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DOE OSTI2022

Production and Catalytic Upgrading of 2,3-Butanediol Fermentation Broth into Sustainable Aviation Fuel Blendstock and Fuel Properties Measurement

With the increasing demand for sustainable supplies of aviation fuel and need to address climate change, new conversion technologies are needed to efficiently process biomass, produce high quality jet fuel blendstock, and meet carbon emission targets. This study demonstrates the synthesis, conditioning, and catalytic upgrading of 2,3-butanediol (BDO) fermentation broth into a jet fuel blendstock candidate. A high-titer 2,3-BDO fermentation broth (i.e., ~90 g/L) was produced at a 100-L scale and pretreated via nanofiltration to decrease the impurities level in the broth from 4.6 to 0.6 wt%. A novel process for catalytic upgrading of aqueous 2,3-BDO into a jet fuel blendstock candidate was developed, and each step was efficiently demonstrated. The catalytic steps include 1) 2,3-BDO dehydration into methyl ethyl ketone (MEK) over AlPO4, 2) MEK conversion into olefins over Zn1Zr10Ox, 3) oligomerization of olefins over a zeolite beta, and 4) hydrogenation over platinum/carbon. Both the model feed and real 2,3-BDO fermentation broth were tested for upgrading 2,3-BDO to MEK. With the real feed, a continuous loss of conversion (i.e., >50% loss over ~140 h time-on-stream [TOS]) was partly attributed to reversible deactivation from coking species. However, the conversion remained stable with the model feed, which demonstrates the efficiency of the first step for converting aqueous 2,3-BDO (10 wt% in water). For upgrading MEK to olefins, high selectivity to olefins (i.e., 82.5%) was obtained at high conversion levels (i.e., 93-98%) with stable conditions being achieved for > 70-hours TOS. Oligomerization of light olefins, which was demonstrated for > 270 h TOS, mainly led to the formation of dimers (C8-10) and trimers (C13-14). The oligomerized product was hydrogenated and distilled to recover the jet fraction (35 mass% or 40.9% carbon based yield), which consists mostly of desired isoalkanes (31.7 wt%), n-alkanes (24.5 wt%), and cycloalkanes (29.6 wt%). While some improvement is still needed to meet ASTM D7566 specifications for viscosity and final boiling point temperature, freezing point, density, aromatics content, and sulfur content of the jet blendstock candidate were within acceptable ranges, thus highlighting the potential of this process for production of jet fuel blendstock.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS↗

DOE OSTI2024

Renewable Aromatics from Syngas

This study focuses on developing a catalytic process for the aromatization of mixed olefin (comprised of C 2 -C 6 ) over various metal doped zeolites towards the formation of large aromatics (preferably C 8 -C 16 ) compliance to the sustainable aviation fuel (SAF). Experiments were carried out using model olefin feedstocks containing either ethylene (C 2 ) or mixture of C 2 and C 3+ olefins. Both the catalyst composition and process parameters were evaluated in detail to identify their impact on the formation large aromatics. We specifically focus on the aromatization of ethylene as the model reaction and evaluated the impact of C 2+ olefins and paraffins that may present in the real feedstock. In all the reaction condition, aromatization of ethylene was used as the baseline to evaluate the effect of larger olefins or paraffins. Our results show that at this reaction condition paraffins remained either inert or show positive impact on the formation of large aromatics. While C 2 and C 3 olefins are highly reactive towards aromatization during reaction condition, large olefins are less reactive and thus, strategy was developed to oligomerize these large olefins (C 4+ ) alongside the aromatization of smaller olefins (C 2 /C 3 ).

10 SYNTHETIC FUELS↗

DOE OSTI2023

Surface Science Studies of Selective Fischer-Tropsch Chemistry on Cobalt Carbide Surfaces

