In a major advancement for waste management, researchers at the University of Delaware have developed a novel catalyst that accelerates the conversion of plastic waste into liquid fuels, as detailed in a September 22, 2025, study published in Chem Catalysis. Led by chemical engineer Dongxia Liu, the team used MXene-based catalysts to enhance hydrogenolysis, breaking down plastics like polyethylene and polypropylene into hydrocarbons at lower temperatures and with fewer byproducts than traditional methods. This pilot-stage technology achieves up to 90% yield in converting mixed plastics into diesel-like fuels, reducing energy use by 30% and minimizing environmental impact, per the study’s findings.
The technique employs two-dimensional MXene materials, layered transition metal carbides/nitrides, which provide high surface area and catalytic activity for selective hydrogenolysis. Unlike conventional pyrolysis, which requires high heat (500–600°C) and produces char and gases, this method operates at 250–350°C, yielding clean liquid fuels with over 80% selectivity for gasoline-range hydrocarbons. The process handles real-world mixed waste, including food packaging and bottles, without pre-sorting, making it scalable for industrial use. Funded by the U.S. Department of Energy’s Center for Plastics Innovation, the innovation addresses the 400 million tons of annual global plastic production, of which only 9% is recycled, per UNEP data.
This breakthrough could transform waste management and energy sectors, diverting plastics from landfills and oceans while producing sustainable fuels equivalent to 1.5 million barrels of oil daily from U.S. waste alone, per EPA estimates. Industries like aviation and shipping, seeking net-zero goals, stand to benefit, with potential integration into biofuel blends. Economically, it could create $100B in new markets by 2030, reducing reliance on fossil fuels and cutting CO2 emissions by 20% in fuel production. Collaborations with firms like ExxonMobil are exploring commercialization, per Liu’s team.
Despite promise, scaling remains a hurdle: catalysts degrade after 50 cycles, requiring cost-effective regeneration, and initial setup costs exceed $50M for pilot plants. Regulatory approval for fuel standards (e.g., ASTM D7566) and public acceptance of “recycled” fuels pose additional barriers. Researchers plan lab-to-factory trials by 2026, with DOE funding supporting lifecycle assessments. Globally, similar efforts in China and India could amplify impact, but policy incentives like carbon credits are essential for adoption.
