Upcycling of mixed polyolefin wastes to 3D structured carbon Joule heaters for decarbonized hydrogen production.

Societal decarbonization is essential for environmental sustainability and prosperity, requiring cohesive efforts to advance materials circularity alongside the development of zero-carbon energy and heat solutions. In most systems, these challenges are addressed separately. However, creating integrated solutions that connect opportunities across energy and materials loops can be transformative and critical for achieving lasting impact. This work shows the innovative use of mixed polyolefin wastes for electrification of heating to enable industrial decarbonization. We demonstrate the conversion of mixed polyolefin wastes into structured carbon with exceptional Joule heating properties using fused filament fabrication (FFF) printing, crosslinking, and pyrolysis. This waste-derived carbon serves as both a catalyst support and heating element for electrified hydrogen production via ammonia decomposition. This Joule heating-enabled process leads to enhanced intrinsic catalytic activity and demonstrates accelerated reaction start and shutdown speeds compared to the convection heating method, while having the advantage of reducing global warming and life cycle energy consumption impacts. By simultaneously upcycling mixed plastic waste and enabling hydrogen production through energy-efficient processes, this work presents a robust and integrated pathway toward industrial decarbonization.