Transforming polypropylene waste into transparent anti-corrosion weather-resistant and anti-bacterial superhydrophobic films.

The global pollution crisis arising from the accumulation of plastic in landfills and the environment necessitates addressing plastic waste issues. Notably, polypropylene (PP) waste accounts for 20% of total plastic waste and holds promise for hydrophobic applications in the realm of recycling. Herein, the transparent and non-transparent superhydrophobic films made from waste PP are reported. A hierarchical structure with protrusions is induced through spin-casting and thermally induced phase separation. The films had a water contact angle of 159° and could vary in thickness, strength, roughness, and hydrophobicity depending on end-user requirements. The Bode plot indicated enhanced corrosion resistance in the superhydrophobic films. Antibacterial trials with Escherichia coli and Staphylococcus aureus microbial solutions showed that the superhydrophobic film had a significantly lower rate of colony-forming units compared to both the transparent surface and the control blank sample. Moreover, a life cycle assessment revealed that the film production resulted in a 62% lower embodied energy and 34% lower carbon footprint compared to virgin PP pellets sourced from petroleum. These films exhibit distinctiveness with their dual functionality as coatings and freestanding films. Unlike conventional coatings that require chemical application onto the substrate, these films can be mechanically applied using adhesive tapes on a variety of surfaces. Overall, the effective recycling of waste PP into versatile superhydrophobic films not only reduces environmental impact but also paves the way for a more sustainable and eco-friendly future.

Sustainable Solution for Plastic Pollution: Upcycling Waste Polypropylene Masks for Effective Oil-Spill Management.

The use of Polypropylene PP in disposable items such as face masks, gloves, and personal protective equipment has increased exponentially during and after the COVID-19 pandemic, contributing significantly to microplastics and nanoplastics in the environment. Upcycling of waste PP provides a useful alternative to traditional thermal and mechanical recycling techniques. It transforms waste PP into useful products, minimizing its impact on the environment. Herein, we synthesized an oil-sorbent pouch using waste PP, which comprises superposed microporous and fibrous thin films of PP using spin coating. The pouch exhibited super-fast uptake kinetics and reached its saturation in fewer than five minutes with a high oil uptake value of 85 g/g. Moreover, it displayed high reusability and was found to be effective in absorbing oil up to seven times when mechanically squeezed between each cycle, demonstrating robust oil-sorption capabilities. This approach offers a potential solution for managing plastic waste while promoting a circular economy.

Designing super-fast trimodal sponges using recycled polypropylene for organics cleanup.

Sorbent pads and films have been commonly used for environmental remediation purposes, but designing their internal structure to optimize access to the entire volume while ensuring cost-effectiveness, ease of fabrication, sufficient strength, and reusability remains challenging. Herein, we report a trimodal sorbent film from recycled polypropylene (PP) with micropores, macro-voids, and sponge-like 3D cavities, developed through selective dissolution, thermally induced phase separation, and annealing. The sorbent has hundreds of cavities per cm2 that are capable of swelling up to twenty-five times its thickness, allowing for super-fast saturation kinetics (within 30 s) and maximum oil sorption (97 g/g). The sorption mechanism follows a pseudo-second-order kinetic model. Moreover, the sorbent is easily compressible, and its structure is retained during oil sorption, desorption, and resorption, resulting in 96.5% reuse efficiency. The oil recovery process involves manually squeezing the film, making the cleanup process efficient with no chemical treatment required. The sorbent film possesses high porosity for effective sorption with sufficient tensile strength for practical applications. Our integrated technique results in a strengthened porous polymeric structure that can be tailored according to end-use applications. This study provides a sustainable solution for waste management that offers versatility in its functionality.

Non-Wettable Microporous Sheets Using Mixed Polyolefin Waste for Oil-Water Separation.

Mixed polyolefin-based waste needs urgent attention to mitigate its negative impact on the environment. The separation of these plastics requires energy-intensive processes due to their similar densities. Additionally, these materials cannot be blended without compatibilizers, as they are inherently incompatible and immiscible. Herein, non-wettable microporous sheets from recycled polyethylene (PE) and polypropylene (PP) are presented. The methodology involves the application of phase separation and spin-casting techniques to obtain a bimodal porous structure, facilitating efficient oil-water separation. The resulting sheets have an immediate and equilibrium sorption uptake of 100 and 55 g/g, respectively, due to the presence of micro- and macro-pores, as revealed by SEM. Moreover, sheets possess enhanced crystallinity, as evidenced by XRD; hence, they retain their structure during sorption and desorption and are reusable with 98% efficiency. The anti-wetting properties of the sheets are enhanced by applying a silane coating, ensuring waterless sorption and a contact angle of 140°. These results highlight the importance of implementing sustainable solutions to recycle plastics and mitigate the oil spill problem.

Up-cycling plastic waste into swellable super-sorbents.

Environmental pollution caused by plastic waste and oil spills has emerged as a major concern in recent years. Consequently, there has been a growing interest in exploring innovative solutions to address these challenges. Herein, we report a method to upcycle polyolefins-based plastic waste by converting it into a bimodal super-oleophilic sorbent using dissolution, spin-coating, and annealing techniques. The resulting sorbent possesses an extensive network of pores and cavities with a size range from 0.5 to 5 µm and 150-200 µm, respectively, with an average of 600 cavities per cm2. Each cavity can swell up to twenty times the thickness of the sorbent, exhibiting sponge-like behavior. The sorbent had an oil uptake capacity of 70-140 g/g, depending on the type of sorbate and dripping time. Moreover, the sorbent can be mechanically or manually squeezed to recover the sorbed oil. Our integrated methodology provides a promising approach to upcycling plastic waste as an abundant source of value-added materials.

3D Oleophilic Sorbent Films Based on Recycled Low-Density Polyethylene.

Recycling low-end, one-time-use plastics-such as low-density polyethylene (LDPE)-is of paramount importance to combat plastic pollution and promote sustainability in the modern green economy. This study valorizes LDPE waste by transforming it into 3D oleophilic swellable thin films through a process involving dissolution, phase separation, and extraction. These films are subsequently layered using a customized polypropylene (PP) based nonwoven fabric separator and securely sealed in a zigzag pattern. The zigzag-shaped seal enhances the adhesion of pollutants to the sorbent by providing wire curvatures that increase retention time and uptake capacity. As a result, the sorbent exhibits impressive oil uptake capacities, with immediate and equilibrium values of 120 g/g and 85 g/g, respectively. Notably, the as-prepared sorbent demonstrates low water retention and high selectivity for oil, outperforming commercially available oil sorbents. The unique design involving a 3D-film structure, superposed films, and a zigzag-shaped seal offers a sustainable and value-added solution to the issues of LDPE waste and oil spills on water surfaces.