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<p>Converting plastic waste into jet fuel could support the decarbonization of the aviation industry, yet current upcycling routes rely on high pressures (~3 MPa) and prolonged reaction times (up to 144 h). Here we report a tandem hydropyrolysis and vapour-phase hydrogenation strategy enabled by a single-atom Ru catalyst on Co-Al oxides (Ru<sub>SA</sub>@CoAlO<sub><i>x</i></sub>). The catalyst achieves a turnover frequency of 144 s<sup>−1</sup> for benzene hydrogenation at atmospheric pressure, exceeding that of commercial Ru/C by over 100-fold. In a tandem fixed-bed reactor with hydropyrolysis at 460 °C and downstream vapour-phase hydrogenation at 160 °C, polystyrene is converted to 94.8 wt% cycloalkanes at 0.15 MPa and to 59 wt% cycloalkanes at atmospheric pressure. The approach extends to mixed plastics, achieving jet-fuel-range hydrocarbon yields above 82 wt%. The catalyst remains stable for over 110 h during continuous vapour-phase hydrogenation. Life-cycle analysis indicates a 73% reduction in well-to-pump CO<sub>2</sub> emissions relative to petroleum-based jet fuel, and techno-economic analysis suggests a competitive minimum selling price of US$1.0–1.8 per kg.</p>

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Ambient-pressure conversion of plastic waste to jet fuel cycloalkanes by tandem hydropyrolysis and vapour-phase hydrogenation

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Jia Wang,
  • Zedong Zhang,
  • Shule Wang,
  • Ya-Fei Jiang,
  • He Zhou,
  • Wenhui Zhong,
  • Yiyun Zhang,
  • Dongxian Li,
  • Wenjun Zhong,
  • Shiyao Li,
  • Daniel L. Sanchez,
  • Dingsheng Wang,
  • Jun Li,
  • Jianchun Jiang,
  • Yadong Li

摘要

Converting plastic waste into jet fuel could support the decarbonization of the aviation industry, yet current upcycling routes rely on high pressures (~3 MPa) and prolonged reaction times (up to 144 h). Here we report a tandem hydropyrolysis and vapour-phase hydrogenation strategy enabled by a single-atom Ru catalyst on Co-Al oxides (RuSA@CoAlOx). The catalyst achieves a turnover frequency of 144 s−1 for benzene hydrogenation at atmospheric pressure, exceeding that of commercial Ru/C by over 100-fold. In a tandem fixed-bed reactor with hydropyrolysis at 460 °C and downstream vapour-phase hydrogenation at 160 °C, polystyrene is converted to 94.8 wt% cycloalkanes at 0.15 MPa and to 59 wt% cycloalkanes at atmospheric pressure. The approach extends to mixed plastics, achieving jet-fuel-range hydrocarbon yields above 82 wt%. The catalyst remains stable for over 110 h during continuous vapour-phase hydrogenation. Life-cycle analysis indicates a 73% reduction in well-to-pump CO2 emissions relative to petroleum-based jet fuel, and techno-economic analysis suggests a competitive minimum selling price of US$1.0–1.8 per kg.