Advances in catalysis science are critical to the progress of the United States. Catalysis is employed, in one way or another, in the production of almost every chemical and product manufactured. The catalysis research that we undertook here, regarding the role of specific facets of cobalt carbide in the Fischer-Tropsch production of low molecular weight olefins (FTO), is motivated by the work of many previous investigators. In particular two research groups from China had discovered FTO catalysts that work very selectively for low molecular weight olefins coupled with low production of methane. These are potentially very important findings that could find significant industrial utility if improvements can be discovered. With the research undertaken here we chose to focus on one of these studies and especially the Co 2 C surfaces that they implicate as being responsible for this exciting FTO catalysis with low production of methane. In this study, Zhong and co-workers investigated cobalt-manganese oxide catalysts for the Fischer-Tropsch to Olefins process. After reaching steady-state their catalyst showed a good selectivity to light olefins and low selectivity to methane with a carbon monoxide conversion of 31.8% at one atmosphere (with a H 2 /CO ratio of two and a temperature of 250°C). Lower H 2 /CO ratios and lower pressures increased the olefin production. Their catalyst characterization studies indicated that cobalt carbide quadrangular nanoprisms with preferentially exposed (101) and (020) facets were important in favoring lower olefin production and inhibiting methane formation. The authors stated that these cobalt carbide nanoprisms are a promising new catalyst system for directly converting synthesis gas to lower olefins. Motivated by the studies of Zhong and co-workers, our goal with the research here was to contribute to a better understanding of catalysis science through the study of surface chemical reactions related to the Fischer-Tropsch to Olefins reaction on specific facets of planar model cobalt carbide catalysts in ultrahigh vacuum.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Rhodium-Catalyzed Oxidative Alkenylation of Anisole: Control of Regioselectivity

We report the conversion of anisole and olefins to alkenyl anisoles via a transition metal-catalyzed arene C–H activation and olefin insertion mechanism. The catalyst precursor, [(η 2 -C 2 H 4 ) 2 Rh(μ-OAc)] 2 , and the in situ oxidant Cu(OPiv) 2 (OPiv = pivalate) convert anisole and olefins (ethylene or propylene) to alkenyl anisoles. When ethylene is used as the olefin, the o/m/p ratio varies between approximately 1:3:1 (selective for 3-methoxystyrene) to 1:5:10 (selective for 4-methoxystyrene). When propylene is the olefin, the o/m/p regioselectivity varies between approximately 1:8:20 to 1:8.5:1. The o/m/p ratios depend on concentration of pivalic acid and olefin. For example, when using ethylene, at relatively high pivalic acid concentrations and low ethylene concentrations, the o/m/p regioselectivity is 1:3:1. Conversely, again for use of ethylene, at relatively low pivalic acid concentrations and high ethylene concentrations, the o/m/p regioselectivity is 1:5:10. Mechanistic studies of the conversion of anisole and olefins to alkenyl anisoles provides evidence that the regioselectivity is likely under Curtin-Hammett conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Towards cost-competitive middle distillate fuels from ethanol within a market-flexible C2 platform-based biorefinery concept

Ethanol to middle distillates (ETMD) is a promising pathway to produce sustainable liquid fuels to decarbonize the hard-to-electrify transportation sectors due to (1) the abundant sugar/starch and lignocellulosic biomass, (2) the existing deployment scale of fuel ethanol production (similar to 29 billion gallons per year globally), and (3) emerging opportunities in C2+ alcohol synthesis from CO2. Here we report a conceptual market-responsive biorefinery centered around a new ETMD pathway based on one-step ethanol to butene-rich olefins (ETO) over a Cu-Zn-Y/Beta catalyst. Specifically, this ethanol conversion pathway comprises one-step ETO, oligomerization, and hydrotreating. This ETO is distinct from that in the conventional ethanol-to-jet process which is based on two-step ethanol to ethylene and ethylene oligomerization to butenes. Butene-rich olefins can be shifted to butadiene-rich products by simply changing the reaction atmosphere from hydrogen to inert gas over the same ETO catalyst. Leveraging the experimental results, baseline techno-economic analysis (TEA) and sensitivity analysis indicate that the ethanol conversion cost is $0.60 per gallon gasoline equivalent (GGE), with opportunities for further cost reduction via improving the liquid hydrocarbon yield and space velocities, and process optimization on balancing dewatering of ethanol feed prior to the ETO step. The minimum fuel selling price (MFSP) of liquid hydrocarbons derived from corn starch ethanol with butadiene as coproduct is $1.64 per GGE, in the range that is cost competitive with petroleum kerosene-type jet fuel. Projected MFSP for cellulosic ethanol (corn stover) derived hydrocarbons is below $3.00 per GGE and co-production of butadiene further reduces the MFSP to $1.70 per GGE. The Well-to-Wake life-cycle analysis indicates that 85% greenhouse gas emission reduction can be achieved when using corn stover compared to petroleum reference and the associated carbon credits will provide significant economic incentives to favor the cellulosic ethanol-derived hydrocarbon fuels. This study demonstrates a low-cost pathway to middle distillate fuels leveraging existing ethanol infrastructure, where catalysis innovation drives the reduction of process complexity and flexible coproduction of a value-added chemical product.

