Public Abstract

DE-SC0025622: Microwave Catalytic Recycle Propylene from Polypropylene Plastic Waste

Award Status: Active

Institution: West Virginia University, Morgantown, WV
UEI: MNL4D3VQUWA5
DUNS: 929332658

Most Recent Award Date: 09/24/2024
Number of Support Periods: 1
PM: Fitzsimmons, Timothy

Current Budget Period: 09/01/2024 - 08/31/2025
Current Project Period: 09/01/2024 - 08/31/2028
PI: Wang, Yuxin

Supplement Budget Period: N/A

Public Abstract

Polypropylene (PP) is the world's second-largest plastic resin based on production volume, after polyethylene. In 2018, the global production of PP amounted to 56 million metric tons and is likely to reach 88 million metric tons by 2026. PP is produced via polymerization of propylene. Current global production of propylene is 150.3 million metric tons per year via energy-intensive processes such as ethane steam cracking and propane dehydrogenation. However, PP has a notably low recovery rate of only 1%, with the majority ending up in landfills or the environment. Significant efforts have been made to recover propylene monomer from PP waste via technologies such as pyrolysis, gasification, and hydrogenolysis so that the monomer can be used for further production of new plastics. PP plastic generally resists selective chemical transformation through conventional energy-intensive thermochemical processes. For example, the pyrolysis of PP typically results in a propylene yield of only about 10% without catalysts and less than 25% using optimized catalysts. Thus, a challenge lies in the lack of selective and energy-efficient methods to convert PP to propylene that can be reused for constructing new plastics. The proposed technology is focused on efficient upcycling of PP wastes and producing cost-competitive propylene through microwave catalysis. The overarching objective of this research is to gain a fundamental understanding of the mechanisms and kinetics involved in the recovery of propylene from PP waste under microwave irradiation. Through collaboration with Argonne National Laboratory (ANL), this research will leverage microwave susceptible catalytic materials design and synthesis, in-situ/operando characterizations, kinetics-mechanism analysis, microwave heating behavior and non-thermal effects studies. A techno-economic analysis and a life-cycle analysis will be conducted to assess the cost of this new technology and to ensure that the greenhouse gas emissions in this new technology are lower than conventional manufacturing methods. The successful development of microwave catalytic plastic upcycling technology will address the remaining challenges for plastic waste upcycling and move it towards practical implementation. This could diversify the strategies available to utilize the nation's abundant plastic waste and enable energy and emissions reduction throughout the lifecycle of plastics. Additionally, it aligns with the missions of the DOE, particularly to improve the productivity and energy efficiency of U.S. manufacturing, reduce the lifecycle energy and resource impacts of manufactured goods, leverage diverse domestic energy resources in U.S. manufacturing, and strengthen environmental stewardship. Furthermore, this EPSCoR project will enhance collaboration between West Virginia University and Argonne National Laboratory and will lead to the training of researchers to tackle difficult global problems of this nature.

Polypropylene (PP) is the world's second-largest plastic resin based on production volume, after polyethylene. In 2018, the global production of PP amounted to 56 million metric tons and is likely to reach 88 million metric tons by 2026. PP is produced via polymerization of propylene. Current global production of propylene is 150.3 million metric tons per year via energy-intensive processes such as ethane steam cracking and propane dehydrogenation. However, PP has a notably low recovery rate of only 1%, with the majority ending up in landfills or the environment. Significant efforts have been made to recover propylene monomer from PP waste via technologies such as pyrolysis, gasification, and hydrogenolysis so that the monomer can be used for further production of new plastics. PP plastic generally resists selective chemical transformation through conventional energy-intensive thermochemical processes. For example, the pyrolysis of PP typically results in a propylene yield of only about 10% without catalysts and less than 25% using optimized catalysts. Thus, a challenge lies in the lack of selective and energy-efficient methods to convert PP to propylene that can be reused for constructing new plastics.
The proposed technology is focused on efficient upcycling of PP wastes and producing cost-competitive propylene through microwave catalysis. The overarching objective of this research is to gain a fundamental understanding of the mechanisms and kinetics involved in the recovery of propylene from PP waste under microwave irradiation. Through collaboration with Argonne National Laboratory (ANL), this research will leverage microwave susceptible catalytic materials design and synthesis, in-situ/operando characterizations, kinetics-mechanism analysis, microwave heating behavior and non-thermal effects studies. A techno-economic analysis and a life-cycle analysis will be conducted to assess the cost of this new technology and to ensure that the greenhouse gas emissions in this new technology are lower than conventional manufacturing methods.
The successful development of microwave catalytic plastic upcycling technology will address the remaining challenges for plastic waste upcycling and move it towards practical implementation. This could diversify the strategies available to utilize the nation's abundant plastic waste and enable energy and emissions reduction throughout the lifecycle of plastics. Additionally, it aligns with the missions of the DOE, particularly to improve the productivity and energy efficiency of U.S. manufacturing, reduce the lifecycle energy and resource impacts of manufactured goods, leverage diverse domestic energy resources in U.S. manufacturing, and strengthen environmental stewardship. Furthermore, this EPSCoR project will enhance collaboration between West Virginia University and Argonne National Laboratory and will lead to the training of researchers to tackle difficult global problems of this nature.