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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Conversion of Polystyrene to Terephthalic Acid via Sequential Acetylation and Mn/Br-Catalyzed Autoxidation

Most methods for the oxidative deconstruction of polystyrene produce benzoic acid, which has a low market size relative to the production of waste polystyrene. Here, the present study demonstrates a method for conversion of polystyrene into terephthalic acid, a high-volume chemical, by introducing a carbon-containing fragment into the para position of the phenyl groups in polystyrene, followed by Mn/Br-catalyzed autoxidation. Acetylated polystyrene is shown to be the most effective substrate for oxidation, affording an 81% yield of terephthalic acid. Mechanistic studies highlight the effectiveness of bromide as a cocatalyst and offer insight into the underlying reasons the acetyl group undergoes efficient oxidation.

Mid-Century Process↗
DOE OSTI2026

Depolymerization of Vinyl Polymers

Depolymerization is a promising approach to reduce plastic waste by regenerating monomers from polymers, presenting a compelling solution to maintain a circular polymer economy. However, vinyl polymers with all-carbon backbones are especially difficult to depolymerize due to significant thermodynamic and kinetic barriers. Developments in reversible-deactivation radical polymerization and catalytic methods demonstrate how tuning polymer structure and reaction conditions can address these challenges. This Viewpoint revisits early studies on radical depolymerization and recent advances enabling monomer recovery at lower temperatures. Exciting current trends to utilize depolymerization as a strategy for tuning polymer material properties and upcycling waste polymer to high-value products are discussed. Finally, we outline key directions to make vinyl polymer depolymerization scalable, efficient, and economically viable.

depolymerization↗
DOE OSTI2025

Large-Scale Compatibilization of Postconsumer Polyolefins in the Presence of Paraffin Wax as a Rheology Modifier

Postconsumer polyolefins (r-POs) are leading plastic waste contributors today. This study reports, for the first time, the compatibilization of r-POs at a 50 kilogram (kg) scale with a styrene block copolymer compatibilizer in the presence of paraffin waxes as rheology modifiers (RMs). The addition of the rheological modifier (RM) and compatibilizer enhances the melt flow indices (MFIs) and mechanical properties, respectively. One aspect of this study is to compare the effectiveness of low-cost paraffin wax to that of specialized and expensive RMs in r-POs. The mechanical and rheological properties such as the melt flow index (MFI) of r-POs were compared in the presence of two types of RMs. Next, the study explores the challenges encountered when scaling the compatibilization of r-POs in the presence of paraffin wax from a 10-g to a 50-kg scale. The mechanical properties were determined and compared for samples at different scales. The study further investigated the effect of the method used for blending paraffin wax with r-PO and its impact on the value of their MFI and mechanical properties. This at-scale validation could pave the way for the commercialization of r-POs.

crystallinity↗
DOE OSTI2021

Harnessing autocatalytic reactions in polymerization and depolymerization

Abstract Autocatalysis and its relevance to various polymeric systems are discussed by taking inspiration from biology. A number of research directions related to synthesis, characterization, and multi-scale modeling are discussed in order to harness autocatalytic reactions in a useful manner for different applications ranging from chemical upcycling of polymers (depolymerization and reconstruction after depolymerization), self-generating micelles and vesicles, and polymer membranes. Overall, a concerted effort involving in situ experiments, multi-scale modeling, and machine learning algorithms is proposed to understand the mechanisms of physical and chemical autocatalysis. It is argued that a control of the autocatalytic behavior in polymeric systems can revolutionize areas such as kinetic control of the self-assembly of polymeric materials, synthesis of self-healing and self-immolative polymers, as next generation of materials for a sustainable circular economy. Graphic Abstract

36 MATERIALS SCIENCE↗
DOE OSTI2020

Plastics for a Circular Economy Workshop: Summary Report

This report summarizes the results of a public workshop sponsored by the Bioenergy Technologies Office, the Advanced Manufacturing Office, and Mars held on December 11–12, 2019 in Golden, Colorado. The Plastics for a Circular Economy Workshop brought together experts from industry, academia, and national laboratories to discuss opportunities and challenges facing the development of new technologies to address plastic waste.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Carbon Fiber-Based Vitrimer Composites: A Path toward Current Research That Is High-Performing, Useful, and Sustainable

In the polymeric material industry, thermosets and related composites have played a substantial role in the production of rubber and plastics. One important subset of these is thermoset composites with carbon reinforcement. The incorporation of carbon fillers and fibers gives polymeric materials improved electrical and mechanical properties, among other benefits. However, the covalently crosslinked network of thermosets presents significant challenges for recycling and reprocessing because of its intractable nature. The introduction of vitrimer materials opens a new avenue to produce biodegradable and recyclable thermosets. Carbon-reinforced vitrimer composites are pursued for high-performance, long-lasting materials with attractive physical properties, the ability to be recycled and processed, and other features that respond uniquely to stimuli. The development of carbon-reinforced vitrimer composites over the last few years is summarized in this article. First, an overview of vitrimers and the methods used to prepare carbon fiber-reinforced vitrimer composites is provided. Because of the vitrimer nature of such composites, reprocessing, healing, and recycling are viable ways to greatly extend their service life; these approaches are thoroughly explained and summarized. The conclusion is our prediction for developing carbon-based vitrimer composites.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Performance Advantaged ..beta..-Ketone Containing Polymers - Benefits in Manufacturing, Performance, and End-of-Life

