New 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,