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.

Bridged Bicyclic Lactam Enables Chemically Recyclable Nylon

Nylon, a widely-used high-performance thermoplastic, boasts exceptional durability and resistance to various solvents and weak acids, making it indispensable across diverse applications. However, its nonbiodegradable nature has led to alarming environmental pollution in land and oceans. Chemical recycling to monomers (CRM) stands as a crucial strategy for establishing a circular plastic economy, but the CRM of nylon remains largely unexplored. Herein, we introduce the bridged bicyclic lactam 5-azabicyclo[2.2.1]octan-6-one (5/6-LM), evolved from δ-valerolactam and pyrrolidone, to solve the trade-off in depolymerizability and performance. Notably, 5/6-LM exhibits nearly 95 % conversion in mild polymerization conditions and efficient depolymerization catalyzed by lewis acids. This compound is synthetically accessible from commercially available chemicals in a single step at room temperature, demonstrating high efficiency and scalability up to 50 g in laboratory. Furthermore, the resulting polyamide displays remarkable attributes including high crystallinity and thermostability up to 283 °C, significantly broadening the scope of chemically recyclable nylons.

Redesigned Nylon 6 Variants with Enhanced Recyclability, Ductility, and Transparency

Geminal (gem-) disubstitution in heterocyclic monomers is an effective strategy to enhance polymer chemical recyclability by lowering their ceiling temperatures. However, the effects of specific substitution patterns on the monomer's reactivity and the resulting polymer's properties are largely unexplored. Here we show that, by systematically installing gem-dimethyl groups onto ϵ-caprolactam (monomer of nylon 6) from the α to ϵ positions, both the redesigned lactam monomer's reactivity and the resulting gem-nylon 6's properties are highly sensitive to the substitution position, with the monomers ranging from non-polymerizable to polymerizable and the gem-nylon properties ranging from inferior to far superior to the parent nylon 6. Remarkably, the nylon 6 with the gem-dimethyls substituted at the γ position is amorphous and optically transparent, with a higher Tg (by 30 °C), yield stress (by 1.5 MPa), ductility (by 3×), and lower depolymerization temperature (by 60 °C) than conventional nylon 6.

Catalytic thiolation-depolymerization-like decomposition of oxyphenylene-type super engineering plastics via selective carbon-oxygen main chain cleavages

As the effective use of carbon resources has become a pressing societal issue, the importance of chemical recycling of plastics has increased. The catalytic chemical decomposition for plastics is a promising approach for creating valuable products under efficient and mild conditions. Although several commodity and engineering plastics have been applied, the decompositions of stable resins composed of strong main chains such as polyamides, thermoset resins, and super engineering plastics are underdeveloped. Especially, super engineering plastics that have high heat resistance, chemical resistance, and low solubility are nearly unexplored. In addition, many super engineering plastics are composed of robust aromatic ethers, which are difficult to cleave. Herein, we report the catalytic depolymerization-like chemical decomposition of oxyphenylene-based super engineering plastics such as polyetheretherketone and polysulfone using thiols via selective carbon-oxygen main chain cleavage to form electron-deficient arenes with sulfur functional groups and bisphenols. The catalyst combination of a bulky phosphazene base P4-tBu with inorganic bases such as tripotassium phosphate enabled smooth decomposition. This method could be utilized with carbon- or glass fiber-enforced polyetheretherketone materials and a consumer resin. The sulfur functional groups in one product could be transformed to amino and sulfonium groups and fluorine by using suitable catalysts.

Hydroxylation-Depolymerization of Oxyphenylene-Based Super Engineering Plastics To Regenerate Arenols

Super engineering plastics, high-performance thermoplastic resins, show high thermal stability and mechanical strength as well as chemical resistance. On the other hand, chemical recycling for these plastics has not been developed due to their stability. This study describes depolymerization of oxyphenylene super engineering plastics via carbon-oxygen main chain cleaving hydroxylation reaction with an alkali hydroxide nucleophile. This method is conducted with cesium hydroxide as a hydroxy source and calcium hydride as a dehydration agent in 1,3-dimethyl-2-imidazolidinone, which provides hydroxylated monomers effectively. In the case of polysulfone, both 4,4'-sulfonyldiphenol (bisphenol S) and 4,4'-(propane-2,2-diyl)diphenol (bisphenol A) were obtained in high yields. Other super engineering plastics such as polyethersulfone, polyphenylsulfone, and polyetheretherketone were also applicable to this depolymerization.

