Argonne, UChicago research aims to shrink landfills by turning ‘waste into wealth’

‘Circular economy’ seeks to turn old tech, carbon and organic waste into value

Nature is full of interconnected loops. Water travels in a never-ending cycle, going from the ground to the sky and back again. When living things die and decompose, elements such as carbon and nitrogen are absorbed by Earth’s crust and used to create new life. These systems of nature are closed loops, meaning they are self-sustaining, and they have no beginning or end.

Humans exist within these cycles; like all living things, we both influence and benefit from them. But the ways in which we currently manage our waste are anything but sustainable or circular.

Researchers at Argonne National Laboratory, a U.S. Department of Energy lab affiliated with the University of Chicago, are working toward a more regenerative future — one where Earth’s resources are circulated sustainably. In this type of economic system, called a  circular economy, a product’s end of life is planned for at the design stage. This way, would-be waste becomes a valuable resource for creating new or refurbished products.

Argonne and UChicago scientists are developing methods to recover and reuse precious metals and other valuable materials from batteries and devices at their end of life. They’re also developing technologies to turn waste into valuable commodities. And by collaborating with industry partners, other research institutions and local communities, they’re helping to bridge the gap between laboratory discovery and large-scale societal impact.

Closing the trash-to-treasure loop

The emissions humans produce and the plastics, devices, food and other waste we discard do not always get folded back into Earth’s natural cycles.

Instead, much of our waste is either left sitting in rapidly growing landfills, polluting the environment or both. Meanwhile, our emissions are accumulating in the atmosphere, driving rising global temperatures and damaging ecosystems. And despite our efforts so far, less than 10% of the approximately 7 billion tons of plastic waste ever generated has been recycled.

To address this problem, we can take steps to move towards a circular economy instead. A circular economy turns industrial waste into feedstock for the creation of new products. This means viewing landfills less like putrid, mountainous eyesores and more like massive treasure troves waiting to be mined for their stores of valuable materials.

“Plastic contains a lot of energy. It’s like pre-purified crude oil, and it’s already out of the ground,” said Max Delferro, a chemist with Argonne and the UChicago Pritzker School of Molecular Engineering, and Argonne’s Circular Economy lead. ​“In the future, as technologies improve, there could be a financial incentive to digging for plastic in landfills.”

Delferro and his team at Argonne are pioneering new and improved methods for recycling plastic waste. For example, they are using chemical tools called catalysts to convert plastic bags and films into higher-value products, such as lubricants and waxes. They’re also reimagining how plastic products are designed to begin with.

For example, as part of the Department of Energy’s Institute for Cooperative Upcycling of Plastics (iCOUP), Delferro and other scientists from Argonne and Cornell University developed a new method for recycling high-density polyethylene, or Type 2 plastic. Their technique transforms postconsumer products into a new type of plastic material that can be recycled repeatedly without loss of quality.

Wanted and unwanted

Even society’s stinkier waste streams can be used as valuable feedstock. Argonne scientist Meltem Urgun Demirtas is researching ways to recover resources from food waste and sludge generated from cities, wastewater treatment plants and industrial processes. In the lab, she and her team have experimented with waste from local restaurants, pig farms, breweries, cheese producers and even their own homes.

“My motivation is to clean up the world,” said Urgun Demirtas, who leads Argonne’s Sustainable Materials and Processes department. ​“Anything that nobody wants in their backyard or in their city is of interest to me.”

Urgun Demirtas and her colleagues are feeding these waste streams to colonies of highly diverse and resilient microorganisms. Microorganisms can digest organic waste streams, such as wastewater and sludge, and convert them into fuels, including renewable methane and sustainable jet fuel.

And to close as many loops as possible, the nutrient-dense leftovers from these processes can be used as fertilizer or soil conditioner. Recovering nutrients from waste has the added benefit of preventing harmful algae blooms that they can cause if left unchecked in the environment.

Waterwise

Junhong Chen, lead water strategist at Argonne and a professor at the University of Chicago’s Pritzker School of Molecular Engineering, is also working to accelerate the creation of technologies for water treatment and resource recovery.

“Water is not just vital for sustaining our lives; it’s also needed for manufacturing products in virtually every industry,” said Chen, who serves as the co-principal investigator for Great Lakes ReNEW, a Regional Innovation Engine awarded by the U.S. National Science Foundation. ​“As long as water touches society, there will be a critical need and opportunity for a circular blue economy.”

Coordinated by the Chicago-based water innovation hub Current, in partnership with Argonne and the University of Chicago, Great Lakes ReNEW will develop and deploy improved technologies for recovering critical minerals and nutrients from wastewater and purifying it of contaminants.

