Articles tagged with "plastic-recycling"
MacroCycle found a shortcut for plastic recycling — catch it at TechCrunch Disrupt 2025
MacroCycle, a startup co-founded by Stewart Peña Feliz, has developed an innovative plastic recycling technology that promises to make recycled plastic as inexpensive as virgin material. Unlike traditional chemical recycling methods that break down plastic polymers into monomers, MacroCycle’s process loops polymer chains into macrocycles, which allows contaminants to be washed away and later reforms the polymers without retracing all the energy-intensive steps. This approach uses 80% less energy than producing virgin polyester, significantly outperforming other chemical recycling processes that only reduce energy use by 20-30%. The company is scaling up production with a reactor capable of producing 100-kilogram batches and is already generating revenue from fashion brands interested in sustainable materials. Peña Feliz, who previously managed ExxonMobil’s chemical recycling plant, recognized the environmental and energy drawbacks of existing methods and pursued a more efficient solution in collaboration with MIT postdoc Jan-Georg Rosenboom. Since starting the business in 2022, MacroCycle has raised $6.5 million in seed
plastic-recyclingsustainable-materialschemical-recyclingpolymer-scienceenergy-efficiencycircular-economytextile-recyclingNovoloop’s upcycled plastic takes a step closer to production
Novoloop, a plastic recycling startup based in Menlo Park, has secured a commercial-scale production deal with Huide Science and Technology to supply a chemical building block—polyol—used to make thermoplastic polyurethane (TPU). Novoloop’s polyol is produced from post-consumer polyethylene waste, such as plastic bags, which are notoriously difficult to recycle. TPU is a versatile plastic used in products ranging from running shoes to medical devices. This agreement marks a significant milestone for Novoloop as it navigates the challenging “valley of death” phase common to hardware-dependent climate tech startups, where technology validation has occurred but revenue generation remains limited. Currently, Novoloop operates a demonstration plant in India capable of producing tens of tons of polyol annually, sufficient for major pilot projects including an upcoming footwear collaboration. The company previously supplied Swiss shoe manufacturer On with its Lifecycled TPU material. CEO Miranda Wang emphasized that achieving economies of scale through deals like the one with Huide is critical
materialsplastic-recyclingthermoplastic-polyurethaneupcycled-materialssustainable-materialschemical-building-blocksclimate-techInnovative catalyst transforms plastic trash into liquid fuels
A research team led by the University of Delaware has developed an innovative mesoporous MXene catalyst that significantly improves the conversion of plastic waste into liquid fuels. This catalyst enhances the hydrogenolysis process, which breaks down polymers in plastics using hydrogen gas and a catalyst. Unlike conventional catalysts that struggle with bulky polymer molecules, the mesoporous MXene catalyst features silica pillars inserted between its stacked two-dimensional layers, allowing polymers to flow more easily and increasing reaction rates nearly twofold. Tested on low-density polyethylene (LDPE), a common plastic, the catalyst not only accelerated the conversion but also improved fuel quality by producing liquid fuels efficiently while minimizing unwanted byproducts like methane. The success of this catalyst is attributed to the stabilization of ruthenium nanoparticles within the MXene layers, which enhances both speed and selectivity in the plastic-to-fuel conversion. This advancement points to a more energy-efficient and environmentally friendly method for plastic upcycling, turning plastic waste into valuable fuels and chemicals rather than letting it accumulate as
energycatalystplastic-recyclingMXenenanomaterialssustainable-fuelschemical-engineeringPlastic Recycling Not Requiring Sorting Could Be Coming - CleanTechnica
Northwestern University chemists have developed a novel plastic upcycling process using an inexpensive nickel-based catalyst that can selectively break down polyolefin plastics—primarily polyethylene and polypropylene, which constitute nearly two-thirds of global plastic use. This catalyst enables the recycling of large volumes of unsorted polyolefin waste, bypassing the traditionally labor-intensive sorting step. The catalyst converts low-value solid plastics into liquid oils and waxes, which can be upcycled into higher-value products like lubricants, fuels, and candles. Notably, it can also process plastics contaminated with polyvinyl chloride (PVC), a toxic polymer that typically hinders recycling efforts. Polyolefins are ubiquitous in everyday items such as condiment bottles, milk jugs, plastic wrap, and disposable utensils, and they are mostly single-use plastics with very low recycling rates globally—ranging from less than 1% to 10%. This low recycling rate is largely due to the chemical resilience of polyolefins, which consist of
materialsplastic-recyclingcatalystpolyolefinsupcyclingsustainabilitychemical-engineeringWorld-first hydrogen plasma torch recycles plastic waste in 0.01 secs
