Conversion of Waste to Catalysts and other Value-added Products

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"What if waste wasn't?" is a slogan used by several companies to challenge our view of the byproducts from different processes. Even if a process was 100% efficient, all products deteriorate over time and so waste would still be generated. Ideally the byproducts and spent products could be reused in the same or a different process (the so called "circular economy"). Waste materials represent tremendous resources that are inexpensive, accessible, and abundant. Because waste contains many different components, however, the materials generally cannot directly replace pure feedstocks in existing processes. The process and the waste material must be carefully matched to consider the compositions, reactions, and possible interactions throughout the entire system. Even after careful matching, the waste materials may require some processing before being reused. In my research group, we have developed new methods to prepare catalysts from waste materials. Catalysts are substances that increase reaction rates and selectively produce desired products. Used in 90% of all industrial processes, catalysts cannot only be prepared from the millions of tonnes of waste that are available but also convert this waste to value-added products. This proposal describes my plans to reuse two waste products that are primarily made of carbon - petroleum coke produced from heavy oil and bitumen processing, and carbon black from recycled tires. The petroleum coke will be converted to i. solid acid catalysts for the conversion of waste plastics to carbon fibres and nanotubes, and ii. sulfide catalysts that can be used to partially upgrade bitumen to increase its value and make it more easily transportable. The carbon black will be added to cement to catalyze the hydration reactions and ultimately improve the qualities of the concrete. The latter application is a natural extension of our work with carbon. We will continue to explore applications for which carbon-based waste materials are suitable. Through this work, post-doctoral fellows, graduate students, and undergraduate students will be trained to conduct thorough, impactful research by preparing, characterizing, and testing different catalysts. Teamwork and collaboration will promote communication and facilitate diverse ways of approaching different problems. These are all skills that are required by industry to maintain a strong and innovative workforce and stimulate the Canadian economy.