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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Green Biodegradation: Analysis of Potential Polyurethane-degrading Enzymes and Their Secretion in Chlamydomonas reinhardtii

Plastic pollution is a critical global issue, with only 5% of plastics currently recycled. Polyester polyurethane (PU), a widely used plastic, can potentially be broken down using enzymatic biodegradation rather than mechanical processing that generates microplastics. This study focuses on PS5, a potential PU-degrading enzyme with esterase activity, capable of cleaving ester bonds found in PU structures. Researchers investigated the expression and secretion of PS5 in the green microalga Chlamydomonas reinhardtii, a sustainable production platform capable of generating PU precursors such as lipids and diacids while sequestering carbon. Experiments demonstrated that PS5 significantly outperformed commercial lipase in cleaving the FDA substrate, indicating high esterase activity. Algal transformants expressing PS5 also showed halo formation on Impranil®-agar plates, suggesting PU dispersion degradation. These findings highlight C. reinhardtii as a viable chassis for the production and secretion of plastic-degrading enzymes, offering a sustainable route to both upcycle and degrade PU products at the end of their lifecycle.

Diaz, Crisandra Jade↗
DOE OSTI2024

Polyolefin melt-phase effects on alkane hydrogenolysis over Pt catalysts

Supported transition metal catalyzed, chemical upcycling of polyolefins by hydrogenolysis typically occurs in a polymer melt phase at elevated temperatures (T > 200 ºC). Currently, the impact of the melt phase on the catalytic activity and selectivity of the transition metal is largely unknown. Herein, we use a hybrid quantum mechanical/molecular mechanical (QM/MM) approach to investigate the melt-phase effects on the adsorption free energy (∆∆G$^{gas→liq}_{Adsorbate}$) of atomic hydrogen, 12 hydrocarbon molecules, and 4 transition states in the hydrogenolysis mechanism of butane on a Pt(111) catalyst surface at 573 K in the presence of a polyethylene surrogate melt consisting of C 36 H 74 chains. The smallest and largest endergonic melt phase effects, (∆∆G$^{gas→liq}_{Adsorbate}$), belong to hydrogen (0.045 eV) and butane (1.357 eV). Altogether, we find melt-phase effects are significant and change the activity of transition metal catalysts. Beyond an overall reduced adsorption strength, elementary surface reactions are also affected by the melt phase.

Pt catalysis↗
DOE OSTI2024

Catalytic Hydrogenolysis of Polyethylene Under Reactive Separation

Deconstruction of polyolefins by catalytic hydrogenolysis is typically accompanied by the generation of undesired light gases. At reaction temperatures, the desired liquid products also tend to be volatile. Secondary cleavage of these liquid products contributes to light gas formation. The latter process was mitigated by reactive separation, continuously separating the liquid products from the catalyst throughout the experiment. At equivalent conversion, the yield and selectivity for oligomeric liquid species are increased under reactive separation, even though the carbon–carbon bond cleavage rate is slower than that in sealed experiments. More light gas is formed in the sealed reactor. Under 1 atm H 2 partial pressure, alkenes accompany the typical alkane hydrogenolysis products. Further, the alkene yield is higher, with greater selectivity for valuable α-olefins under reactive separation. These results provide the mechanistic insight that terminal alkenes are primary products of carbon–carbon bond cleavage during hydrogenolysis under experimental conditions, and secondary deconstruction of these species produces light gases.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Polyethylene upcycling to fuels: Narrowing the carbon number distribution in n-alkanes by tandem hydropyrolysis/hydrocracking

