Search

Less than 10% of the plastics generated globally are recycled, while the rest are incinerated, accumulated in landfills, or leach into the environment. New technologies are emerging to chemically recycle waste plastics that are receiving tremendous interest from academia and industry. Chemists and chemical engineers need to understand the fundamentals of these technologies to design improved systems for chemical recycling and upcycling of waste plastics. In this paper, we review the entire life cycle of plastics and options for the management of plastic waste to address barriers to industrial chemical recycling and further provide perceptions on possible opportunities with such materials. Knowledge and insights to enhance plastic recycling beyond its current scale are provided. Outstanding research problems and where researchers in the field should focus their efforts in the future are also discussed.

We demonstrate a joint computational and experimental approach to predict polymer solubilities at a large scale. This approach can facilitate solvent screening and process design for dissolution-based plastic recycling processes.

Food packaging often appears in the form of multilayer (ML) plastic films, which leverage the functional properties of different polymers to achieve specific food protection goals (e.g., oxygen, water, and temperature barriers). These properties are essential to enable long shelf lives, reduce refrigeration usage, mitigate food waste, and increase food accessibility. However, ML f film production processes generate large amounts of plastic waste that cannot be mechanically recycled. Recently, we have proposed a process, which we call solvent-targeted recovery and precipitation (STRAP), that enables the separation and recycling of the constituent polymers of ML films. This technology uses a series of solvent washes that selectively dissolve and precipitate target polymers. Quantifying the environmental benefits of STRAP over virgin resin production is essential for the commercial deployment of this technology. This work uses life cycle assessment (LCA) methods to evaluate these impacts in terms of carbon footprint, energy use, water use, and toxicity. We analyze three STRAP process variants that use anti-solvent and temperature-driven precipitation and that target different types of ML films. Our analysis reveals that a couple of STRAP process variants can provide environmental benefits over virgin film production and also provides valuable insight into the key components of ML films and of the STRAP process that are responsible for the highest impacts. Ultimately, we believe that the proposed analysis framework can lead to the design of more environmentally-friendly ML films and recycling processes.

One promising approach to recycle multicomponent plastic waste (e. g., multilayer plastic films) is selective dissolution. Selective dissolution is a solvent-mediated process in which differences in polymer solubility in a carefully chosen solvent system are exploited to recover a target polymer. Here, a computational approach was developed that rapidly predicts temperature-dependent polymer solubilities to guide the design of solvent systems for solvent-mediated polymer recycling. Polymer conformations were obtained from molecular dynamics simulations by modeling the polymer as a short oligomer and then used as input to the conductor-like screening model for real solvents (COSMO-RS) for solubility predictions. Using polyethylene (PE) and ethylene vinyl alcohol (EVOH) as representative polymers, the effect of simulation parameters was systematically studied, and predicted solubilities were found to be in good agreement with experimental measurements. The applicability of the approach was demonstrated by identifying selective solvents for PE and EVOH dissolution from a library of 524 solvents.

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. 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.

Correction for ‘Expanding plastics recycling technologies: chemical aspects, technology status and challenges’ by Houqian Li et al., Green Chem., 2022, 24, 8899–9002, https://doi.org/10.1039/D2GC02588D.