Leian
Bartolome
a,
Muhammad
Imran
b,
Kyoung G.
Lee
c,
Arvin
Sangalang
a,
Jeong Keun
Ahn
d and
Do Hyun
Kim
*a
aDepartment of Chemical & Biomolecular Engineering (BK21 Program), KAIST, 291 Daehak-ro, Yuseong-gu, Daejeon 305-701, Republic of Korea. E-mail: DoHyun.Kim@kaist.ac.kr; Fax: +82 42 350 3910; Tel: +82 42 350 3929
bChemical Engineering Department, King Saud University, Saudi Arabia
cDepartment of Chemical Engineering, University of Michigan, Ann Arbor, MI 48109-2136, USA
dDepartment of Microbiology, School of Bioscience & Biotechnology, Chungnam National University, Daejeon, 305-764, Republic of Korea
First published on 7th October 2013
There have been numerous studies to develop catalysts for the chemical recycling of poly(ethylene terephthalate) (PET) via glycolysis. However, in the field of PET glycolysis, only a few have attempted to recover and reuse the catalysts. This research utilized easily recoverable superparamagnetic γ-Fe2O3 nanoparticles as a reusable catalyst for PET glycolysis. γ-Fe2O3 nanoparticles were produced by calcining Fe3O4 nanoparticles prepared by the co-precipitation method. The produced γ-Fe2O3 nanoparticles had an average size of 10.5 ± 1.4 nm, and a very high surface area reaching 147 m2 g−1. Its superparamagnetic property was also confirmed. Glycolysis reactions were carried out, and the γ-Fe2O3 catalysts were recovered after the reactions by simple magnetic decantation. The use of magnetic iron oxide allowed the easy recovery of the catalyst from the glycolysis products. At 300 °C and a 0.05 catalyst/PET weight ratio, the maximum bis(2-hydroxyethlyl) terephthalate (BHET) monomer yield reached more than 90% in 60 min. At 255 °C and a 0.10 catalyst/PET weight ratio, the BHET yield reached more than 80% in 80 min. The catalyst was reused 10 times, giving almost the same BHET yield each time.
Various processes have been developed and utilized in PET chemical recycling. Among them, glycolysis is the most established and popular, because of its simplicity and low cost. In addition, glycolysis produces the monomer BHET, which can be used in both dimethyl terephthalate (DMT) and terephthalic acid (TPA) production lines to make virgin PET, or other advanced materials.2
Studies on the kinetics show that without catalysts, PET glycolysis is very slow, and complete conversion of PET to monomer BHET is almost impossible.3,4 Metal acetates were the first reported catalysts for PET glycolysis.5–8 Later, researchers developed more environment-friendly alternatives like mild alkalies,9,10 sulfates,10,11 metal chlorides,12 and zeolites.13 However, even with these aforementioned catalysts, the PET glycolysis still required long reaction times, and gave low BHET monomer yields. These catalysts could only increase the glycolysis rate at temperatures below the melting point of PET, and had no catalytic activity in melt-phase glycolysis due to mass transfer limitations.14 A list of all the studied catalysts for PET glycolysis can be found in previous work.15
Recently, our group has developed thermally stable and highly selective silica nanoparticle-supported metal (Mn, Zn, Ce) oxide16,17 and graphene oxide–manganese oxide18 catalysts for melt-phase PET glycolysis. Catalysts fabricated at nanoscale have increased catalytic efficiency, due to the increased number of active sites. In addition, the change of intrinsic properties of the catalysts at nanoscale usually leads to better catalytic performance.19 As a result, the metal oxide catalysts gave a higher monomer yield, exceeding 90%, at a shorter reaction time compared to the other previously studied catalysts.16
In spite of previous research efforts, there is still a problem as the toxic metals in these catalysts are harmful when released to the environment. The difficulty of separation of nanomaterials after the reaction makes the problem even more challenging. The failure to separate the catalyst from the glycolysis products not only poses environmental risks, but may also change the properties of the products. Thus, there has been a need to find a catalyst that is both efficient and easily recoverable.