Zhang, Junyan↗

DOE OSTI2024

Aliphatic Amines from Waste Polyolefins by Tandem Pyrolysis, Hydroformylation, and Reductive Amination

Pyrolysis of waste plastics can produce a product mixture with a high concentration of olefins (>50 wt%). The olefins, as building blocks in the petroleum industry, are potential precursors for valuable commodity chemicals with higher values (>$2000 per ton). In this work, we produce aldehydes by hydroformylation of the olefins present in pyrolysis oil from colored post-consumer recycled high-density polyethylene (PCR-HDPE). The obtained aldehydes in the oil are then converted into aliphatic amines via reductive amination with a Ru/C catalyst. The aminated oil was characterized by multiple analytical chemistry techniques including elemental analysis, nuclear magnetic resonance spectroscopy, high-resolution liquid chromatography-mass spectrometry, and gas chromatography-mass spectrometry with a Polyarc flame ionization detector. The concentration of metals in the PCR-HDPE and oil changes during the tandem processes, showing limited effects of these elements (e.g., Al, Ca, Fe, Mg, Ti, Zn) on hydroformylation and reductive amination. Additionally, we demonstrated that reductive amination of aldehydes with varied carbon numbers and branching properties can be achieved in the presence of a complex mixture, including paraffins and aromatics. The results indicate that waste plastics have the potential to serve as a renewable source for mono and di aliphatic amines, thereby diminishing reliance on fossil feedstocks as the current primary amine source.

aliphatic amines↗

DOE OSTI2026

Harnessing ketones as hydrogen acceptors for atom-efficient upgrading of oxygenates to fuels over H/ZSM-5

Heterogeneous mixtures of bio-derived oxygenates are promising feedstocks for synthetic aviation fuel (SAF), but conversion strategies for one common component—short-chain (C 5–7 ) internal ketones—are lacking. Previous work has shown that cyclization of ketones over H/ZSM-5 is limited by its high productivity of light paraffins. We study 4-heptanone upgrading over H/ZSM-5 and show that aromatics and olefins can be formed at high carbon yield when operating at up to 90% conversion. The yield of desirable products is not impacted by the introduction of a recycle stream of the unconverted 4-heptanone and other products with similar boiling points. We hypothesize, based on first-principles calculations, that the higher olefin yield is driven by the ease of hydrogen transfer to unreacted ketones as opposed to hydrogenating olefin products. We demonstrate how this ease of hydrogen transfer to ketones can be leveraged to enhance olefin selectivity in the conversion of methanol to olefins as well by co-feeding ketones. Olefinic products of the cyclization reaction are then oligomerized to a SAF blendstock to demonstrate an end-to-end ketone-to-SAF process facilitated by upgrading ketones over H/ZSM-5 at partial conversion with a recycle stream. The results of this work demonstrate a strategy to improve the carbon yield from bio-derived acids to SAF to over 75%, representing a relative improvement of more than 50% compared to previously reported data.

08 HYDROGEN↗

DOE OSTI2023

Thermochemical processes for CO 2 hydrogenation to fuels and chemicals: Challenges and opportunities

This manuscript discusses the potential use of CO 2 as a carbon and oxygen carrier to return it to the carbon life cycle in the form of fuels or chemicals via thermochemical catalytic pathways. Theoretically, CO 2 hydrogenation can form a variety of fuels and chemicals. Practically, however, the selectivity, conversion, operating range, and kinetic limitations and operational cost determine the end product. Because of their high value and versatility as a chemical or fuel, small olefins (i.e., C 2 H 4 ) and methanol are often considered as target species. Whether alcohol or olefin formation, CH 4 and CO are the nature’s primary choices of CO 2 conversion. They can be formed over a wide operating temperature, pressure, and CO 2 :H 2 ratios. They are often competitive carbon species in olefin or methanol formation steps. Although they are less valuable as end products, they can be used as intermediate species. Secondary processes of CO and CH 4 to form chemicals and fuels can increase the overall CO 2 hydrogenation yield. Independent of the choice of end product, CO 2 hydrogenation requires hydrogen. Pure hydrogen derived mostly from fossil fuels adds to the overall process cost and also increases the CO 2 emissions. Hydrogen produced from water electrolysis is a renewable green pathway but is limited by the process efficiency and cost. As an alternative to pure hydrogen, low-value, small chain paraffins are suggested as the hydrogen carriers. Carbon dioxide–assisted oxidative dehydrogenation of paraffins to olefins process is a direct pathway to olefin formation. The paper discusses these potential pathways for CO 2 utilization based on theoretical analysis and recent advances in academia and industry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Expanding the horizon of bio-naphtha beyond gasoline blend: property characterization and conversion opportunity assessment through technoeconomic and life-cycle analyses

