The global plastics crisis has recently focused scientists’ attention on finding technical solutions for the ever-increasing oversupply of plastic waste. Black plastic is one of the greatest contributors to landfill waste, because it cannot be sorted using industrial practices based on optical reflection. However, it can be readily upcycled into carbon nanotubes (CNTs) using a novel liquid injection reactor (LIR) chemical vapor deposition (CVD) method. In this work, CNTs were formed using black and white polystyrene plastics to demonstrate that off-the-shelf materials can be used as feedstock for growth of CNTs. Scanning electron microscopy analysis suggests the CNTs from plastic sources improve diameter distribution homogeneity, with slightly increased diameters compared with control samples. Slight improvements in quality, as determined by Raman spectroscopy of the D and G peaks, suggest that plastics could lead to increased quality of CNTs. A small device was constructed as a demonstrator model to increase impact and public engagement.

For every three people on the planet, there are approximately two Tonnes (Te) of plastic waste. We show that carbon recovery from polystyrene (PS) plastic is enhanced by the coaddition of solvents to grow carbon nanotubes (CNTs) by liquid injection chemical vapour deposition. Polystyrene was loaded up to 4 wt% in toluene and heated to 780 °C in the presence of a ferrocene catalyst and a hydrogen/argon carrier gas at a 1:19 ratio. High resolution transmission electron microscopy (HRTEM), scanning electron microscopy (SEM), thermogravimetric analysis (TGA) and Raman spectroscopy were used to identify multiwalled carbon nanotubes (MWCNTs). The PS addition in the range from 0 to 4 wt% showed improved quality and CNT homogeneity; Raman “Graphitic/Defective” (G/D) values increased from 1.9 to 2.3; mean CNT diameters increased from 43.0 to 49.2 nm; and maximum CNT yield increased from 11.37% to 14.31%. Since both the CNT diameters and the percentage yield increased following the addition of polystyrene, we conclude that carbon from PS contributes to the carbon within the MWCNTs. The electrical contact resistance of acid-washed Bucky papers produced from each loading ranged from 2.2 to 4.4 Ohm, with no direct correlation to PS loading. Due to this narrow range, materials with different loadings were mixed to create the six wires of an Ethernet cable and tested using iPerf3; the cable achieved up- and down- link speeds of ~99.5 Mbps, i.e., comparable to Cu wire with the same dimensions (~99.5 Mbps). The lifecycle assessment (LCA) of CNT wire production was compared to copper wire production for a use case in a Boeing 747-400 over the lifespan of the aircraft. Due to their lightweight nature, the CNT wires decreased the CO2 footprint by 21 kTonnes (kTe) over the aircraft’s lifespan.

For every three people on the planet there is approximately two Tonne (Te) of available plastic waste. We show that carbon recovery from polystyrene (PS) plastic is enhanced by the co-addition to solvents to grow carbon nanotubes (CNTs) by liquid injection chemical vapour deposition. Polystyrene was loaded up to 4 wt% in toluene and heated to 780 °C in the presence of a ferrocene catalyst and a hydrogen/argon carrier gas in a 1:19 ratio. High resolution transmission electron microscopy (HRTEM), scanning electron microscopy (SEM), thermogravimetric analysis (TGA) and Raman spectroscopy were used to identify multi-walled carbon nanotubes (MWCNTs). The PS addition in the range from 0 to 4 wt% showed improved quality and CNT homogeneity; Raman “Graphitic/Defective” (G/D) values increased from 1.9 to 2.3; mean CNT diameters increased from 43.0 to 49.2 nm; and maximum CNT yield increased from 11.3% to 14.2%. Since both the CNT diameters and the percentage yield increased with respect to polystyrene addition, we conclude that carbon from the PS contributes to the carbon within the MWCNTs. The electrical contact resistance of acid washed Bucky papers produced from each loading, ranged from 2.2 to 4.4 Ohm, with no direct correlation to PS loading. Due to this narrow range, the materials with different loading were mixed to create six wires of an Ethernet cable and tested using iPerf to give uplink and downlink speeds of ~99.5 Mbps, comparable to Cu wire of identical dimension (~99.5 Mbps). The lifecycle assessment (LCA) of CNT wire production was compared to copper wire production for the use case in a Boeing 747-400 over the lifespan of the craft. Due to their lightweight nature the CNT wires decreased the CO2 footprint by 21 kTonne (kTe) over the aircraft lifespan.