There have been efforts recently to utilize recoverable catalysts for PET glycolysis, yet there are still issues that need to be addressed. Wang et al. have reported that various ionic liquid catalysts for PET glycolysis could be recovered, and then used repeatedly.20–22 In a separate study, Yue et al. used basic ionic liquids.23 These ionic liquid catalysts had less than 80% BHET yield, which is evidently lower than the yield from metal oxide catalysts.16–18 More recently, Wang et al. reported urea to be a reusable catalyst with good low-temperature catalytic activity for the glycolysis of PET.24 However, the catalyst was recovered using vacuum distillation, which is an energy intensive process. Thus, to date, the issues of catalyst efficiency and environmental sustainability have not yet been resolved simultaneously. Eco-friendly catalysts, such as mild alkalies and chlorides, show less efficiency compared to the not-so-eco-friendly ones (e.g. metal oxides) usually containing toxic metals.
In this paper, we present superparamagnetic γ-Fe2O3 nanoparticles as an efficient and environment-friendly catalyst for a sustainable PET chemical recycling. γ-Fe2O3 nanoparticles are easily recoverable and reusable. By recovering the catalyst, the danger of releasing harmful catalyst components to the environment is reduced. By reusing the catalyst, the process becomes more cost-effective and sustainable.
As a reusable catalyst, γ-Fe2O3 nanoparticles have shown good performance in a number of reactions.25–27 However, to the best of our knowledge, superparamagnetic γ-Fe2O3 nanoparticles have never been used in any glycolysis reactions, particularly in PET. In fact, to date, no magnetic nanomaterial has been applied as a recoverable and reusable solid catalyst in PET glycolysis. Among the magnetic materials, we selected nano-γ-Fe2O3, because of its stability, high catalytic activity and magnetic susceptibility.25 In addition, it is cheap, nontoxic, environment-friendly and abundant. Most importantly, due to its superparamagnetic property, it can be easily recovered by simple magnetic decantation.
The black Fe3O4 precipitate was then separated via magnetic decantation. It was washed with water, and centrifuged at 4000 rpm for 4 min. This was done four times. Finally, the precipitate was washed with 0.01 M HCl solution to neutralize the anionic charges on the surface of the nanoparticles.30 The obtained Fe3O4 precipitate was dried and then calcined at 210 °C for 3 hours to produce γ-Fe2O3.
The morphology of the produced nanoparticles was observed using a JEOL JEM-2100F 200 kV transmission electron microscope (TEM). Its specific surface area was estimated using the N2 adsorption isotherm obtained by a Micrometrics ASAP 2020 BET surface area and porosimetry analyzer. To evaluate the crystallinity of the material, X-ray diffraction (XRD) spectra with 2θ ranging from 10° to 80° were obtained using a RIGAKU D/MAX-2500(18 kW) Micro-Area X-ray Diffractometer. X-ray photoelectron spectroscopy (XPS) measurements were carried out using a Thermo VG Scientific Sigma Probe Multi Purpose X-Ray Photoelectron Spectrometer. To confirm its superparamagnetic nature, a Lakeshore EM4-HVA Vibrating Sample Magnetometer (VSM) was used to obtain the magnetization curve of the nanoparticles. A thermogravimetric curve was obtained using a NETCH TG209F3 Thermogravimetric Analyzer (TGA). Temperature profile desorption with NH3 as a molecular probe (NH3-TPD) was also done to investigate the acidity of the produced material.
The performance of γ-Fe2O3 was also compared with urea. The glycolysis reactions were carried out at 255 °C, with a 0.1 catalyst/PET weight ratio.
The BHET monomer yield was measured with Agilent 1000 series Reverse Phase High Performance Liquid Chromatography (HPLC). The use of HPLC for the qualitative and quantitative analysis of the BHET monomer was discussed in detail in previous work.28 After quenching the reaction, the glycolysis product was dissolved in 20 mL THF. From this solution, the catalysts were recovered via magnetic decantation and reused. For the HPLC sample, 0.1 mL was taken out from the solution and diluted to 24 mL 50/50 (v/v) THF–H2O solution. This solution was used in the HPLC analysis. The UV detector was set to 254 nm, and the flow rate of the mobile phase was set to 1.0 mL min−1. The mobile phase used was 50/50 (v/v) THF–H2O solution. The BHET monomer yield was calculated using the equation:
BHET from the glycolysis product was also recovered for further characterization. After the catalyst was recovered, the solution was kept at 90 °C for 45 min under vigorous stirring. The PET residual was separated from the mixture through filtration. When the resulting filtrate reached 60 °C, it was re-filtered to remove the dimers from the BHET monomers. The resulting filtrate from the second filtration was refrigerated for 24 h, and then filtered to recover the monomer BHET. The recovered BHET crystals were dried, and characterized by Nuclear Magnetic Resonance Spectroscopy (NMR).