Bio-naphtha, a common by-product of biorefineries, is expected to experience substantial growth in supply due to increasing demands for renewable diesel and synthetic aviation fuel (SAF). However, demand for bio-naphtha itself as a gasoline blendstock is limited because of the electrification of light-duty vehicles. This work investigated valorization opportunities for bio-naphtha from catalytic fast pyrolysis, hydrothermal liquefaction, Fischer–Tropsch synthesis, and hydrotreated esters and fatty acids pathways. These opportunities include producing polymer-grade olefin via steam cracking, SAF via steam cracking followed by olefin oligomerization, and renewable aromatics benzene, toluene, and xylene (BTX) and hydrogen via catalytic reforming. Process models were developed in Aspen Plus V14 and Aspen HYSYS V14 to calculate the mass and energy balances for each conversion step. Technoeconomic assessment and life-cycle analysis were conducted to evaluate the minimum fuel/product selling price, conversion cost, and life-cycle CO2 equivalent (CO2e) emission reduction. Technoeconomic assessment results suggest a minimum fuel/product selling price as low as $1.9/kg of olefins, $6.30/gal of gasoline-equivalent SAF, and $1.2/kg of BTX without any incentives. For all pathways, these prices are dominated by bio-naphtha feedstock costs, which account for at least 76% of the total cost. Compared with petroleum baselines, bio-naphtha-derived SAF, olefins, and BTX can achieve significant CO2e emission reductions from the use of renewable carbon resources. The results of life-cycle analysis and subsequent technoeconomic assessment, incorporating carbon credits, indicate the economic viability of using bio-naphtha for polymer-grade olefin and BTX production, with product costs comparable to market prices.

Xu, Shuang↗

DOE OSTI2025

The role of the Pt-group dehydrogenation catalyst in alkane metathesis for polyolefin deconstruction

Recent proposed approaches in the depolymerization of waste plastics employ an olefin intermediate to produce alkanes or alkenes using olefin metathesis in tandem chemistry. Here, in this study, we investigated the role of the dehydrogenation catalyst on reaction rate, kinetics, and product distribution in heterogeneous tandem dehydrogenation and olefin metathesis (alkane metathesis) of three different alkane reactants, including polyethylene. We found that many properties to which alkane dehydrogenation rates were sensitive-including metal composition, nanoparticle size, and surface doping of Re species also controlled activity in Tandem D/OM. When comparing Pd, Pt, and Pt 3 Sn 1 , supported Pd in tandem with a Re 2 O 7 olefin metathesis catalyst showed four-fold higher activity (surface area basis) compared to Pt or Pt 3 Sn 1 catalysts on the same support, mainly due to differences in the rate of hydrogenation. Catalyst preparation resulted in metal nanoparticles partially covered by ReO x , as seen from elemental mapping. Co-location of Re 2 O 7 and Pd correlated with increased rates of hydrogenation (i.e., an increase in the rate of alkane formation and simultaneous lowering of the rate of alkene formation), with a reaction order in catalyst study that further supported this conclusion. The Pd and Re 2 O 7 system displayed marked improvement compared to Pt or Pt 3 Sn 1 with Re 2 O 7 , and previous work, in the depolymerization rate of a linear polyethylene feedstock, with over 94 % reduction in polymer molecular weight in 15 h at 190 °C using less catalyst and increased reactant loadings, while keeping solvent to polymer consumption below 2.5.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Production of drop-in biodiesel blendstocks via competitive acid-catalyzed dehydration reactions using ethanol oligomerization products

Ethanol can be converted into diesel fuel ethers using a three-step catalytic approach that involves ethanol oligomerization to larger alcohols, hydrogenolysis of the esters followed by dehydration of the C4 to C8 alcohols into ethers. In this paper we report results for the dehydration of a mixture of C4 – C8 alcohols using a zeolite Y catalyst in a continuous flow reactor. Mono-molecular dehydration of the alcohols produces olefins while bi-molecular dehydration of the alcohol produces ethers. Increasing the pressure increases the ether selectivity while decreasing the pressure produces more olefins. Linear alcohol feeds produce more C8+ ethers, while branched and secondary alcohols lead to more olefins. Olefin and coke selectivities increase with increasing carbon chain length of alcohols. Secondary alcohols lead to higher coke selectivities. Furthermore, ethanol/Butanol oligomerization experiments showed that the incoming dehydration feedstock can be grown to larger C6+ alcohol fractions, leading to higher yields of C10+ diesel-range ethers.

