Upcycling Real‐World Post‐Consumer Polyolefins Plastics Into Light Olefins Via Microwave‐Assisted Processing

ABSTRACT

The rapid accumulation of plastic waste, particularly post‐consumer polyolefins (POs), poses severe environmental and economic challenges worldwide. Recycling of post‐consumer POs remains inefficient due to difficulties in separating mixed plastics, complex additive compositions, and high processing costs, resulting in recycling rates of less than 9%. To address these critical issues, this study utilized an innovative microwave‐assisted catalytic upcycling approach for the efficient upcycling of complex post‐consumer POs mixtures into valuable light olefins. Using the microwave‐assisted catalytic upcycling approach, gas yields reached up to 80 wt.% from post‐consumer POs mixtures, accompanied by a high selectivity (> 70 wt.%) toward valuable light olefins. The upcycling of POs under microwave conditions is fully investigated, including additives in real‐world plastics, mixtures of different POs, reusability of catalyst, and more. Techno‐economic analysis (TEA) and life‐cycle assessment (LCA) further indicate that the process is economically viable, with a positive net present value (NPV) of +$81.67MM, and environmentally favorable, with a gate‐to‐gate greenhouse gas footprint of only 0.0468 kg CO ₂ eq/kg ethylene‐equivalent product, substantially lower than conventional steam cracking. The microwave‐assisted catalytic upcycling approach offers an efficient, scalable, and cost‐effective solution for upcycling post‐consumer plastic mixtures, thereby advancing the principles of a circular economy.