Scientists from the US and China have introduced a breakthrough one-step technique that transforms mixed plastic waste into gasoline at ambient temperature and pressure—with conversion rates exceeding 95%.
Unlike traditional methods, this innovative approach requires minimal energy, simpler equipment, and fewer stages, making it potentially viable for large-scale industrial use. The team—which includes experts from the US Department of Energy’s Pacific Northwest National Laboratory, Columbia University, the Technical University of Munich, and East China Normal University (ECNU)—detailed their findings in Science, published on August 14, 2025.
How the Process Works
By combining mixed plastic waste with light isoalkanes—hydrocarbon byproducts readily available from refineries—the researchers achieve “gasoline‑range” hydrocarbons (typically C₆–C₁₂ molecules), along with hydrochloric acid as a valuable byproduct. The hydrochloric acid can be neutralized and reused in various industries such as water treatment, metal processing, pharmaceuticals, food production, and the petroleum industry.
As the researchers highlight: “The method supports a circular economy by converting diverse plastic waste into valuable products in a single step”.
Handling PVC’s Chlorine Content
PVC—making up about 10% of global plastic production—is notoriously difficult to process due to its chlorine content and the carcinogenic nature of vinyl chloride, which typically necessitates a separate dechlorination step to avoid toxic emissions.
This new method eliminates that step entirely. It efficiently processes mixed PVC and polyolefin waste in one combined stage, marking the first time mixed contaminated plastics have been directly converted into high-quality petrol in a single process under mild conditions.
Revitalizing a Circular Economy
This breakthrough aligns with the principles of a circular economy, where waste becomes a resource. By handling varied and contaminated plastics in one simplified and efficient stage—at room temperature and atmospheric pressure—it promises to lower the energy and infrastructure barriers typically associated with plastic-to-fuel conversion.