09 BIOMASS FUELS↗

DOE OSTI2023

Investigation of Cu Species in Dealuminated Beta Zeolite Studied by Operando Closed-Cell Gas Reaction STEM

Direct conversion of ethanol to C3+ olefins is an attractive pathway to produce sustainable aviation fuels [1]. We recently reported a copper-containing catalyst supported on dealuminated (DeAl) beta zeolite that is capable of catalyzing cascade ethanol to olefins reactions with high olefins selectivity (88% C3+ olefin selectivity at 100% ethanol conversion). However, one of the deactivation mechanisms of the catalyst is copper sintering [2]. It was found that copper agglomerates can be redispersed through a simple oxidative treatment. To better understand the kinetics and process conditions conducive to redispersion, we studied the atmosphere and temperature dependent Cu species in Cu/DeAl-Beta catalyst under conditions matching those of the working catalyst.

beta zeolite↗

DOE OSTI2023

Chapter 6: Recycling Plastic Waste to Produce Chemicals - A Techno-Economic Analysis and Life-Cycle Assessment

This study presents the results of a preliminary assessment on the technology, economics, and sustainability of using waste plastics as a feedstock to produce low molecular weight olefins via pyrolysis and gasification pathways. We also studied the formation of formaldehyde - an important polymer precursor - via the gasification of waste plastics. Process pathways for recovery of ethylene and propylene and production of formaldehyde from a simulated mixed plastic waste were constructed based on literature data. They included direct and indirect pathways based on either gasification or pyrolysis as the primary conversion step. Results of these studies have shown that significant economic challenges exist of producing olefins via pyrolysis and gasification, with the latter pathway especially difficult. Base costs of pyrolysis naphtha from waste plastics are higher when compared to the same material produced from fossil feedstocks. Base olefin costs for one direct route are two times higher than comparable costs from steam cracking of fossil naphtha. These costs are driven primarily by feedstock costs; some pyrolysis scenarios become more economically feasible when very low feedstock costs are used. Similarly, for gasification, the cost of methanol - the central intermediate - was found to be noticeable higher when produced by gasification of waste plastics compared to current selling prices, which negatively impacts all pathways that go through methanol as the central intermediate. Life-cycle assessment indicates that the production of pyrolysis naphtha from plastics is a carbon intensive operation; no major advantages were found in terms of greenhouse gas emissions for any of the pathways producing C2 and C3 olefins. The results of this study can serve as the baseline for future comparison to other plastic waste valorization processes.

BIOMASS FUELS,ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

Microchannel Reactor for Ethanol to Butene: CRADA 503 [Abstract only]

A key challenge facing most bioprocessing operations is that multiple unit operations are required, thereby resulting in complex, energy-intensive, and expensive processes. Further, biomass transportation costs drive the need for smaller, distributed processing plants. To incorporate the smaller scales desirable for biomass, novel processes must be developed with reduced capital costs. With over 20 years of experience in the development and commercialization of microchannel reactor technology, Oregon State University will partner with Pacific Northwest National Laboratory to demonstrate a microchannel reactor with lower capital costs for an alcohol-to-jet (ATJ) process technology that is currently being commercialized by LanzaTech. Ethanol can be produced from biomass feedstocks such as LanzaTech’s proprietary biochemical process using carbon from a number of possible feedstocks; syngas generated from biomass resources (e.g., MSW, organic industrial waste, agriculture waste) or reformed biogas, or from other biomass feedstocks such as corn kernel fiber. Ethanol then undergoes catalytic dehydration to form ethylene followed by a two-step oligomerization, hydrogenation, and fractionation to control the hydrocarbon product slate to the jet-range. Successful process development aided by a market pull for low carbon aviation fuel has spurred scale-up and commercial demonstration. However, Sustainable Aviation Fuel is a very price sensitive market and improved economics through process intensification will make the current ATJ process even more attractive. Recent efforts at PNNL have culminated in the development of a new catalyst technology for the conversion of ethanol to n-butene-rich olefins. A greater than 90% conversion, total olefin selectivity of 80-90% (n-butene selectivity ~60%), and good stability over a 100 hour test duration has been demonstrated at the bench scale. Producing butene-rich olefins directly from ethanol with high yield is new and impactful because the higher olefins can be selectively oligomerized to distillate-range hydrocarbons, thus eliminating one process step from the current ATJ process. Further, coupling the severely endothermic ethanol dehydration with exothermic C-C bond formation results in more energy efficient processing. Additional intensification and energy savings will stem from incorporating this new ethanol to n-butene catalyst technology within the ATJ process implemented using a microchannel reactor platform. Due to recent advances in microchannel manufacturing methods and associated cost reductions we believe the time is right to adapt this technology toward new commercial bioconversion applications.