The extensive use of plastics in modern life has resulted in a global waste crisis to the environment. Polyethylene (PE) is one of the most popular and hardest plastics to recycle because of its strong C(sp 3 )-C(sp 3 ) bonds. In this study, a tandem conversion process, i.e., hydropyrolysis and subsequent vapor-phase hydrocracking of primary intermediates (C n>5 alkenes and long-chain alkanes), was conducted via a two-step pressurized flow-through fixed-bed reactor over a CoAl 2 O 4 spinel-derived catalyst. The product distribution could be flexibly tuned by regulating operating parameters in the cascade fixed-bed reactor and Co/Al molar ratio in CoAl 2 O 4 spinel catalysts. Under optimal reaction conditions (0.2 MPa H 2 , 550 °C for hydropyrolysis in the 1st reactor, 300–325 °C for hydrocracking in the 2nd reactor, 20 s -1 of gas hourly space velocity), the maximum single-pass yields of gasoline (C 5 -C 12 ) and jet-fuel (C 8 -C 16 ) range n-alkanes reached 86.0 wt% and 68.1 wt%, respectively. The CoAl 2 O 4 spinel catalysts also gained high activity in degrading realistic post-consumer plastics such as linear low-, low-, and high-density PE, and a ~ 73.1 wt% gasoline yield and a ~ 54.7 wt% C 8 -C 16 yield were retained even after 3 cycles in-situ regeneration of deactivated CoAl 2 O 4 catalysts. This work provides an efficient and tunable approach to upcycle PE wastes into liquid fuels with an ideal carbon length.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Catalytic upcycling of high-density polyethylene via a processive mechanism

The overconsumption of single-use plastics is creating a global waste catastrophe, with widespread environmental, economic and health-related consequences. In this work we show that the benefits of processive enzyme-catalysed conversions of biomacromolecules can be leveraged to affect the selective hydrogenolysis of high-density polyethylene into a narrow distribution of diesel and lubricant-range alkanes using an ordered, mesoporous shell/active site/core catalyst architecture that incorporates catalytic platinum sites at the base of the mesopores. Solid-state nuclear magnetic resonance revealed that long hydrocarbon macromolecules readily move within the pores of this catalyst, with a subsequent escape being inhibited by polymer–surface interactions, a behaviour that resembles the binding and translocation of macromolecules in the catalytic cleft of processive enzymes. Accordingly, the hydrogenolysis of polyethylene with this catalyst proceeds processively to yield a reliable, narrow and tunable stream of alkane products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Biochemical and structural characterization of an aromatic ring–hydroxylating dioxygenase for terephthalic acid catabolism

Significance More than 400 million tons of plastic waste is produced each year, the overwhelming majority of which ends up in landfills. Bioconversion strategies aimed at plastics have emerged as important components of enabling a circular economy for synthetic plastics, especially those that exhibit chemically similar linkages to those found in nature, such as polyesters. The enzyme system described in this work is essential for mineralization of the xenobiotic components of poly(ethylene terephthalate) (PET) in the biosphere. Our description of its structure and substrate preferences lays the groundwork for in vivo or ex vivo engineering of this system for PET upcycling.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Effect of Macro- and Microstructures on Catalytic Hydrogenolysis of Polyolefins

