Production of Branched Alkanes by Upcycling of Waste Polyethylene over Controlled Acid Sites of SO4/ZrO2‐Al2O3 Catalyst

Branched alkanes, which enhance the octane number of gasoline, can be produced from waste polyethylene. However, achieving highly selective production of branched alkanes presents a significant challenge in the upcycling of waste polyethylene, and the maximum selectivity for branched alkanes reported up to date is about 70%. Here, we report a one‐pot process to convert polyethylene into gasoline‐range hydrocarbons (C4‐C13) with yield of 73.3% over SO42‐ZrO2‐Al2O3 catalyst at 280 °C. The proportion of branched alkanes reaches 90.1% within the C4‐C13 fraction. Incorporation of sulfate group endows the catalyst with strong Lewis acid sites and weak and moderate Brønsted acid sites. In situ X‐ray absorption, in situ infrared spectroscopy, in situ small angle neutron scattering, and DFT calculations reveal that polyethylene activation occurs through the synergy between sulfate groups and strong Lewis acid sites (Zr sites). The weak and moderate Brønsted acid sites preferentially catalyze the isomerization and type A β‐scission processes, which favors the formation of branched alkanes, while suppressing competing reactions that produce straight‐chain alkanes.