Researchers in Japan have developed a method that reduces the energy needed to recycle Teflon by 50%, using an electron beam to break down the highly durable plastic. The technique fully decomposes the material at 370 °C (698 °F), a temperature significantly lower than that current industrial processes require.
Their study details a process that could improve the economic feasibility of recycling polytetrafluoroethylene (PTFE), the chemical compound known as Teflon.
The National Institutes for Quantum Science and Technology (QST) research team reports that their method could cut the energy cost of recycling—which currently stands at 2.8 to 4 MWh per ton for conventional pyrolysis—in half. Pyrolysis typically requires 600−1000 °C (1112 °F – 1832 °F).
“By applying heat during irradiation, we were able to reduce the energy required to decompose PTFE by 50% compared to traditional methods,” said Dr. Akira Idesaki, the senior principal researcher on the project.
“This makes large-scale recycling of fluoropolymers much more viable.”
Irradiating PTFE at different temperatures
The technique’s effectiveness stems from combining moderate heat with electron beam irradiation.
The study found that while irradiating PTFE at room temperature (30 °C or 86 °F) decomposed only 10% of the material, the decomposition rate rose to 86% at 270 °C (518 °F) and reached 100% at 370 °C (698 °F).
“When PTFE powder was irradiated with a dose of 5 MGy at 30 °C, only 10% decomposed. But at 270 °C, that number rose to 86%. At 370 °C, full decomposition was achieved,” explained the researchers.
This process converts the solid PTFE into gaseous products, identified as oxidized fluorocarbons and perfluoroalkanes. According to the researchers, these gases could potentially be collected and used as raw materials in chemical manufacturing, supporting a circular use of resources.
Alters internal structure of plastic
The study also noted that the process alters the internal structure of the plastic.
“High-temperature irradiation not only enhances decomposition but also changes the internal structure of PTFE,” said Dr. Hao Yu, the paper’s first author.
This structural change is a factor in the increased efficiency of the process at higher temperatures.
PTFE is part of the PFAS family of chemicals, informally called “forever chemicals” because their strong carbon-fluorine bonds make them incredibly resistant to breaking down in the environment. This durability makes them useful in industry, but they are also a persistent pollutant.
The new technology represents a significant step forward in managing this hazardous waste safely and cost-effectively.
“We hope this technology will contribute to the safer, cleaner, and more cost-effective recycling of high-performance plastics,” remarked Dr. Yasunari Maekawa, who led the research project.
Global efforts to combat PFAS
Several research teams across the world are working on new methods to tackle the issues related to ‘forever chemicals.’
Recently, researchers at the University of Leicester developed a new technique that uses sound waves to separate materials for recycling, which could help prevent potentially harmful chemicals from leaching into the environment.
“This method is simple and scalable. We can now separate PFAS membranes from precious metals without harsh chemicals—revolutionizing how we recycle fuel cells,” highlighted Dr Jake Yang from the University of Leicester School of Chemistry.