South Korean researchers, led by the Korea Institute of Machinery and Materials (KIMM), have developed the world’s first hydrogen-powered plasma torch capable of breaking down unsorted plastic waste into valuable chemicals in just 0.01 seconds. Operating at ultra-high temperatures of up to 2,000°C, this plasma-based process rapidly decomposes mixed plastics without the need for prior sorting, overcoming a significant barrier in current recycling methods. Unlike traditional pyrolysis, which operates at lower temperatures and produces numerous unwanted by-products, this hydrogen-fueled plasma torch selectively converts plastic waste into ethylene and benzene with 70-90% selectivity, yielding raw materials over 99% pure after purification—suitable for manufacturing new plastics. The use of 100% hydrogen fuel prevents carbon soot formation, enabling stable and continuous operation. This technology also effectively processes waxy residues from other recycling methods with over 80% selectivity. The project, involving multiple Korean research institutes and universities, has demonstrated that the
energyhydrogen-energyplasma-torchplastic-recyclingsustainable-technologychemical-recyclingcarbon-free-technologyNew catalyst breaks down mixed plastics into fuels at low heat
Northwestern University chemists have developed an innovative nickel-based catalyst that efficiently converts mixed single-use polyolefin plastics—such as milk jugs, plastic wraps, and disposable utensils—into valuable oils, waxes, and lubricants at relatively low temperatures and pressures. This process bypasses the traditionally necessary and labor-intensive sorting step, addressing a major bottleneck in plastic recycling. Unlike existing methods that require high heat and expensive catalysts, this single-site nickel catalyst operates at temperatures 100 degrees lower and half the hydrogen pressure, using significantly less catalyst material while achieving tenfold greater activity. The catalyst selectively breaks down branched polyolefins, enabling a cleaner and more efficient chemical recycling that produces high-quality products suitable for upcycling. A notable and unexpected finding was the catalyst’s improved performance in the presence of polyvinyl chloride (PVC), a toxic polymer that typically inhibits recycling processes. Even with PVC constituting up to 25% of the plastic mix, the catalyst maintained and enhanced its activity,
materialscatalystplastic-recyclingnickel-catalystchemical-recyclingpolyolefinssustainable-materialsWorld's first method turns plastic into fuel with 95% efficiency
A collaborative team of scientists from the US and China has developed the world’s first one-step method to convert mixed plastic waste into petrol with over 95% efficiency at room temperature and ambient pressure. This low-energy process simultaneously produces gasoline-range hydrocarbons, chemical raw materials, and hydrochloric acid, enabling a circular economy approach by turning diverse plastic waste into valuable products in a single step. The method uses light isoalkanes, refinery byproducts, to break down plastics, yielding hydrocarbons primarily composed of six to twelve carbon atoms, the main constituents of gasoline. The hydrochloric acid byproduct can be safely neutralized and reused, potentially replacing several energy-intensive industrial production routes. A significant innovation of this method is its ability to handle polyvinyl chloride (PVC), a challenging plastic due to its chlorine content, which traditionally requires separate, high-temperature dechlorination steps to avoid toxic emissions. The new process integrates dechlorination with fuel production, converting PVC into chlorine-free fuel hydrocarbons and hydrochloric
energyplastic-recyclingfuel-conversionsustainable-technologycircular-economychemical-upcyclingwaste-to-energyScientists mimic seashells to improve recycled plastic performance
Researchers at Georgia Tech, led by aerospace engineering assistant professor Christos Athanasiou, have developed a bio-inspired material that mimics the structure of seashells to improve the performance and consistency of recycled plastics. By replicating nacre—the natural architecture of seashells composed of brittle mineral “bricks” bonded with soft protein “mortar”—the team created a composite using recycled high-density polyethylene (HDPE) sheets layered with a softer adhesive polymer. This design significantly reduces variability in mechanical properties, maintaining the strength of virgin plastics while improving reliability, particularly in maximum elongation by over 68%. This advancement addresses a major challenge in recycling, where less than 10% of plastics are effectively reused due to inconsistent material quality. The seashell-inspired approach restores trustworthiness in recycled HDPE, which typically degrades after exposure to sunlight and heat, limiting its reuse in high-performance applications. The researchers also introduced an “uncertainty-aware” Tension Shear Chain model to quantify both
materialsrecycled-plasticsbio-inspired-designsustainabilitypolymer-compositesplastic-recyclingmaterial-scienceThe science behind plastic recycling and why it needs a rethink
