Researchers Develop Scalable Way To Turn Common Plastics Into Single‑Atom Catalysts

Researchers at the University of Adelaide report a scalable method to upcycle common plastic waste into single‑atom catalysts—metal atoms isolated and anchored on graphene—offering a promising route to turn low‑value plastics into high‑value materials.

The study, published in Nature Communications, addresses a long‑standing obstacle: mass loss during thermal conversion of polymers. When plastics decompose, volatile small molecules typically evaporate, reducing the solid yield and limiting large‑scale application of plastic‑to‑carbon processes.

To avoid that loss, the team developed a universal approach that uses metal chloride salts as both structural templates and graphitization catalysts during the plastic‑to‑carbon transformation. The conversion is carried out in an ammonia atmosphere, which promotes spontaneous nitrogen doping of the carbon matrix and helps retain mass and structure.

Before demonstrating applications, the researchers probed the atomic structure of the resulting materials. Using ANSTO’s Australian Synchrotron and X‑ray absorption spectroscopy (XAS), they showed that the metal species exist as truly isolated single atoms dispersed on a graphene substrate rather than aggregated nanoparticles—an important distinction because single‑atom sites often deliver superior catalytic activity and selectivity.

Performance and Potential Applications

Single‑atom catalysts derived from plastic feedstocks exhibited strong activity for degrading micropollutants in water and improved reaction performance in energy‑storage contexts. The paper reports enhanced activity for reactions relevant to lithium–sulfur (Li‑S) battery systems, including nitrogen‑reduction‑type processes that are important for battery chemistry and efficiency.

Although the laboratory results are promising and the method is designed for scalability, the authors caution that broad adoption by the recycling and materials industries will depend on further optimization, cost analyses, and demonstration at pilot and industrial scales.

“This project highlights how advanced characterization at the Synchrotron enables breakthroughs in sustainability,” said co‑author and senior scientist Dr. Bernt Johannessen, as reported by AZO Materials. He added that XAS is “a uniquely powerful tool” for distinguishing nanoparticles from genuine single‑atom sites and that demand for these measurements is growing worldwide.

Overall, the work suggests a pathway to transform carbon‑rich plastic waste—including common polymers such as polyvinyl chloride, polystyrene, and polyethylene—into valuable catalysts that can help address water pollution and support cleaner energy technologies.