In-situ exsolution of Fe-Ni alloy catalysts for H2 and carbon nanotube production from microwave plasma-initiated decomposition of plastic wastes

The management of plastic wastes has become an urgent issue due to the overconsumption of single-use plastic products. As a promising avenue for plastic waste valorization, chemical recycling by converting plastics into value-added products has attracted tremendous attention. In this paper, the Fe-Ni alloy catalysts via in-situ exsolution were employed for the straightforward microwave plasma-initiated decomposition of plastic wastes for high yield H2 and carbon nanotubes. The partial substitution of Fe by Ni promoted in-situ exsolution of alloy nanoparticles homogeneously. Specifically, characterization results showed that the introduction of Ni modulated metal-support interaction, which further affected the crystalline phase, nanoparticle size and oxygen vacancies. The exsolved Fe-Ni alloy catalyst exhibited the highest catalytic activity, over which 96 % hydrogen of plastic wastes rapidly evolved out in the form of gas products accompanied with high-purity carbon nanotubes. The H2 yield was 415 mmol·g−1Hplastic, which exhibited an over 2 times improvement versus the supported catalyst. Moreover, the successive cycle test displayed the potential for converting plastic wastes into H2-rich fuels and high-quality CNTs continuously. Generally, the in-situ exsolution strategy of Fe-Ni alloy catalysts contributed to the sustainable and high-efficient recycling of plastic wastes into H2-rich gas products and carbon nanotubes under microwave plasma. [Display omitted] •Partial substitution of Fe by Ni promoted in-situ exsolution of nanoparticles.•96 % hydrogen was converted into gas fuels with H2 yield of 415 mmol·g-1Hplastic.•H2 yield of Fe0.7Ni0.3-Al2O3 increased over 2 times versus the supported catalyst.•High quality CNTs were fabricated over exsolved Fe-Ni alloy catalyst continuously.