Researchers have developed a one-pot synthesis method for hierarchical ZSM-5 catalysts that significantly extends their lifetime during microwave-assisted catalytic pyrolysis of plastic waste. The study, published in Sustainable Carbon Materials, shows that tuning crystallization temperature between 120 and 220 degrees Celsius controls pore structure and acidity. The best catalyst maintained gasoline-range yields above 70% for nearly 7 hours, compared to just over 2 hours for denser variants. This offers a practical, scalable route to turn plastic waste into higher-quality liquid fuels without frequent catalyst replacement. The work addresses a key bottleneck in plastic valorization: catalyst deactivation from coke buildup. By creating hierarchical ZSM-5 with both micropores and mesopores, the researchers improved molecular transport and delayed pore clogging. The one-pot synthesis method is simpler than multi-step alternatives, which could lower production costs. For anyone tracking low-carbon industrial processes or circular economy solutions, this is a concrete step toward making plastic waste a viable feedstock for fuels and chemicals rather than a disposal problem.
