Scientists at Newcastle University and the University of Birmingham have found a simple way to break down Teflon using sodium metal and mechanical shaking at room temperature. This process converts the durable plastic into reusable sodium fluoride without toxic solvents or high energy. The discovery offers a sustainable alternative to landfills and polluting disposal methods for the widely used material.
Teflon, or polytetrafluoroethylene (PTFE), is prized for its heat and chemical resistance in applications like non-stick cookware, lubricants, and electronics. However, its durability makes recycling challenging; incineration releases persistent PFAS pollutants known as 'forever chemicals' that linger in ecosystems.
A new study outlines a mechanochemical approach to address this. Researchers place small pieces of sodium metal and discarded Teflon in a sealed steel ball mill, where grinding at room temperature triggers a reaction. This breaks the strong carbon-fluorine bonds, yielding harmless carbon and sodium fluoride—a salt used in toothpaste and water fluoridation.
"The process we have discovered breaks the strong carbon-fluorine bonds in Teflon, converting it into sodium fluoride which is used in fluoride toothpastes and added to drinking water," said Dr. Roly Armstrong, Lecturer in Chemistry at Newcastle University. He noted that hundreds of thousands of tonnes of Teflon are produced annually, often ending in landfills due to limited disposal options. This method extracts fluorine for upcycling into new materials.
The sodium fluoride produced requires no purification and can directly synthesize fluorine compounds for pharmaceuticals and specialty chemicals. Associate Professor Dr. Erli Lu of the University of Birmingham emphasized fluorine's role in one-third of new medicines and advanced materials, traditionally sourced via energy-intensive mining. "Our method shows that we can recover it from everyday waste and reuse it directly—turning a disposal problem into a resource opportunity."
Advanced solid-state NMR spectroscopy confirmed the reaction's cleanliness. "We used advanced solid-state NMR spectroscopy... to prove that the process produces clean sodium fluoride without any by-products," explained Associate Professor Dr. Dominik Kubicki.
Published in the Journal of the American Chemical Society on November 24, 2025, the research promotes a circular fluorine economy, reducing environmental harm from PFAS waste and inspiring green chemistry innovations.