Newcastle and Birmingham Scientists Develop Green Method to Recycle Teflon into Valuable Fluorine Compounds

The Newcastle research team (L-R): Dr Matthew Hopkinson, Dr Roly Armstrong and Matthew Lowe.

(IN BRIEF) A joint team from Newcastle University and the University of Birmingham has discovered a simple, energy-efficient method to recycle Teflon® using only sodium metal and mechanical motion at room temperature. The process breaks carbon–fluorine bonds, converting the plastic into sodium fluoride without toxic waste, offering a sustainable alternative to traditional fluorine extraction. Verified through advanced NMR spectroscopy, the method provides a model for circular fluorine chemistry, potentially transforming how fluorinated materials are reused across industries such as pharmaceuticals, electronics, and renewable energy. The research marks an important milestone in green chemistry and environmental sustainability.

(PRESS RELEASE) NEWCASTLE, 22-Oct-2025 — /EuropaWire/ — Researchers from Newcastle University and the University of Birmingham have developed a groundbreaking, eco-friendly technique to recycle Teflon® (PTFE), one of the most durable and environmentally persistent plastics in the world. The new method, published in the Journal of the American Chemical Society (JACS), uses sodium metal and simple mechanical motion—shaking—to break down Teflon® at room temperature, eliminating the need for high energy or toxic solvents.

This innovative process disrupts the extremely strong carbon–fluorine bonds that make Teflon® so resistant to heat and chemicals, converting the waste material into sodium fluoride—a compound commonly used in toothpaste and drinking water. Unlike incineration, which produces harmful “forever chemicals” (PFAS), the method creates no toxic by-products and generates useful chemicals that can be repurposed for pharmaceutical and industrial applications.

Dr Roly Armstrong, Lecturer in Chemistry at Newcastle University and corresponding author of the study, explained: “Hundreds of thousands of tonnes of Teflon® are produced globally each year, and much of it currently ends up in landfill. Our process provides a clean and efficient way to extract and reuse fluorine from this waste, upcycling it into new, valuable materials.”

The research, led collaboratively by Dr Armstrong and Associate Professor Dr Erli Lu from the University of Birmingham, represents a major step toward a circular economy for fluorine. Dr Lu highlighted the broader impact of this discovery: “Fluorine is essential for modern technologies, including medicine and electronics, but traditional extraction methods are highly polluting. Recovering fluorine from waste allows us to reduce the environmental footprint of vital industries while turning a disposal problem into a resource.”

The study also involved Associate Professor Dr Dominik Kubicki, who led the Birmingham team’s solid-state NMR spectroscopy analysis. This advanced technique provided atomic-level insight into the reaction process, confirming that the recycling method produces clean sodium fluoride with no unwanted side products. “This is a perfect demonstration of how state-of-the-art materials characterisation can drive sustainable innovation,” Dr Kubicki noted.

By using mechanochemistry—a green chemistry approach that drives reactions through physical movement rather than heat—the research provides a low-cost, scalable path toward sustainable fluorine recovery. Beyond Teflon®, the findings open possibilities for reusing other types of fluorinated waste materials, which could reduce pollution and resource consumption across multiple industries.

Dr Lu added: “Our method is simple, fast, and affordable. We hope it inspires future research into greener ways to recycle fluorinated compounds and helps build a more sustainable future for fluorine-based chemistry.”

Media Contact:

Jen Middleton
Director of Communications
Email: jen.middleton@newcastle.ac.uk

SOURCE: Newcastle University