Engineering topics

Gracida-Alvarez, Ulises R. [Argonne National Laboratory (ANL), Argonne, IL (United States)] (ORCID:000000025061169X)

Publications and source records attributed to Gracida-Alvarez, Ulises R. [Argonne National Laboratory (ANL), Argonne, IL (United States)] (ORCID:000000025061169X).

7 records

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Life-cycle analysis of microalgae-based polyurethane foams

Polyurethane plastics are essential in many consumer and commercial products such as insulation, furniture, automotive interiors, and clothing. Pathways for producing polyurethane from microalgae offer an opportunity to reduce greenhouse gas emissions and other environmental impacts and can incorporate processes that avoid the use of toxic isocyanates typically used in conventional polyurethane production processes. In this study, the greenhouse gas emissions, fossil energy, and water consumption of biobased polyurethane and biobased non-isocyanate polyurethane were evaluated via life-cycle analysis using the R&D Greenhouse Gases, Regulated Emissions, and Energy Use in Technologies model. Microalgae-based polyurethane foam was found to achieve greenhouse gas emission reductions of up to 79% compared with conventional polyurethane foam production. The greenhouse gas reductions for the non-isocyanate microalgae polyurethane pathway are slightly lower at 58% compared with conventional polyurethane foam. However, it offers additional benefits by reducing toxicity potential compared to the isocyanate polyurethane pathway. The analysis also included a biorefinery-level analysis to evaluate the impact of incorporating polyurethane production into fuel-processing microalgae biorefineries. The sensitivity analyses conducted in this study reveal that improved algae cultivation strategies can lead to decreases of up to 127% and 80% in GHG emissions from the baseline process of Bio-PU and Bio-NIPU, respectively. Likewise, implementation of renewable electricity can result in up to 128% and 74% lower GHG emissions compared to the baseline production of Bio-PU and Bio-NIPU, respectively. Finally, the analysis evaluated different coproduct handling methods including displacement and allocation (based on mass, energy, and market-value). The results suggest that it is important to consider both the displacement and allocation methods as these led to significant differences in the environmental impacts.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Summary of Expansions and Updates in R&D GREET® 2025

The research and development (R&D) version of Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET®) model, or R&D GREET, is developed by Argonne National Laboratory (Argonne) with the support of the U.S. Department of Energy (DOE) and other federal agencies. R&D GREET is a life cycle analysis (LCA) model, structured to systematically examine the energy and environmental effects of a wide variety of transportation fuels and vehicle technologies in all transportation sub-sectors (i.e., road, air, marine, and rail) and other end-use sectors, and energy technology systems. Argonne has expanded and updated the model in many areas in R&D GREET 2025. This report provides a summary of the expansions and updates. R&D GREET is designed as an attributional LCA model, but specific consequential effects for certain pathways are included by default when they are scientifically important and/or highly policy relevant. For example, two major consequential elements – induced land use change (ILUC) for biofuels and avoided emissions for certain RNG-based pathways – are implemented by default in R&D GREET because they are highly relevant to our user base and crucial for a comprehensive evaluation of the environmental effects of these technologies. In a future version of R&D GREET, these consequential elements for biofuels and RNG could be more clearly distinguished from core attributional results. We will consider adding a highly visible toggle that would allow users to turn off or adjust these consequential impacts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Energy, greenhouse gas, and water life cycle analysis of synthetic graphite anode production in the United States

This study presents a comprehensive life cycle analysis of potential synthetic graphite battery anode material (BAM) production in the U.S. based on industrial-scale data. The analysis focuses on three impacts: greenhouse gas (GHG) emissions, total energy use, and water consumption. We also conducted sensitivity analyses to evaluate the effect of variation in process parameters and energy sources used for synthetic graphite BAM production on its life cycle GHG emissions. A detailed supply chain analysis of graphite BAM in the U.S. was also undertaken, along with a study of its associated GHG emissions. The results show GHG emissions of 29.7 kg CO 2 -eq. per kg BAM, total energy use of 580 MJ kg −1 BAM, and water consumption of 121 L kg −1 BAM for the baseline condition. The graphitization step is a major process hotspot, contributing to over 74% of all impacts. This is attributed to the energy and material input requirements for this step, particularly through the use of crucibles. Across the entire synthetic graphite production process, electricity is the primary contributor, followed by crucibles used in graphite block production, and then calcined petroleum coke. Sensitivity analyses indicate that improvement in micronization yield, reuse of crucibles, and use of low-carbon nuclear energy can significantly reduce GHG emissions of potential domestic graphite production (by ∼70%). Supply chain analysis identified major graphite BAM sources in the U.S. and showed that the U.S. has a competitive advantage in domestic production of synthetic graphite BAM in terms of reduced life cycle GHG emissions compared to present-day imported sources (by ∼20%).

