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Conversion of LDPE waste into light olefins using a Cu/ZSM-5 catalyst
A new catalytic approach enables the direct conversion of low-density polyethylene (LDPE) waste into C2–C4 light olefins. A copper-modified ZSM-5 catalyst increases olefin yield to nearly 66 %, while minimising liquid by-products, wax and char formation.
Light olefins such as ethene, propene and butenes are essential petrochemical building blocks. Currently, more than half of global production relies on naphtha steam cracking – one of the most energy-intensive industrial processes. Catalytic cracking of plastic waste is being explored as a lower-carbon alternative, yet the technology is still in early development.
This study focuses on the single-step conversion of LDPE waste – the second largest plastic fraction in municipal solid waste – into C2–C4 olefins. The researchers employed ZSM-5 zeolite with different Si/Al ratios, analysing how acidity and textural properties affect product distribution. The influence of metal oxide promoters on catalytic activity was also examined.
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Increased gas fractions and improved olefin yields
In a two-stage semi-batch reactor operated at atmospheric pressure, the process achieved gas fractions of around 80 wt%, with approximately 60 wt% C2–C4 olefins. The copper-supported ZSM-5 catalyst further increased the light-olefin yield to about 65.9 % of the feed, while keeping liquid, wax and char formation very low. Optimal process temperatures ranged between 450 and 550 °C.
The findings suggest a promising pathway for converting plastic waste into high-value petrochemical feedstocks, reducing reliance on energy-intensive primary production routes.
Source: Raghav, H. et al., Conversion of waste plastic into low-carbon olefins: directly producing C2–C4 light olefins from low-density polyethylene waste using a Cu/ZSM-5 catalyst. Green Chemistry 47, 2025.