For instance, the team is developing a network of interconnected sensors across the Great Lakes region to monitor levels of different materials present in wastewater in real time. This information could help wastewater treatment plants optimize their facilities to process incoming waste, which can change day by day.

The science of deconstruction

A main challenge in developing any recycling or resource recovery method is to separate the valuable materials and components from the rest of the waste. It’s an even bigger challenge to separate them in a way that’s cost-effective and environmentally sustainable.

“We spent a hundred years developing our plastics to have very particular properties, and only in the last several years have we really started to think about how to take them apart responsibly,” Delferro said. ​“It’s an exciting time to be a scientist because we’re at the inception of a new science: the science of deconstruction.”

For example, plastic waste is generally not pure plastic. It often contains contaminants and additives (like dyes and flame retardants) that need to be separated out with series of catalysts. This is a complex science. So far, the best catalysts researchers have discovered for recycling plastics consist of rare and expensive metals.

Delferro and his colleagues are working to make effective catalysts from earth-abundant materials that can be mined in the U.S. His team is also collaborating with another group at Argonne to assess the potential environmental effects of the plastics they’re developing.

“We have to make sure that even when the biodegradable plastics break down, it won’t be toxic to the environment,” Delferro said. ​“There’s a lot to consider, and all of it feeds into a circular economy.”

The same is true for recycling batteries and microelectronics. ​“A lot of this waste is all chewed up or meshed together. In order to make recycling profitable, you need to find technologies to separate glass, plastic, metal, liquids and other materials using technologies that are cheap and easy to operate,” said Jeffrey Spangenberger, leader of Argonne’s Materials Recycling Research and Development group and director of the ReCell Center.

Real-world recycling plants use a series of machines like shredders, strong magnets and furnaces to separate out different materials. Even when they involve the more delicate touch of artificially intelligent sorting robots, many of the existing processes to recover recyclable materials from electronic devices are inefficient, energy intensive or expensive.

Spangenberger and his colleagues are helping industry partners discover the most profitable and sustainable ways to approach their recycling processes.

For example, he and his team are collaborating with Toyota Motor Engineering & Manufacturing, North America, to explore a new approach — called direct recycling — which separates entire components of batteries, leaving them intact to be used again in another battery. This reduces the need for the expensive manufacturing processes used to create the components from scratch.

The team is also building a pilot recycling plant at Argonne. The plant will allow the team to test new recycling technologies integrated with existing ones, and to scale up processes to be tested in real-world industrial conditions with real-world feedstocks.

The science of reconnection

When we burn fossil fuels and release our CO2 emissions, we are simultaneously harming Earth’s systems and surrendering large quantities of a valuable resource; Carbon is the main component of many fuels because it releases large amounts of energy when it’s burned.

Argonne chemist Di-Jia Liu is working to funnel carbon that would otherwise be emitted as CO2 to industries that can use it as a raw material for some of the most-produced fuels and chemicals in the U.S. These include ethanol, acetic acid, ethylene and propanol, which are used in gasoline and as intermediate products for the chemical, pharmaceutical and cosmetics industries.

Liu and his team envision a future where all of the CO2 we produce remains in the closed loop of our circular economy, gradually reduced from the atmosphere and infinitely reused. However, it is expensive and energy intensive to convert CO2 to fuels and chemicals using existing technologies.

To make the process more affordable, Liu’s team is creating more efficient catalysts and developing a CO2 conversion device called an electrolyzer. The device works at low temperatures and pressures compared with existing technologies, and it can turn on and off quickly without much energy loss. These features make it ideal for coupling with renewable energy sources such as wind and solar power, whose availability can be intermittent.

“To make this profitable in the near term, the idea is to use renewable energy to convert locally produced CO2 into value-added chemicals and products for local consumption,” Liu said. ​“This eliminates the costs associated with transportation and distribution.”

With full awareness of the challenges ahead, the Argonne researchers remain energized and optimistic.

“It took about 50 years to produce the large volumes of gasoline — and about 20 years to produce the large volumes of corn ethanol — that meet our fuel needs today,” Urgun Demirtas said. ​“With dedicated science, education and partnership, it’s only a matter of time before we achieve our vision for a more sustainable energy future.”

Funding: National Science Foundation, DOE’s Office of Science’s Office of Basic Energy Sciences and DOE’s Office of Energy Efficiency and Renewable Energy’s offices of Bioenergy Technologies, Vehicle Technologies, Advanced Materials and Manufacturing Technologies, and Industrial Efficiency and Decarbonization

—Adapted from an article first published by Argonne National Laboratory.