Disposable masks have been produced at unprecedented amounts throughout the COVID-19 pandemic. Their increased use imposes significant stress on current waste management practices including landfilling and incineration. This results in very large volumes of discarded masks entering the environment as pollutants, and alternative methods of waste management are required to mitigate the negative effects of mask pollution. While current recycling methods (e.g. mechanical recycling) can supplement conventional waste management, they often result in products with downgraded material properties and a loss of value. This work introduces a simple method to upcycle mask waste into highly functional carbon nanofibers. The inherent structure of the polypropylene fiber mats that comprise the layers of common surgical masks can be directly converted into carbonaceous structures through a simple, scalable thermal stabilization process. Our method allows high degrees of carbon yield of masks after carbonization. The product exhibits excellent retention of initial shape and enhanced material properties, such as electrical conductivity. This process can provide a useful alternative solution to conventional waste management by converting environmentally harmful mask waste into a new product with enhanced value.

Upcycling structured plastic waste into highly functional carbon nanofibers

ACS Spring 2022

The official archive and repository for all ACS Meetings & Expositions abstracts and select posters or presentations.