Fig. 1 TEM images of (a, b) pristine and (c, d) used γ-Fe2O3, and (e) the TEM histogram for the pristine catalyst. |
Due to the small size of the γ-Fe2O3 nanoparticles produced, it exhibited superparamagnetism, as confirmed by the magnetization curve from the VSM. It can be seen in Fig. 2 that when magnetic field was applied, the material showed a strong response, and the saturation magnetization reached 47 emu g−1. More importantly, the curve did not have any hysteresis loop, a unique property of superparamagnetic materials. The absence of hysteresis loop implies that the catalyst will re-disperse when used again in the subsequent reactions.
The XRD pattern in Fig. 3a shows sharp peaks, with major peaks at (311) and (440), indicating good crystallinity of the obtained product. The peaks in the XRD pattern coincided with those of standard γ-Fe2O3 (JCPDS 39-1346, space group P4132). The XRD pattern suggests that the material is γ-Fe2O3. However, since Fe3O4 and γ-Fe2O3 have the same crystalline structure, they give the same XRD pattern. Hence, further analysis was done to confirm the nature of the material. The confirmation of the transformation of Fe3O4 during the calcinations to γ-Fe2O3 is important, since Fe3O4 is unstable at high temperatures, and may affect the glycolysis reaction; starting at 200 °C, Fe3O4 transforms to γ-Fe2O3, and at 375 °C, γ-Fe2O3 begins to transform to α-Fe2O3.33
The unstable nature of Fe3O4 was also one of the reasons why γ-Fe2O3 was used as a catalyst instead of Fe3O4. To confirm that the produced nanoparticles after calcination were indeed γ-Fe2O3 and not Fe3O4, XPS was done. The Fe2p XPS patterns of the material before and after calcinations are presented in Fig. 4. Before calcination, the Fe2p3/2 and Fe2p1/2 were located at approximately 711.6 eV and 724.8 eV, respectively. After calcination, they were located at approximately 710.9 eV and 724.2 eV, respectively. The set of higher binding energies before calcination (Fig. 4a) is a characteristic of Fe3O4. The shift to relatively lower binding energies after the calcination implies the transformation from Fe3O4 to γ-Fe2O3. Additionally, the satellite peak at approximately 720 eV in Fig. 4b is characteristic of γ-Fe2O3.34 Thus, the Fe3O4 nanoparticles produced from the precipitation method did transform to γ-Fe2O3 during calcination.
The thermal stability of the catalyst is also essential in melt-phase glycolysis, because it affects catalyst performance and reusablity. The thermo-gravimetric curve in Fig. 5 shows only one stage of weight loss. The drop in weight below 200 °C is a result of the evaporation of the adsorbed water from the surface. Aside from this, there were no other transformations observed, indicating that the material did not degrade, and maintained its oxidation state at temperatures up to 800 °C. Thus, the thermal stability of the catalyst was confirmed. Although transformation from γ-Fe2O3 to α-Fe2O3 is also possible, it did not occur during the reactions as confirmed by the XRD spectrum of the used catalyst shown in Fig. 3b–3e.