Here, polyethylenes of varying molecular weight and branch density, as well as polypropylenes of varying molecular weight and tacticity, were catalytically converted to lower-molecular-weight liquid products to showcase how these various properties in a mixed waste plastic stream could affect the final product. A Pt nanoparticle on a strontium titanate nanocuboid (Pt/STO) catalyst was used under solvent-free conditions in the presence of 170 psi of H 2 at 300 °C for hydrogenolysis. The initial molecular weight of polyethylene was found to have a moderate effect on the yield to the final product (ranging from 55 wt% for M n ~ 7600 Da to 67 wt% for M n ~ 50,950 Da). The microstructure, defined as the length and density of branches in a polymer, of higher-molecular-weight polymers was the dominant factor in determining the yield (ranging from 67 wt% for M n ~ 50,950 Da for linear low-density polyethylene (LLDPE) with C 2 branches to 97 wt% for M n ~ 38,850 Da for LLDPE with C 6 branches). The same products (M n = C 29 –C 46 , Ð = 1.1–1.6) and distribution of undesired light gases (C 1 –C 4 ≈ 90 mol%, C 5 –C 8 ≈ 10 mol%) are obtained from conversions of PE of varying molecular weight. The tacticity of polypropylene at a given molecular weight had a significant effect on the molecular weight of the final product, while not strongly affecting conversion. Hydrogenolysis of isotactic polypropylene (iPP) produced ≈C 18 with a wider polydispersity (Ð ~ 1.4) compared to the narrow ≈C 64 (Ð ~ 1.0) and ≈C 54 (Ð ~ 1.0) products from atactic (aPP) and syndiotactic (sPP) polypropylene, respectively. The stereochemistry of the methyl groups dictates the shape and structure of the polymer in the melt, which in turn affects how the hydrocarbon chain interacts with the catalyst surface, thereby impacting the number of C–C scissions. These results show how various characteristics such as the molecular weight and structure of a waste plastic stream could affect the final product.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Antioxidant-induced transformations of a metal-acid hydrocracking catalyst in the deconstruction of polyethylene waste

Plastics are ideal for numerous applications, as driven by the development of complex formulations containing various additives to improve performance and processability. Unfortunately, chemical valorization strategies (e.g., catalytic deconstruction) often can be challenged by the presence of small-molecule additives, and quantification of the impact of these molecular constituents on upcycling processes remains elusive. Here, this dearth of information restricts catalyst design efforts to combine the robustness and performance necessary to improve plastics circularity. In this communication, we describe a systematic study of common plastics additives—phenolic antioxidants, and we quantify the relationship between additive content and deconstruction yields of high-density polyethylene (HDPE) over a platinum on tungstated zirconium (Pt/WO 3 /ZrO 2 ) hydrocracking catalyst. In the simplest case of a base (antioxidant- and slip agent-containing) HDPE resin versus a pure (additive-stripped) HDPE polymer, a two-fold decrease in the yield of gas and liquid products is noted for base HDPE resin. Furthermore, both antioxidant chemistry and concentration strongly impact conversion and individual product selectivities. Using infrared spectroscopy, we determine that antioxidants change the effective ratio of metal to acid sites (i.e., metal-acid balance) through reactions of phenols and/or other functional groups (e.g., acids, esters) with catalyst active sites. Overall, this work demonstrates the impact of one common set of additives on plastics deconstruction, and the analysis herein provides a blueprint for quantitatively assessing the effects of additives on plastics deconstruction processes and for evaluating the development of more robust catalytic strategies or more tolerable additive formulations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Converting plastic waste pyrolysis ash into flash graphene

Pyrolysis of plastic waste (PW), a commercial method of recycling, is currently economically challenging and produces up to 20% by mass valueless pyrolysis ash (PA) as a byproduct. Here, direct, facile upcycling of PW-derived PA into high purity turbostratic flash graphene (tFG) is demonstrated. The tFG displays excellent dispersibility, yielding a concentration of 2.84 mg/mL in aqueous surfactant solution. The tFG was used to fabricate tFG-PVA nanocomposites, and low doses of tFG (0.1%–1%) improve failure strain by 15%–30% when compared to the samples of neat PVA. Furthermore, the addition of tFG to PVA films showed decreased hydrophilic interactions, increasing the water contact angle by 235% and adsorbing 500% less water than neat PVA. The tFG was also added to Portland cement paste as well as concrete, and exhibited 43% and 25% increases in compressive strength, respectively. The tFG is used directly in both composite applications, requiring no purification or chemical functionalization, unlike many other products used in nanocomposites.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Thermal Oxo-degradation and Catalytic Upgrading of Plastic Waste to Light Olefins for a Circular Economy

