Extracting Caprolactam from PA6 Waste: Progress in Chemical Recycling and Sustainable Practices

Abstract

This review critically evaluates current PA6 recycling technologies, with a specific focus on caprolactam-oriented chemical recycling pathways, including hydrolysis, pyrolysis, glycolysis, ammonolysis, hydrothermal treatment, ionic-liquid-assisted depolymerization, and microwave-assisted processes. Reported caprolactam yields vary significantly depending on reaction conditions and catalyst systems, ranging from below 60 wt% in conventional hydrolysis to above 90 wt% under optimized catalytic, hydrothermal, or microwave-assisted conditions. Among these approaches, microwave-assisted hydrolysis and catalytic depolymerization have emerged as particularly promising, offering substantially reduced reaction times (minutes rather than hours), improved energy efficiency, and high monomer selectivity at moderate temperatures (typically 200–350 °C). This review integrates kinetic modeling approaches, analytical methods for monitoring depolymerization, and downstream separation considerations that govern monomer purity and recyclability. Key challenges, including energy demand, feedstock contamination, scalability, and economic competitiveness, are critically discussed in relation to industrial implementation. Overall, hydrolysis-based and microwave-assisted chemical recycling routes are the most viable pathways for closed-loop recycling of PA6. Future progress will rely on integrated reaction–separation–repolymerization designs, catalyst optimization, and process intensification to enable sustainable and industrially relevant PA6 circularity.