Efficient conversion of polyethylene to light olefins by self-confined cracking and reforming

Zhongwen Dong, Bo Peng, Nantian Xiao, Wenjun Chen, Tingyu Lei, Meng Wang, Cheng Li, Rongxin Zhang, Zhengxing Qin, Xingchen Liu (), Xiaodong Wen, Mingfeng Li (), Ding Ma () and Fan Zhang ()
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Zhongwen Dong: Sichuan University
Bo Peng: SINOPEC Research Institute of Petroleum Processing Co. Ltd
Nantian Xiao: Sichuan University
Wenjun Chen: Sichuan University
Tingyu Lei: Chinese Academy of Sciences
Meng Wang: Peking University
Cheng Li: Sichuan University
Rongxin Zhang: SINOPEC Research Institute of Petroleum Processing Co. Ltd
Zhengxing Qin: China University of Petroleum (East China)
Xingchen Liu: Chinese Academy of Sciences
Xiaodong Wen: Chinese Academy of Sciences
Mingfeng Li: SINOPEC Research Institute of Petroleum Processing Co. Ltd
Ding Ma: Peking University
Fan Zhang: Sichuan University

Nature Communications, 2025, vol. 16, issue 1, 1-11

Abstract: Abstract The production of light olefins from polyethylene (PE) has significant industrial potential. Zeolites have been widely used in petroleum refining for their ability to cleave C–C/C–H bonds and facilitate light olefins selectivity, thanks to their adjustable acidity and pore structure. However, the interaction between zeolites and conventional hydrocarbons or polymer reactants is quite different, a distinction frequently overlooked but has great influence on their reaction. Based on this, we describe a PE self-confined cracking mechanism that can produce C3-C8 olefins with exceptional yields, surpassing 70% under mild conditions (300 °C). Interestingly, the product distribution is only dependent on the degree of self-confinement and melt mass-flow rate (MFR) of PE, regardless of the porous structure, metal content, and internal acid properties of zeolite. Most importantly, this process allows for flexible tandem catalytic reforming to yield more than 67% C2–C4 light olefins and 23% separable BTX, demonstrating great potential to promote chemical recycling of waste polyolefin plastics.

Date: 2025
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DOI: 10.1038/s41467-025-63116-8

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