Biomass derived chemicals can possess extended functionality, often in the form of heteroatoms like oxygen and nitrogen, that can enable performance advantaged properties in emergent materials. These performance advantages can manifest in multiple ways such as reduced manufacturing intensity, better performance, or enhanced end-of-life options. One illustrative example of this concept is ..beta..-ketoadipic acid (..beta..KA), a C6 dicarboxylic acid with a ketone in its backbone. ..beta..KA can be obtained via biological cultivation from aromatic compounds, sugars, and even waste plastics. When ..beta..KA is implemented into polymers, namely nylons, in place of adipic acid the overall material properties are increased. Specifically, the glass transition temperature (which is the measurement at which temperature a plastic softens) is increased by 69 degrees C and the water permeability is reduced by 20%. Molecular dynamic (MD) simulations reveal that the ..beta..-ketone in ..beta..KA leads to restricted movement across multiple backbone carbons when compared to adipic acid. Furthermore, MD simulations reveal that the ..beta..-ketone, when compared to no-ketone or an a-ketone, can lead to an increase in hydrogen bonding between neighboring chains. Both phenomena may help explain the molecular origin of the increases in polymer performance. When implemented into polyesters, namely PET, ..beta..KA can maintain the requisite performance while enabling enhanced degradation. Aside from performance advantages in thermomechanical performance, the production of ..beta..KA also is advantaged in its manufacturing. Although estimates for the minimum selling price (MSP) of ..beta..KA exceed adipic acid the manufacture of ..beta..KAwould reduce supply chain energy and GHG emissions by >50% and >30% respectively. Further TEA analysis reveals that the MSP of ..beta..KA is primarily driven by the feedstock cost while the capital expenditures are driven largely by fermentation costs. Overall, the work presented within will be illustrative of how biomass derived molecules, namely ..beta..KA, can manifest performance advantages across multiple benchmarks and may enable a path to market for biomass-derived materials.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS↗
DOE OSTI2024

Bioderived recyclable epoxy-anhydride thermosetting polymers and resins

The present disclosure relates to a composition that includes a structure that includes where R1 includes at least one of a carbon atom and/or an oxygen atom, R2 includes at least one of a carbon atom and/or an oxygen atom, and represents a covalent bond. In some embodiments of the present disclosure, the composition may be bioderived.

Wang, Chen↗
DOE OSTI2023

Benefits and Risks of New Polymers in the Current and Future Recycling System

New plastics are increasingly being developed to address challenges around plastic pollution and end-of-life management. However, the incorporation of these new polymers into the existing plastic ecosystem raises numerous risks, as well as some benefits. This flash talk briefly discusses how new plastics could raise contamination levels and prevent mechanical recycling, how we could mitigate that risk by improving education around recycling collection, and how new plastics could potentially reduce the cost and environmental impact of certain chemical recycling technologies.

benefit-risk analysis↗
DOE OSTI2022

Circularity in mixed-plastic chemical recycling enabled by variable rates of polydiketoenamine hydrolysis

Footwear, carpet, automotive interiors, and multilayer packaging are examples of products manufactured from several types of polymers whose inextricability poses substantial challenges for recycling at the end of life. Here, we show that chemical circularity in mixed-polymer recycling becomes possible by controlling the rates of depolymerization of polydiketoenamines (PDK) over several orders of magnitude through molecular engineering. Stepwise deconstruction of mixed-PDK composites, laminates, and assemblies is chemospecific, allowing a prescribed subset of monomers, fillers, and additives to be recovered under pristine condition at each stage of the recycling process. We provide a theoretical framework to understand PDK depolymerization via acid-catalyzed hydrolysis and experimentally validate trends predicted for the rate-limiting step. The control achieved by PDK resins in managing chemical and material entropy points to wide-ranging opportunities for pairing circular design with sustainable manufacturing.

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

Reducing Antisolvent Use in the STRAP Process by Enabling a Temperature–Controlled Polymer Dissolution and Precipitation for the Recycling of Multilayer Plastic Films

