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Innovative Catalytic Technologies for Plastic Waste Upcycling via 3D-Printed Metal Structures

Objective

3D-UPCAT addresses plastic upcycling within catalysis, focusing on thermo-, electro-, and photochemical routes for plastic upcycling. Global plastic production has increased 20-fold over the last decades, yet only ~9% is recycled. Most plastic is landilled, incinerated, or leaked into the environment. Mechanical recycling reduces emissions but causes quality loss and cannot achieve full circularity, requiring chemical valorisation routes. Upcycling depends on polymer type and it can be converted into fuels via pyrolysis, or depolymerised into high-value monomers. However, current processes suffer from low selectivity, energy inefficiency, catalyst deactivation, and poor integration with sustainability assessment. Conventional catalyst synthesis also limits control over structure and transport phenomena.3D-UPCAT develops 3D-printed functional materials and magnetically induced catalytic systems integrated with thermo-, photo-, and electrocatalytic routes, including CO2 valorisation. Data-driven optimisation and machine learning will enable real-time process control under variable feedstocks. 3D-printed metallic and magnetic supports enhance heat and mass transfer, while magnetic induction heating reduces thermal gradients, improving energy efficiency and suppressing catalyst deactivation. Ni-based catalysts are targeted for improved resistance to coking in dry reforming, while electro- and photocatalysis enable selective PET conversion under mild conditions.The project integrates six disciplines: materials chemistry, catalysis, operando surface science, chemical engineering, computational chemistry, and digitalisation with LCA, TEA, and logistics optimisation. The consortium spans Europe, Asia, and Latin America, combining academic and industrial expertise. Overall, 3D-UPCAT is a strongly intersectoral and interdisciplinary effort linking catalysis, engineering, modelling, and data science to enable plastic valorisation from molecular design to system implementation.

Keywords

Programme(s)

Topic(s)

Funding Scheme

HORIZON-TMA-MSCA-SE - HORIZON TMA MSCA Staff Exchanges

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Call for proposal

(opens in new window) HORIZON-MSCA-2026-SE-01

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Coordinator

AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICAS
Net EU contribution
€ 165 440,00
Address
CALLE SERRANO 117
28006 Madrid
Spain
Region
Comunidad de Madrid Comunidad de Madrid Madrid
Activity type
Research Organisations
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Total cost
No data

Participants (5)

Partners (3)