Electrochemical upcycling of mixed plastics with integrated metal recovery
This innovative electrochemical process upcycles multi-layer flexible packaging by converting polyolefin-rich polymers into valuable chemicals and recovering metals. The method uses tunable catalysts for efficient, low-energy processing, aligning with circular economy goals.
Overview
The electrochemical upcycling technology provides a unique solution for valorizing multi-layer flexible packaging. It converts polyolefin-rich polymers into high-value C1–C2 chemicals such as methane, formate, and acetate, while simultaneously recovering metals from inks and coatings. This process not only addresses the challenge of recycling complex packaging materials but also contributes to a circular economy by producing higher purity products under mild conditions, utilizing renewable electricity.
Technical specifications
The process involves mechanical grinding and chemical dissolution of waste, followed by electrochemical conversion using Ru/Pd/Pt catalysts. Key features include:
- High selectivity and efficiency: Tunable catalysts allow for flexible processing of different plastics and enhanced product purity.
- Simultaneous metal recovery: Metals from inks and coatings are electrodeposited and later released for reuse.
- Low-temperature operation: The method operates under mild conditions, reducing energy consumption and facilitating scalability.
- Applicable to diverse packaging: Efficiently processes multilayer films containing PE, PP, PET, and various inks or barrier layers.
Technology readiness level
The technology is at TRL 4, with proof of concept studies underway using a batch three electrode cell. Further validation will involve optimizing pretreatment, catalyst screening, and transitioning to a lab scale flow cell for continuous operation. This will establish operating parameters and design criteria for pilot scale development.
About University of Waterloo
University of Waterloo is a public research university in Ontario, Canada, known for an entrepreneurial, STEM‑driven culture. A globally recognized co‑op program places students with employers year‑round, creating direct talent pipelines and de‑risked pathways into sponsored research and contract development. An adjacent research and technology park hosts corporate R&D alongside faculty labs, and the campus sits within the Toronto–Waterloo innovation corridor for ready access to partners, investors, and scale‑up resources. Research is supported by competitive federal funding from Canada’s Tri‑Council agencies (NSERC, CIHR, SSHRC) and international programs. A creator‑owned IP policy and a dedicated tech transfer office enable flexible agreements, licensing, and spinouts.
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