Fe@C3N4 Photocatalyst for Plastic Waste-to-Acetic Acid Upcycling

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Solution Overview

Problem

Current methods for plastic waste recycling and upcycling are inefficient, energy-intensive, and environmentally harmful, failing to effectively convert plastic waste into value-added chemicals while producing CO2 emissions and toxic byproducts.

Innovation Solution

A one-step photocatalytic process using an Fe single-atom catalyst embedded on a graphitic carbon nitride (C3N4) support framework (Fe@C3N4 SAC) converts plastic waste into acetic acid through a cascade reaction mechanism, mimicking microbial degradation processes, without requiring pre-treatment or additional energy inputs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional recycling methods are used, then plastic waste can be processed, but the methods are inefficient and energy-intensive

Engineering Contradiction:

Improverecycling efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent replaces conventional mechanical and thermal recycling processes with a photocatalytic chemical system. The Fe@C3N4 SAC catalyst enables plastic degradation through photo-induced chemical reactions, substituting energy-intensive mechanical grinding and high-temperature processing with light-driven catalytic conversion that operates under milder conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the operational parameters from high-temperature and high-pressure conventional recycling to ambient temperature and pressure photocatalytic conditions. The Fe@C3N4 SAC catalyst enables the reaction to proceed efficiently under visible light irradiation at room temperature, dramatically reducing energy input requirements while maintaining high conversion efficiency.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional recycling methods are used, then plastic waste can be processed, but toxic byproducts and CO2 emissions are generated

Engineering Contradiction:

Improvewaste conversion efficiencyVSAvoidCO2 emissions and toxic byproducts

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful plastic waste into valuable acetic acid product through photocatalytic conversion. The Fe@C3N4 SAC catalyst facilitates selective transformation of plastic polymers into useful chemicals, turning an environmental hazard into an economic resource while avoiding CO2 emissions and toxic byproducts that characterize conventional incineration and recycling methods.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The Fe@C3N4 SAC catalyst acts as an intermediary that enables selective chemical transformation of plastic waste into acetic acid. This catalyst mediates the conversion process by providing active sites for photo-induced reactions, ensuring selective production of valuable chemicals rather than uncontrolled degradation that produces harmful emissions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If existing upcycling methods are used, then some value-added products can be produced, but metal leaching and sludge generation occur

Engineering Contradiction:

Improveacetic acid production yieldVSAvoidmetal leaching and sludge

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a stable, non-leaching Fe@C3N4 SAC catalyst that can be easily separated from the reaction mixture. The catalyst maintains structural integrity throughout the photocatalytic process, preventing metal dissolution into the product stream and eliminating the need for complex purification steps to remove metal contaminants, thus producing clean acetic acid without sludge generation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS20250297079A1Plastic waste upcycling using photocatalytic reactions

Publication Date: 2025.09.25 WU YIMIN A

AI summary

An example method of upcycling plastic waste includes: providing plastic waste to be upcycled; applying an iron (Fe) single-atom catalyst to the plastic waste to be upcycled; and catalyzing, using the Fe single-atom catalyst, a reaction to upcycle the plastic waste to produce acetic acid. The Fe single-atom catalyst may include Fe atoms embedded on a graphitic carbon nitride (C3N4) support framework (Fe@C3N4 SAC). The Fe@C3N4 SAC may operate using a cascade photocatalytic reaction mechanism coupling Fenton and CO2 reduction reactions.