Breakthrough turns carbon dioxide into high-strength plastics using clean power

Caltech researchers have developed an innovative system that converts carbon dioxide (CO₂) from the air into durable, industrial-grade plastics using only electricity and chemistry. This breakthrough mimics natural photosynthesis but employs machines instead of plants, utilizing renewable electricity to first transform CO₂ into simple building blocks such as ethylene and carbon monoxide. These compounds are then fed into a second catalytic loop where they are converted into polyketones—high-strength plastics valued for their durability and thermal stability, commonly used in adhesives, automotive parts, sports equipment, and industrial piping. Unlike previous methods relying on fossil-derived ethylene, this process uses sustainably sourced CO₂, water, and electricity, potentially reducing emissions and dependence on petroleum-based feedstocks. The system operates via two separate loops optimized for different reaction conditions. The first loop uses gas diffusion electrode cells with copper-coated hydrophobic polymers to electrochemically reduce CO₂ into ethylene and carbon monoxide at relatively high concentrations (11% and 14%, respectively). These gases