The accumulation of plastic waste in oceans, soils, and even inside living beings is one of the planet’s most pressing pollution challenges. Billions of tonnes have been cast aside in natural environments, both marine and terrestrial. Despite strong recycling efforts, recovering this heterogeneous mix of materials remains difficult. Researchers in the United States have now identified a potentially more effective route to reuse plastic waste.
One major hurdle is the variety of plastics in today’s waste streams. Recycling processes tend to be highly specialized for each plastic type. Sorting streams that include soda bottles, detergent containers, and plastic toys is laborious and impractical at scale. As a result, much of the plastic collected by recycling programs still ends up in landfills around the world.
Propane as a Unified Recycling Product
New findings from a collaboration among the Massachusetts Institute of Technology and other institutions point to a more efficient recycling approach. A cobalt-based catalyst has demonstrated the ability to separate diverse plastics into a single end product: propane. This method targets common plastics such as polyethylene terephthalate (PET) and polypropylene (PP), among others, converting their long-chain molecules into a usable propane stream.
Propane can then serve as fuel for stoves, heaters, and vehicles, or as a synthetic feedstock for a broad array of products, including new plastics that could support a partially closed-loop recycling system. The process promises a simpler downstream path, potentially reducing the number of purification steps needed to recover useful materials.
The simplicity and potential low cost of this approach have drawn attention as an option for improving plastic waste management. The concept envisions a future where a single hydrocarbon product drives multiple reuse possibilities instead of fragmenting waste into many disparate streams.
The open-access research describes a catalytic system that brings together a zeolite’s microporous structure with cobalt nanoparticles. Researchers found that the zeolite’s pores can accommodate polymer chains, and the cobalt–acid sites cooperate to cleave carbon bonds at a precise point. The result is a high yield of propane with minimized formation of unwanted byproducts, like methane, leaving the remaining hydrocarbon fragments ready for reprocessing.
“When you have propane as the end product, the downstream separation burden is reduced,” explains the lead researcher. “We’re not just breaking bonds; we’re creating a single, versatile product that can feed a range of industries.” This broad applicability makes propane a compelling intermediate for many Canadian, American, and international recycling programs seeking more efficient material recovery.
The materials required for the process—zeolites and cobalt—are relatively affordable and widely available. Today, most cobalt is sourced from regions with political or economic instability. The research notes that production capacity is expanding in multiple countries, including North America. Hydrogen, used in the process, can be produced from fossil fuels or via carbon-free methods such as water electrolysis powered by solar or wind energy, aligning with markets pursuing cleaner energy futures.
Real-World Testing and Ongoing Evaluation
Researchers tested the system with a real, mixed sample of recycled plastics and reported promising results. More extensive testing is needed across a broader spectrum of waste streams to understand how contaminants like inks, adhesives, and labels affect long-term performance and stability. Collaboration with national laboratories and energy research centers continues to evaluate the economics and integration potential within existing waste-management infrastructures.
The team emphasizes that the full picture is still evolving. Early analyses suggest the concept could complement current plastics recycling efforts by simplifying product streams and enabling a more consistent end market for recycled materials.
The work involved researchers from multiple leading institutions and national laboratories, supported by energy and science funding bodies. The collaboration reflects ongoing interest in turning plastic waste into valuable resources while reducing pressure on landfills and the environment. This line of inquiry sits at the intersection of materials science, chemistry, and sustainable energy, illustrating how cross-disciplinary innovation can reshape waste handling in North America and beyond.
The overarching goal is clear: improve the efficiency and economic viability of plastic recycling so it serves as a practical, scalable solution rather than a costly, fragmented process. As researchers push forward, it remains essential to monitor environmental implications, regulatory frameworks, and market demand to ensure that any new method truly benefits communities across the United States and Canada.
References and further reading are drawn from peer-reviewed journals and publicly accessible summaries of large-scale materials research programs, with ongoing updates shared through the scientific community and energy research networks.