Earth-abundant metals have recently been demonstrated
as cheap
catalyst alternatives to scarce noble metals for polyethylene hydrogenolysis.
However, high methane selectivities hinder industrial feasibility.
Herein, we demonstrate that low-temperature ex-situ reduction (350
°C) of coprecipitated nickel aluminate catalysts yields a methane
selectivity of <5% at moderate polymer deconstruction (25–45%).
A reduction temperature up to 550 °C increases the methane selectivity
nearly sevenfold. Catalyst characterization (XRD, XAS, 27Al MAS NMR, H2 TPR, XPS, and CO-IR) elucidates the complex
process of Ni nanoparticle formation, and air-free XPS directly after
reaction reveals tetrahedrally coordinated Ni2+ cations
promote methane production. Metallic and the specific cationic Ni
appear responsible for hydrogenolysis of internal and terminal C–C
scissions, respectively. A structure-methane selectivity relationship
is discovered to guide the design of Ni-based catalysts with low methane
generation. It paves the way for discovering other structure–property
relations in plastics hydrogenolysis. These catalysts are also effective
for polypropylene hydrogenolysis.