for CRM of aliphatic polycarbonates, including poly(cyclohexene carbonate) (PCHC), to epoxides and carbon dioxide using solid-state conditions, in contrast with many other CRM strategies that rely on high dilution. The depolymerizations are performed in the solid state giving very high activity and selectivity (PCHC, TOF = 25700 h^–1, CHO selectivity >99 %, 0.02 mol %, 140 °C). Reactions may also be performed in air without impacting on the rate or selectivity of epoxide formation. The depolymerization can be performed on a 2 g scale to isolate the epoxides in up to 95 % yield with >99 % selectivity. In addition, the catalyst can be re-used four times without compromising its productivity or selectivity.

Efficient and Selective Chemical Recycling of CO2 -Based Alicyclic Polycarbonates via Catalytic Pyrolysis

Chemical recycling of polymers to their constituent monomers is the foremost challenge in building a sustainable circular plastics economy. Here, we report a strategy for highly efficient depolymerization of various CO₂ -based alicyclic polycarbonates to epoxide monomers in solvent-free conditions by a simple Cr^III -Salen complex mediated catalytic pyrolysis process. The chemical recycling of the widely studied poly(cyclohexene carbonate) exhibits excellent reactivity (TOF up to 3000 h^-1 , 0.1 mol % catalyst loading) and high epoxide monomer selectivity (>99 %). Mechanistic investigation reveals that the process proceeds in a sequential fashion via a trans-carbonate intermediate.