The Environmental Journal of Southern Appalachia
Tuesday, 25 July 2023 13:43

ORNL scientists are plugging big leaks in the plastics recycling stream

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ORNL plastics 1ORNL polymer scientists Tomonori Saito, left, and Sungjin Kim upcycled waste plastic to create a stronger, tougher, solvent-resistant material for new additive manufacturing applications.  Ben Pounds/Hellbender Press

Thanks to an East Tennessee science powerhouse, recycling might become easier 

This is the first in a series about ORNL’s Technology Innovation Program 2023

OAK RIDGE — Researchers at Oak Ridge National Laboratory developed a catalyst they say can break down a range of plastics, including polyesters, polycarbonates, polyurethanes and polyamides through a low-energy green process. In lay terms, the process can recycle many plastic-based carpets, ropes, other textiles, bottles, mattresses, protective equipment, car components and other things that weren’t previously easy to recycle into valuable chemicals.

Tomoronori Saito, a researcher at ORNL’s chemical sciences division presented some results of research at ORNL on July 14 as part of a symposium highlighting commercially valuable work that takes place at one of the country’s main science laboratories. Saito and fellow researcher Arif Arifuzzaman showed off plastics in varying levels of disintegration using their catalyst. It was part of the lab’s Technology Innovation Program 2023, promoting the lab’s research for possible business partnerships.

“In general, we tried all the consumer products. It works,” Saito told the visitors to his lab regarding the catalyst. Arifuzzaman told the crowd nylon was the most difficult plastic material to work with the catalyst, but the process just needs to be hotter for nylon to break down. “If it’s mixed, no problem,” Saito said regarding mixing different types of plastic. Currently, plastic recycling technology only works well with clean, single types of plastic products, he said.

He called inefficiency and inability to recycle mixed plastics a “bottleneck in plastics recycling.”

“Plastics have numerous benefits in our lives, but plastic waste management has become a global environmental crisis,” the lab stated in a promotional booklet. Only 9 percent of plastic waste, it stated, is recycled, most of which becomes lower value products. 

“This process will not only reduce plastic waste entering landfills but will also add significant commercial value to current plastic wastes, opening a new paradigm of plastic recycling toward a net-zero carbon society,” according to ORNL communications.

Earlier this year, Battelle, which runs ORNL for the Federal Department of Energy, named Saito the ORNL inventor of the year specifically for his “notable inventions in polymer upcycling.”

Saito develops the monomer via the process currently used for raw fossil fuels such as oil. These monomers can also be used for plastic resin and “plastic end-product production.” At present, Saito said, people tend to use petroleum-based monomers for producing these plastics rather than recycled ones.

Last the lab announced Saito’s team had developed a specific “upcycling approach” with one type of plastic. It allows for acrylonitrile butadiene styrene, used in auto parts, LEGO blocks and tennis balls, to be upcycled into an even more durable material.

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