Plastic to fuel conversion advances with new aluminium-based method

Oak Ridge National Laboratory researchers have developed a method to convert polyethylene plastic waste into fuel at temperatures below 200°C.

The process uses a molten salt solution containing aluminium chloride. It breaks down plastic into smaller molecules that can be used as fuel. Around 60 per cent of the output is similar to gasoline, making it suitable for transport and industrial use.

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This approach uses much lower temperatures than existing methods. Most conventional processes require 450 to 500°C. The lower temperature reduces energy use and may make the process easier to scale for industrial use.

The method focuses on polyethylene. This plastic is widely used in packaging, bags, and other everyday products. It is produced in large quantities and is commonly found in waste streams.

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The process does not require precious metal catalysts, organic solvents, or external hydrogen. The reaction takes place within the molten salt, where active sites help break long plastic chains into smaller compounds.

Zhenzhen Yang, one of the chemists, stated, “Unlike conventional methods for converting plastics into fuel, the new process required neither precious metal catalysts nor organic solvents or external hydrogen.”

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Researchers used techniques such as neutron scattering and spectroscopy to study the reaction. These methods helped track how the plastic breaks down during the process.

One challenge remains. The molten salt solution is sensitive to moisture. Water can affect the reaction and reduce efficiency. Researchers are working to improve stability so the process can be used at a larger scale.

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The study was published in the Journal of the American Chemical Society. It presents a potential way to use plastic waste as a raw material for fuel instead of sending it to landfills or incineration.