The acidity of the γ-Fe2O3 catalyst was evaluated using NH3-TPD analysis, where NH3 is adsorbed on the surface of the material at low temperature, and desorbed at higher temperature. The temperature at which NH3 desorbs depends on the strength of the acid sites in the material.37 The TPD profile in Fig. 6 shows three distinct peaks. By deconvolution, the peaks were determined to be at 177.0, 282.0, and 384.8 °C. The peak at 177.0 °C corresponds to weak acid sites, while the intense peaks at 282.0 °C and 306.0 °C correspond to high concentrations of medium strength acid sites. Thus, the γ-Fe2O3 nanoparticles act predominantly as a mildly acidic catalyst. From this, the glycolysis reaction mechanism for PET glycolysis with γ-Fe2O3 acting as an acidic catalyst may be postulated (Fig. 7). The carbonyl group of the polyester is more vulnerable to attack by any foreign species. The metal (Fe+3) interacts with the oxygen of the carbonyl group and drags more electrons towards itself, creating highly partial positive charge on the carbon. A free lone pair on the EG oxygen then attacks the carbonyl carbon of the ester group of the polyester, resulting in the formation of C–O bond with the oxygen of the EG while breaking the C–O bond of the polyester. In this way, the longer PET chains break down to shorter chain oligomers, dimers, and finally to monomer BHET.36 The transformation of dimers to BHET monomers is a reversible process. Longer reaction after the equilibration of the two is attained will cause the reaction to shift backwards, increasing the amount of dimers and oligomers at the expense of the BHET monomer.30 It is thus important to determine the optimum reaction time for the glycolysis reaction.
Fig. 10 BHET yield with time for glycolysis with γ-Fe2O3 and various silica nanoparticle-supported metal oxides16,17 at a 0.01 catalyst/PET weight ratio and 300 °C. |
It is also observed from Fig. 9 that for the reactions with different amounts of catalyst, maximum BHET yield was reached at different times. The possibility of the catalyst's easy recovery and reuse allowed the use of a higher amount of catalyst. As a result, the higher catalyst/PET weight ratio permitted the reaction to reach equilibrium earlier. The glycolysis reaction with a 0.05 catalyst/PET weight ratio only required 60 min to achieve BHET yield greater than 90%. The shorter reaction time translates to a more energy-efficient and cost-effective process compared to the other metal oxide nanocatalysts studied.
We also evaluated the performance of γ-Fe2O3 at milder temperature, and compared its performance with that of another recently reported recyclable catalyst, urea (Fig. 11). It is apparent that γ-Fe2O3 increased the glycolysis reaction rate. At 255 °C, the γ-Fe2O3-catalyzed reaction gave >80% BHET yield in only 80 min. It also showed better performance compared to urea, which attained the maximum BHET yield in 120 min. Thus, Fe2O3 is effective even at mild temperatures.
Fig. 11 BHET yield with time for non-catalyzed, γ-Fe2O3 catalyzed, and urea-catalyzed glycolysis at 255 °C, and a 0.1 catalyst/PET weight ratio. |
For industrial applications, the catalyst should be easily separated from the product mixture. The superparamagnetic property of γ-Fe2O3 nanoparticles provides a unique condition to serve as a catalyst for PET glycolysis as well as easy separation from the product using a magnet. The separation process does not require any energy-intensive or complicated separation method. The average amounts of recovered catalysts are presented in Table 1. There is a minimal amount of lost catalyst with increased amounts of catalyst used. Since the 15 mg catalyst delivered the highest glycolysis and recovery rate, this amount was used for the evaluation of the reusability of the catalyst. Each time the catalyst was reused, the yield was almost the same (Fig. 12), without any significant drop. Statistical analysis using analysis of variance (ANOVA) at 99.9% confidence level showed that the number of times the catalyst was reused did not significantly affect the BHET monomer yield (see Table S1†). This result confirmed the reusability of the catalyst, which may be attributed to its stability, as evidenced by the TGA (Fig. 5), and the XRD spectra of the used catalyst in Fig. 3b. Thus, the repeated use of the γ-Fe2O3 catalyst for PET glycolysis at high temperature does not affect its performance as a catalyst.
Catalyst/PET weight ratio | Amount of catalyst (g) | Amount of recovered catalyst (g) | Amount of lost catalyst (g) | % Recovery |
---|---|---|---|---|
0.01 | 3 | 2.6 | 0.4 | 87 |
0.015 | 4.5 | 4.1 | 0.4 | 91 |
0.02 | 6 | 5.2 | 0.8 | 87 |
0.05 | 15 | 14.1 | 0.9 | 94 |
Footnote |
† Electronic supplementary information (ESI) available: ANOVA for BHET yield, 13C and 1H NMR spectra of the BHET obtained from the glycolysis reaction. See DOI: 10.1039/c3gc41834k |
This journal is © The Royal Society of Chemistry 2014 |