The recently reported processing strategy called solvent-targeted recovery and precipitation (STRAP) enables deconstruction of multilayer plastic packaging films into their constituent resins by selective dissolution. It uses a series of solvent washes that are guided by thermodynamic calculations of polymer solubility. In this work, the use of antisolvents in the STRAP process was reduced and solvent mixtures were considered to enable the temperature-controlled dissolution and precipitation of the target polymers in multilayer films. This was considered as a means to further improve the STRAP process and its estimated costs. Two STRAP approaches were compared based on different polymer precipitation techniques: precipitation by the addition of an antisolvent (STRAP-A) and precipitation by decreasing the solvent temperature (STRAP-B). Both approaches were able to separate the constituent polymers in a post-industrial film composed primarily of polyethylene (PE), ethylene vinyl alcohol (EVOH), and polyethylene terephthalate (PET) with near 100 % material efficiency. Technoeconomic analysis indicates that the minimum selling price (MSP) of the recycled resins with STRAP-B is 21.0 % lower than that achieved with STRAP-A. This provides evidence that thermally driven polymer precipitation is an option to reduce the use of antisolvents, making the STRAP process more economically and environmentally attractive. A third process, STRAP-C, was demonstrated with another post-industrial multilayer film of a different composition. Here, the results demonstrate that this process can also recover polymers at similar costs to those of virgin resins, indicating that the STRAP technology is flexible and can remain economically competitive as the plastic feed complexity is increased.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Assessment of Different Application Grades of Post-Consumer Recycled (PCR) Polyolefins from Material Recovery Facilities (MRFs) in the United States

The recycling of plastics has been gaining traction in the following years as many companies, organizations, and governments are pushing toward a more circular economy. However, plastic recycling rates are still small compared to those of plastic production, especially for polyolefins, such as high-density polyethylene (HDPE) and polypropylene (PP). With the goal of finding applications for recycled plastic resin, recyclers can face some challenges associated with the heterogeneity in the polymer properties of plastic waste streams, which could hinder the full potential of recycling due to the lack of a consistent feedstock. Here, this study assessed how an additional sorting step of recycled HDPE and PP streams, separating them into two categories based on the previous application, impacts the recycled polymer properties, such as physical, molecular, and thermal. It was demonstrated that manually separating HDPE articles previously processed by extrusion blow molding (EBM) or injection molding (IM) and PP articles by thermoforming (TF) or IM could yield recycled resins with more consistent properties, considering the significant differences between them. This highlights that an additional sorting step would allow recyclers to target more premium or currently unattainable plastic processing applications with postconsumer recycled (PCR) resins, which could significantly promote an increase in plastic recycling rates. Nevertheless, the development of new technologies is needed to automate this extra sorting step, as with the increase in scale manual sortation could not be feasible and cost-effective, reducing the attractiveness of using PCR resins in comparison to virgin ones.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Recycling of Pretreated Polyolefin-Based Ocean-Bound Plastic Waste by Incorporating Clay and Rubber

Plastic waste found in oceans has become a major concern because of its impact on marine organisms and human health. There is significant global interest in recycling these materials, but their reclamation, sorting, cleaning, and reprocessing, along with the degradation that occurs in the natural environment, all make it difficult to achieve high quality recycled resins from ocean plastic waste. To mitigate these limitations, various additives including clay and rubber were explored. In this study, we compounded different types of ocean-bound (o-HDPE and o-PP) and virgin polymers (v-LDPE and v-PS) with various additives including a functionalized clay, styrene-multi-block-copolymer (SMB), and ethylene-propylene-based rubber (EPR). Physical observation showed that all blends containing PS were brittle due to the weak interfaces between the polyolefin regions and the PS domains within the polymer blend matrix. Blends containing clay showed rough surfaces and brittleness because of the non-uniform distribution of clay particles in the polymer matrix. To evaluate the properties and compatibility of the blends, characterizations using differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and small-amplitude oscillatory shear (SAOS) rheology were carried out. The polymer blend (v-LDPE, o-HDPE, o-PP) containing EPR showed improved elasticity. Incorporating additives such as rubber could improve the mechanical properties of polymer blends for recycling purposes.

42 ENGINEERING↗
DOE OSTI2024

Polymer-fiber-reinforced polymers with enhanced interfacial bonding between polypropylene fiber and polyethylene matrix

Self-reinforced composites (SRCs) consist of reinforcing fibers and a base matrix made of the same thermoplastic polymer, offering lightweight, recyclability, and sustainability benefits. However, limited research exists on composites where the reinforcing thermoplastic polymer fibers differ from the base thermoplastic matrix. Here, this study focuses on investigating the mechanical behavior of such composites and exploring different surface modification methods to enhance the fiber/matrix interfacial bonding using polypropylene fibers and a polyethylene matrix as an example. It is shown that surface treatment with a commercial adhesion promoter containing n-butyl acetate significantly improves the interfacial shear strength between polypropylene fibers and the polyethylene matrix, increasing it by 145% compared to other methods investigated. Additionally, increasing the length of the embedded polymer fiber in the matrix leads to a notable increase in specific interfacial energy. Consequently, the thermoplastic polymer-fiber-reinforced polymers (PFRPs) using surface-treated woven polypropylene fabrics and a polyethylene matrix exhibit a 20% higher tensile strength and a 65% higher toughness compared to non-treated PFRPs. This study also shows that specific mechanical properties (normalized by the composite density) of the investigated woven PFRPs are similar to those of non-treated SRCs under uni-axial tension. Particularly, their ductility outperforms carbon-/glass-/aramid-fiber-reinforced polymers by at least 6 times at a same fiber volume fraction. The investigation of such composites and the exploration of surface modification methods present important progress in the field of thermoplastic PFRPs, which serve as a solution for addressing concerns related to recyclability and sustainability.

Fiber pull-out↗