The commercialization of conventional pyrolysis of plastic in an inert atmosphere has been hindered by large thermal requirements stemming from long reaction rates. The rate of thermal depolymerization of waste plastics can be accelerated by the addition of oxygen in a process known as thermal oxo-degradation (TOD). This study offers the prospect of TOD to upcycle postconsumer waste rapidly and efficiently. Using moderate temperatures and small amounts of air in a fluidized bed reactor, we demonstrated that waste high-density polyethylene and polypropylene are rapidly deconstructed to condensable products. These condensable products were catalytically upgraded in a micropyrolysis reactor using commercially available zeolite (HZSM-5) to monomeric olefins. The olefin yields proved to be greater than those achieved through the catalytic upgrading of condensable products from (nonoxidative) the pyrolysis of the same plastic wastes. The coupling of TOD with catalytic upgrading proves to be an energy-efficient pathway in a plastics circular economy for the production of light olefins from wastes.

Enthalpy↗
DOE OSTI2025

Exploring New Applications of Municipal Solid Waste

This study aimed to (i) characterize municipal solid waste (MSW) sourced from Utah and Michigan transfer stations and (ii) upcycle, produce, and evaluate composites derived from this MSW. Composition analysis showed that the MSW was composed of a variety of commodity plastics, paper/cardboard, and inorganic materials. Detailed chemical analysis for lignin, cellulose, hemicellulose, and lipids was performed. The plastics identified were mainly polyethylene, polypropylene, polystyrene, and poly (ethylene terephthalate). The compoundability of the MSW was assessed by torque rheometry. Composites were prepared by compounding the MSW in an extruder. A composite flexural strength of 29 MPa and a modulus of 1.0 GPa was achieved. The thermal properties of the composites were also determined. The melt flow behavior of the MSW composites at 190 °C was comparable to wood plastic composite formulations.

characterization↗
DOE OSTI2025

Integrated low-temperature PVC and polyolefin upgrading

Polyolefins and their chlorinated derivatives such as polyvinyl chloride (PVC) are among the most prevalent plastics in global production and waste streams. Traditional waste-to-energy methods such as incineration and pyrolysis, as well as most chemical upcycling methods for PVC utilization, require thorough, high-temperature dechlorination to prevent the release of toxic chlorinated compounds. Here, we present here a strategy for upgrading discarded PVC into chlorine-free fuel range hydrocarbons and hydrogen chloride in a single-stage process catalyzed by chloroaluminate ionic liquids. This approach offsets endothermic dechlorination and carbon-carbon bond cleavage with exothermic alkylation and hydrogen transfer by isobutane or isopentane in a low-temperature tandem process. The light isoalkanes are available from refinery processes and partly from recycling of the product stream. This process is suitable for handling real-world mixed and contaminated PVC and polyolefin waste streams.

Zhang, Wei [East China Normal Univ. (ECNU), Shangh↗
DOE OSTI2025

Upcycling of polyethylene terephthalate to high-value chemicals by carbonate-interchange deconstruction

Condensation thermoplastics have become ubiquitous. The emergence of chemical upcycling could transform them into valuable feedstocks for chemical manufacturing at their end-of-life. However, current solvolysis processes suffer equilibrium limitations due to the liberation of reactive byproducts. We report a carbonate interchange deconstruction (CID) methodology for poly(ethylene terephthalate) (PET), where carbonates act as both latent nucleophiles and byproduct sequestering agents. High product selectivity (>95%) is achieved regardless of the targeted terephthalate product, originating from removal of ethylene glycol from the reaction equilibrium via its conversion into various oligoethers. CID is robust to the impurities present in post-consumer waste plastics and significantly reduces solvent demand, with just 10 mL of dimethyl carbonate successfully converting ca. 5 g of mixed PET waste into highly pure dimethyl terephthalate in excellent isolated yield (92%). CID opens a new upcycling paradigm wherein CO2, embedded in carbonates, is leveraged to choreograph the selectivity of an otherwise equilibrium-controlled polymer upcycling process.