02 PETROLEUM↗

DOE OSTI2022

Cooperative Research and Development Agreement (CRADA) between National Energy Technology Laboratory and Susteon, Inc. (Final Report)

NETL developed a nanostructured Fe catalyst capable of converting syngas to olefins. Initial laboratory testing demonstrated this technology possessed high reactivity (~70% conversion), good olefin selectivity (~40 weight %), and a long-performance lifetime (greater than 500 h on stream with no degradation). Under CRADA Agreement 0988, NETL and Susteon collaborated to evaluate the commercial potential of this catalyst technology by scaling up the catalyst synthesis and collecting reactivity data to characterize the mass and energy balance associated with utilizing this catalyst in a Fischer Tropsch to Olefins (FTO) reactor. Research under CRADA Agreement 0988 illustrated there are technical barriers associated with synthesizing the catalyst that the team was not able to overcome. Reactivity testing with this material illustrated that the catalyst deactivated in less than 50 hours of time on stream. Due to this technical barrier, the team did not meet its Go/No-Go decision target of creating a FTO process that produces at least a 25% reduction in olefin production cost compared to the current state-of the-art technologies. As a result, the team has stopped all work on CRADA Agreement 0988.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Abstract for CRADA between National Energy Technology Laboratory and American Institute of Chemical Engineers dba RAPID Manufacturing Institute

NETL and RAPID Manufacturing will develop advanced electromagnetic (EM) reactors and catalysts to produce light olefins from alternative feedstocks using CO2 soft oxidation. Light olefins are the building blocks for many plastic products, in addition to synthetic fibers, rubbers, and polymers. This project has the potential to produce high-value light olefins from alternative feedstocks with reduced energy consumption (50-70%), carbon intensity (50-70%), and production cost (15-25%) compared to the traditional olefin production processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Anion exchange membrane and methods of making and using the same

Anion exchange membrane and methods of making and using the same. In one embodiment, the anion exchange membrane may be made by a method that includes a two-step polymerization. In the first step, an α-olefin monomer containing a pendant halide, such as 8-bromo-1-octene, may be polymerized by Ziegler-Natta polymerization to form a first polymer portion, the first polymer portion being a homopolymer. In the second step, the polymerization is charged with a non-functionalized α-olefin monomer, such as ethylene, thereby forming a second polymer portion, the second polymer being a copolymer made up predominantly of the non-functionalized olefin monomer. If desired, a small amount of an α-olefin monomer containing a crosslinking functionality may be included in the first and/or second steps. Following the two-step polymerization, the polymer is fabricated into a thin film. Thereafter, the thin film may be functionalized by replacing the pendant halides with pendant cations.

Strasser, Derek J.↗

DOE OSTI2024

Effect of pyrolysis operating conditions on the catalytic co‐pyrolysis of low‐density polyethylene and polyethylene terephthalate with zeolite catalysts

Abstract In this study, the catalytic (co‐)pyrolysis of low‐density polyethylene (LDPE) and polyethylene terephthalate (PET) with HZSM‐5 and HY zeolite catalysts was conducted in a micro‐pyrolysis reactor coupled to a two‐dimensional gas chromatography system. Pyrolysis operating conditions, such as the pyrolysis temperature, the catalyst to feedstock (CF) ratio, and the LDPE:PET ratio, were varied. It was found that for the co‐pyrolysis of LDPE and PET, HZSM‐5 led to higher yields of C2‐C4 olefins and monoaromatic products. Lower CF ratios increased the yield of C2‐C4 olefins for LDPE pyrolysis, but decreased benzene yield for PET pyrolysis, concomitant with an increased yield in benzoic acid. A lower temperature of 400°C which was sufficient for the pyrolysis of LDPE, led to incomplete conversion of PET. Surface response diagrams were used to visualize the impact of the various pyrolysis operating conditions on the yield of C2‐C4 olefins and BTEX, which serve as target products for the circular economy.

Okonsky, Sean Timothy↗