New Microwave-based Method Upcycles Plastic Waste into CNTs and Clean Hydrogen

Plastic is integrated into our modern life, but 90% of it isn't being recycled and most plastic is incapable of being recycled with today's solutions. In fact, half of all plastic that has ever existed was made in just the last 15 years. By 2050, the world will have exceeded crisis levels without a way to mitigate plastic waste.

NETL and Cecilia Energy have already been working on such a solution.

NETL and Cecilia Energy are developing such a solution. Since 2021, they have worked on a scalable microwave-based (MW) process. This process upcycles plastic waste into clean hydrogen and carbon nanotubes, turning environmental waste into valuable assets.

Carbon nanotubes have many applications, including nanotechnology, automotive parts, electrical circuitry, supercapacitors, solar panels, LEDs, sensors, transistors, fuel cells, batteries, absorbents, catalysts, and storage devices. Hydrogen is a crucial feedstock for decarbonizing the American industrial and energy sectors.

'While much of the focus of the scientific community has rightfully been on addressing the effects of climate change, plastic waste is another environmental priority,' said Christina Wildfire, research scientist for NETL. 'With this application of microwave technology, we have a way to solve two problems at once.'

The initial research was conducted at NETL's Morgantown facility. NETL has used microwaves for electrification and process intensification in many conversion processes. The team applied their waste gasification experience to develop this novel process for mixed plastic waste. Microwaves provide selective heating, efficiently converting plastic to hydrogen and reducing hydrocarbon side products. The process also produces no carbon dioxide, cutting greenhouse gas emissions.

Assembling Pilot Reactor Capable of Processing 5 Kgs of Plastic Per Day

In 2022, after a successful co-invention, Cecilia extracted the technology IP from the U.S. Department of Energy. Cecilia then began commercializing and scaling the technology. They have built a dedicated team for this purpose.

'We are addressing the endgame for plastic waste by commercializing a modular, distributable, microwave-based system that upcycles plastic waste into clean hydrogen and carbon nanotubes,' said Kathryn Carpenter of Cecilia Energy. 'Our electricity-powered microwave reactor can operate entirely on renewable grid power, transforming plastic waste into valuable performance carbon.'

Cecilia Energy is now on its seventh generation of the custom MW reactor. They are assembling a pilot reactor capable of processing five kilograms of waste plastic per day at their Newark laboratory.

'What is unique about this CRADA is that our two organizations worked together from the start to develop this IP, versus taking off-the-shelf IP from the national lab to then commercialize,' Carpenter said. 'It goes to show what can be achieved when the best minds from private companies and DOE's national labs work together from scratch toward a common goal.'

NETL is a U.S. Department of Energy national laboratory that drives innovation and delivers solutions for an environmentally sustainable and prosperous energy future. By leveraging its talent and research facilities, NETL ensures affordable, abundant, and reliable energy. It also develops technologies to manage carbon across the full life cycle, ensuring environmental sustainability for all Americans.

Source: NETL