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<p>This study presents a novel, single-step alkaline hydrolysis method to convert discarded aluminum/polyethylene (Al/PE) laminates from Tetra Pak waste into two valuable products: green hydrogen and a sodium aluminate (SA) microcatalyst. The process, conducted under varying conditions of NaOH concentration (1–4&#xa0;M) and temperature (25–80&#xa0;°C), demonstrated simultaneous hydrogen generation and SA recovery. The kinetic analysis of hydrogen evolution revealed that the reaction mechanism is not static; it is accurately described by a piecewise Shrinking Core Model (SCM) that transitions from reactant diffusion control to chemical reaction control and finally to hydrogen diffusion control. Optimal conditions (80&#xa0;°C and 4&#xa0;M NaOH) significantly accelerated reaction kinetics. The recuperated SA byproduct proved to be a highly effective additive for cement. When incorporated, it dramatically reduced the Vicat setting time from 102&#xa0;min to 53&#xa0;min. Differential Scanning Calorimetry (DSC) confirmed this accelerating effect, showing a significant increase in hydration heat release. This dual recovery of hydrogen and a functional material (SA) from multilayer packaging waste offers a sustainable solution that aligns with circular economy principles.</p> Graphical Abstract <p></p>

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Single-Step Conversion of Aluminum/Plastic Laminates into Green Hydrogen and Functional Material

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • Afef Bouazizi,
  • Salah Jellali,
  • Imene Bekri-Abbes

摘要

This study presents a novel, single-step alkaline hydrolysis method to convert discarded aluminum/polyethylene (Al/PE) laminates from Tetra Pak waste into two valuable products: green hydrogen and a sodium aluminate (SA) microcatalyst. The process, conducted under varying conditions of NaOH concentration (1–4 M) and temperature (25–80 °C), demonstrated simultaneous hydrogen generation and SA recovery. The kinetic analysis of hydrogen evolution revealed that the reaction mechanism is not static; it is accurately described by a piecewise Shrinking Core Model (SCM) that transitions from reactant diffusion control to chemical reaction control and finally to hydrogen diffusion control. Optimal conditions (80 °C and 4 M NaOH) significantly accelerated reaction kinetics. The recuperated SA byproduct proved to be a highly effective additive for cement. When incorporated, it dramatically reduced the Vicat setting time from 102 min to 53 min. Differential Scanning Calorimetry (DSC) confirmed this accelerating effect, showing a significant increase in hydration heat release. This dual recovery of hydrogen and a functional material (SA) from multilayer packaging waste offers a sustainable solution that aligns with circular economy principles.

Graphical Abstract