The article explores the challenges and limitations of plastic recycling, emphasizing that the issue extends beyond consumer behavior to fundamental thermodynamic, chemical, and engineering constraints. Since the invention of the first man-made plastic, Parkesine, in 1862, plastics have evolved into a diverse range of durable materials that have become ubiquitous in daily life. However, by the late 1960s, scientists began detecting widespread plastic pollution in the environment, prompting the adoption of recycling as a solution. Although recycling initially appeared promising by reducing waste and conserving resources, it has revealed significant drawbacks over time, including high costs, inefficiencies, toxicity concerns, and the release of microplastics. The article details the three main recycling methods: mechanical, chemical, and energy recycling. Mechanical recycling, the most common commercial method, involves collecting, sorting, washing, and reprocessing plastics like PET and HDPE but is limited by contamination and material degradation. Chemical recycling, a newer approach, aims to break down plastics to their original raw
materialsplastic-recyclingpolymer-sciencechemical-recyclingsustainable-materialswaste-managementenvironmental-engineeringEnzyme breakthrough cuts plastic recycling energy use by 65%
Scientists from the National Renewable Energy Laboratory (NREL), University of Massachusetts Lowell, and University of Portsmouth have developed a breakthrough enzymatic recycling process for PET plastic that significantly reduces environmental impact and costs. By substituting sodium hydroxide with ammonium hydroxide, the team created a self-sustaining closed-loop system that cuts chemical use by 99%, energy consumption by 65%, and operating costs by nearly 75%. This innovation allows enzymatic recycling to outperform traditional plastic production both environmentally and economically, with recycled PET costing $1.51 per kilo versus $1.87 for virgin plastic. The new method overcomes previous challenges in enzymatic recycling, which struggled with high costs and environmental drawbacks despite its ability to break down complex PET waste types that mechanical recycling cannot process. Ammonium hydroxide maintains optimal pH and regenerates itself during the process, reducing the need for fresh chemicals. Additional improvements in plastic pre-treatment and ethylene glycol recovery further enhance efficiency, enabling complete depolymerization
energyrecyclingenzymatic-recyclingplastic-recyclingsustainabilitychemical-engineeringrenewable-energyWaste to painkiller? Bacteria convert plastic into paracetamol
Researchers at the University of Edinburgh’s Wallace Lab have developed a novel method to convert plastic waste into paracetamol (acetaminophen) using genetically engineered E. coli bacteria. This innovative process transforms terephthalic acid, a compound derived from polyethylene terephthalate (PET) plastic bottles, into paracetamol within 24 hours through a fermentation technique similar to beer brewing. Unlike traditional paracetamol production, which relies on fossil fuels and energy-intensive processes that emit significant carbon emissions, this biological method operates at room temperature and produces minimal emissions, offering a more sustainable and cost-effective alternative. The breakthrough hinges on a previously unobserved chemical reaction called the Lossen rearrangement occurring naturally inside living cells, enabling the bacteria to convert PET-based intermediates into para-aminobenzoic acid (PABA), a precursor molecule. By further inserting genes from mushrooms and soil bacteria, the researchers enabled E. coli to complete the conversion to paracetamol. This approach not only presents a promising
materialsbiotechnologyplastic-recyclingsynthetic-biologysustainable-manufacturingbioconversionpharmaceuticalsSouth Korea turns plastic bottles into hydrogen with solar power
Scientists at South Korea’s Institute for Basic Science (IBS) Center for Nanoparticle Research, led by Professors Kim Dae-Hyeong and Hyeon Taeghwan, have developed an innovative photocatalytic system that converts plastic waste, specifically PET bottles, into clean hydrogen fuel using sunlight. This system addresses the inefficiencies and greenhouse gas emissions associated with conventional hydrogen production methods by harnessing solar energy to break down plastics into byproducts like ethylene glycol and terephthalic acid while releasing hydrogen. A key advancement is the stabilization of the catalyst within a polymer network at the air-water interface, which prevents common issues such as catalyst loss and reverse reactions, enabling stable operation for over two months even in harsh alkaline conditions. The technology was successfully tested outdoors with a one-square-meter device that produced hydrogen from dissolved plastic bottles under natural sunlight. Its floatable catalyst design allows it to function in various water environments, including seawater and tap water. Importantly, simulations indicate the system can
energyclean-energyhydrogen-productionphotocatalysisplastic-recyclingsolar-powersustainable-technology