Galan, Nick [ORNL]↗
DOE OSTI2022

Recent Advances in Biological Recycling of Polyethylene Terephthalate (PET) Plastic Wastes

Polyethylene terephthalate (PET) is one of the most commonly used polyester plastics worldwide but is extremely difficult to be hydrolyzed in a natural environment. PET plastic is an inexpensive, lightweight, and durable material, which can readily be molded into an assortment of products that are used in a broad range of applications. Most PET is used for single-use packaging materials, such as disposable consumer items and packaging. Although PET plastics are a valuable resource in many aspects, the proliferation of plastic products in the last several decades have resulted in a negative environmental footprint. The long-term risk of released PET waste in the environment poses a serious threat to ecosystems, food safety, and even human health in modern society. Recycling is one of the most important actions currently available to reduce these impacts. Current clean-up strategies have attempted to alleviate the adverse impacts of PET pollution but are unable to compete with the increasing quantities of PET waste exposed to the environment. In this review paper, current PET recycling methods to improve life cycle and waste management are discussed, which can be further implemented to reduce plastics pollution and its impacts on health and environment. Compared with conventional mechanical and chemical recycling processes, the biotechnological recycling of PET involves enzymatic degradation of the waste PET and the followed bioconversion of degraded PET monomers into value-added chemicals. This approach creates a circular PET economy by recycling waste PET or upcycling it into more valuable products with minimal environmental footprint.

42 ENGINEERING↗
DOE OSTI2023

Nature-inspired methylated polyhydroxybutyrates from C1 and C4 feedstocks

Polyolefin plastics are widely used due to their low cost and outstanding properties, but their environmental persistence presents a major societal challenge. Polyhydroxyalkanoates (PHA) are biodegradable substitutes for polyolefins, but their high cost and thermal instability are impediments to their widespread application. Here we report a series of methylated polyhydroxybutyrates, poly(3-hydroxy-2-methylbutyrate)s, which are structurally inspired by natural PHAs. The cis homopolymers exhibit tacticity-independent crystallinity, which allows for the discovery of high-melting, thermally stable and mechanically tough copolymers, and a full range of polyolefin-like properties can be further achieved by tailoring the cis/trans ratio of the repeating units. Moreover, these materials can be synthesized from inexpensive carbon monoxide and 2-butene feedstocks, and they can be chemically recycled or upcycled at their end of life. As a result, the versatile properties, abundant feedstocks and end-of-life utility of this family of polyesters will enable a powerful platform for the discovery of sustainable alternatives to polyolefin plastics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Oxidative Funneling of PVDC (CRADA Final Report)

Poly(vinylidene chloride) (PVDC) is a major polymer product from the Participant. PVDC-containing plastics are not commonly recycled. To overcome the challenges associated with recycling PVDC and multi-layer materials, we propose a tandem catalytic-biological process to convert PVDC containing waste to upcycled, tunable products such as polyhydroxyalkanoates (PHAs). PHAs are commercially relevant, biodegradable polymers that are useful in packaging, biomedical, and personal care applications. This technology, which the Contractor has named oxidative funneling (OxFun), uses a metal-promoted autoxidation step to depolymerize co-mingled polymers to a mixture of oxygenated compounds, which an engineered bacterium can funnel to a single bioproduct: here, medium chain length polyhydroxyalkanoates (mcl-PHAs). The proposed oxidation chemistry is amenable to inclusion of additional polymers, and the biocatalyst can be engineered to convert the deconstruction products to a variety of valuable chemicals, thus presenting a tunable system for both feedstock variability and target product. Pseudomonas putida KT2440 – a metabolically robust microbe that has been engineered and proven viable for upcycling deconstructed polystyrene (PS), high density polyethlene (HDPE), and polyethylene terephthalate (PET) – can be engineered with enzymes capable of de-chlorinating PVDC deconstruction products (e.g., 2,2-dichloroacetate) in addition to PE-derived substrates into mcl-PHAs.

36 MATERIALS SCIENCE↗