Acrylic glass recycled to pure monomers at 200°C, in the lab

Acrylic glass, the transparent polymer used in windowpanes, car taillights and furniture, is well suited to recycling, yet much of it still ends up as waste. At ETH Zurich, materials scientist Athina Anastasaki and her team have now reported a lab method that turns it back into its raw material with a yield of up to 98%, at a temperature of just over 200°C.

The key step is depolymerization, the breaking of a polymer's long chains back into their monomers, the small molecules that serve as building blocks. Anastasaki's group had shown earlier that this was possible in principle, but only under specific conditions: the polymer chains had to be chemically altered to add weak points, or large amounts of solvents, catalysts or UV light were needed. Another chemical recycling route, pyrolysis, works above 400°C and often leaves the recovered monomers with impurities of up to 3%, which can degrade the quality of the new plastic made from them.

The new approach relies on a single substance from the class of N-hydroxyimides. Richard Whitfield, lead author of the study in Nature Chemistry and a former research associate in Anastasaki's group, describes the search that led to it: the team tested candidates systematically until it found this one. Once it is added, the reagent attacks the chains and the reaction proceeds without further intervention. Anastasaki says the team was surprised that one compound was enough. The work was carried out with ETH chemistry professors Tae-Lim Choi and Gunnar Jeschke, whose input she described as essential.

For companies, the most concrete change is in the equipment. Anastasaki explains that earlier methods would have required firms to modify their processes and plants, a cost she judges too high for most of them. The new method, according to the researchers, could run on existing infrastructure with standard processes. ETH Zurich has filed a patent application and is now looking for licensees, and the chemical industry has shown interest. No date for an industrial rollout has been announced: the next steps are scaling up and mapping the reaction in detail.

The limits are clear. The method works on acrylic glass only, and other plastics need other approaches. Anastasaki says her group will try to apply the same principle to polystyrene, one of the most widely used plastics in the world, but that is an intention, not a result. For now, the figures come from laboratory experiments, and they will have to be reproduced at larger scale before anyone can judge what the process would cost and yield in a plant.