Ionic Liquids for the Chemical Recycling of Polymeric Materials and Control of Their Solubility

Plastics are wonderful materials that have modernized our daily life; however, importance of effective recycling of plastics is gradually recognized widely. In this account, we describe our discovery of new and efficient methods for the chemical recycling of plastics using ionic liquids (ILs). Since the chemical recycling usually requires high temperature conditions to breakdown chemical bonds in polymeric materials, we thought that less-flammability and non-volatility of ionic liquids are the most suitable physical properties for this purpose. Ionic liquids successfully depolymerized polyamides and unsaturated polyesters smoothly and corresponding monomeric materials were obtained in good yields. To the best of our knowledge, this was the first use of Ionic liquids for such reactions. However, we encountered another difficult problem-separation. To solve the problem, we developed solubility-switchable ionic liquids, a new type of ionic liquids in which solubility is readily changed using the chemistry of protective groups. Conversion between hydrophilic and lipophilic forms was readily achieved using a simple chemical treatment under mild conditions, and the complete separation of products was achieved by liquid-liquid-extraction. The robustness of either form unlocks their wide use as reaction solvents.

Selective Lanthanide-Organic Catalyzed Depolymerization of Nylon-6 to ϵ-Caprolactam

Nylon-6 is selectively depolymerized to the parent monomer ϵ-caprolactam by the readily accessible and commercially available lanthanide trisamido catalysts Ln(N(TMS)₂ )₃ (Ln=lanthanide). The depolymerization process is solvent-free, near quantitative, highly selective, and operates at the lowest Nylon-6 to ϵ-caprolactam depolymerization temperature reported to date. The catalytic activity of the different lanthanide trisamides scales with the Ln³⁺ ionic radius, and this process is effective with post-consumer Nylon-6 as well as with Nylon-6+polyethylene, polypropylene or polyethylene terephthalate mixtures. Experimental kinetic data and theoretical (DFT) mechanistic analyses suggest initial deprotonation of a Nylon terminal amido N-H bond, which covalently binds the catalyst to the polymer, followed by a chain-end back-biting process in which ϵ-caprolactam units are sequentially extruded from the chain end.

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

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

Organocatalysis for depolymerisation

Chemical recycling of plastics offers a green method to deal with plastic waste. In this review, we highlight the recent advances made by applying organocatalysts to chemically degrade polymers as a promising tool to reach a circular plastic economy.

Efficient conversion of polyamides to ω-hydroxyalkanoic acids: a new method for chemical recycling of waste plastics

An efficient transformation of polyamides to ω-hydroxy alkanoic acids was achieved. Treatment of nylon-12 with supercritical MeOH in the presence of glycolic acid gave methyl ω-hydroxydodecanoate in 85% yield and the alcohol/alkene selectivity in the product was enhanced to up to 9.5:1. The use of (18)O-enriched acetic acid for the reaction successfully introduced an (18)O atom at the alcoholic OH group in the product. This strategy may provide a new and economical solution for the chemical recycling of waste plastics.

Preparation of SRN1-Type Coupling Adducts from Aliphatic gem-Dinitro Compounds in Ionic Liquids

S_RN1-type coupling adducts are readily prepared by the reaction between α-sulfonylesters or α-cyanosulfones and gem-dinitro compounds in ionic liquids. The reactions progress smoothly and recovered ionic liquids can be used for several iterations, as long as they are washed with water to remove alkali metallic salts. The reaction rate is slower than the corresponding S_RN1 reaction in DMSO, but no acceleration on irradiation or no inhibition in the presence of m-DNB are observed.

Asymmetric Michael Additions Catalysed by Functionalised Quaternary Alkylammonium Ionic Liquids

Some functionalised quaternary alkylammonium ionic liquids were synthesised and examined as organocatalysts for asymmetric Michael additions of aldehydes and ketones to nitroolefins. All of them exhibited excellent enantioselectivities (>99% ee) and diastereoselectivities (> 99/1 d/r). One of the catalysts ( S)- N,N-dimethyl- N-pyrrolidin-2-ylmethyl)-2-methylpropan-1-aminium bromide could be recovered for reuse with similar results, and triethylamine was found to be an effective additive to enhance its catalytic activity.

Depolymerization of unsaturated polyesters and waste fiber-reinforced plastics by using ionic liquids: the use of microwaves to accelerate the reaction rate

Waste fiber-reinforced plastics (FRP) and unsaturated polyesters were readily depolymerized by subjecting them to a treatment with ionic liquids under heating conditions. The use of microwaves for heating effectively progressed depolymerization, whereas the conventional heating method was ineffective for this purpose. We isolated the monomeric material, phthalic anhydride, by direct distillation from the reaction pot under reduced pressure with yields of more than 90%. We recovered the glass fibers in a pure form and achieved the effective removal of polystyrene, the linker unit of FRP. Ionic liquids were useful for several iterations of the reaction, and purification of the used ionic liquids was also possible. Thus, we developed a new use of ionic liquids for chemical recycling of waste plastics.