Battery anode↗

DOE OSTI2025

Approach to evaluate the effect of selected additives on the environmental impacts of plastic product manufacturing and recycling

Plastic waste management has become a topic of increasing public interest due to the growing amount of plastic waste entering landfills, being combusted, or being leaked into the environment due to mismanagement. The portion of plastic products that is currently recycled remains low (< 9 % in the U.S.). This is driven by numerous factors including infrastructure and collection needs to improve the recycling rate of plastic waste, technological constraints in recycling the wide variety of plastic products associated with the diverse range of (non-transparent) formulations, and economic limitations for recycling plastic and using recycled plastic in new plastic products (e.g., consumer incentives to recycle, economic value of recycled plastic). The relative importance of these factors is not well understood, and each requires additional research.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Techno-economic and life cycle analyses of the synthesis of a platinum–strontium titanate catalyst

The heterogeneous platinum/strontium titanate (Pt/SrTiO 3 or Pt/STO) catalyst has garnered significant attention as a promising candidate for the hydrogenolysis of polyolefins to hydrocarbon oils. This study evaluates the cost and environmental impacts of a newly developed scalable Pt/STO catalyst production, which includes the synthesis of the STO support and the deposition of Pt onto the support. This two-step synthesis plays a significant role in assessing the commercial feasibility of the catalyst, while energy consumption during the process plays an important role in its environmental impacts. The CatCost and the Research and Development Greenhouse Gases, Regulated Emissions, and Energy use in Technologies (R&D GREET) models were used, respectively, to perform techno-economic analysis (TEA) and life cycle analysis (LCA) of the newly developed catalyst. The TEA showed that the raw materials, accounting for approximately 76% of the total operation cost, has a profound effect on the estimated catalyst cost, mainly due to the platinum precursor. The LCA findings indicated that the catalyst production generates greenhouse gas (GHG) emissions of 66 kg CO 2 e per kg, primarily due to the use of solvents and electricity in the process. The sensitivity analysis indicated that the total operating costs (OpEX), platinum precursor cost, and spent catalyst value (SCV) significantly impact the cost of the synthesized catalyst. Additionally, adopting solvent recovery strategies and using renewable electricity can reduce the GHG emissions of catalyst production to 29 kg CO 2 e per kg.

Heterogeneous Platinum/strontium titanate Catalyst↗

DOE OSTI2025

Greenhouse Gas Emissions Associated with Pretreatment Techniques Utilized for Biosugar Production

Less carbon-intensive production of biosugars from lignocellulosic materials can lead to improved manufacturing of biofuels and bioproducts. In this study, the production of biosugars is analyzed to understand the potential of producing bioproducts from biosugars with a low carbon intensity. Life-cycle assessment is conducted on five lignocellulosic feedstocks along with seven pretreatment techniques to produce biosugars as an important platform intermediate for producing bioproducts. The production of electricity using lignin with and without heat integration was also incorporated. In addition, seven bioproducts are analyzed for the estimation of the GHG emissions budget, which represents the emissions available to convert, separate, and upgrade biosugars into bioproducts within the 70% emissions reduction target. Corn stover-deacetylation and dilute acid pretreatment (CS-DDA) provide the lowest GHG emissions for biosugar (0.03 kg CO 2 eq/kg biosugar) and thereby the highest GHG emissions budget for the case of lactic acid production (3.76 kg CO 2 eq/kg lactic acid). Natural gas and chemicals are the major contributors to all of the pretreatment techniques under study. The outcomes from this study can benefit the advancement of upcoming biobased processes that meet decarbonization targets.

Biopolymers↗

DOE OSTI2025

Cradle-to-Gate greenhouse gas emissions of the production of ethylene from U.S. Corn ethanol and comparison to fossil-derived ethylene production

Conventional ethylene production heavily depends on fossil-derived feedstocks via steam cracking, a very energy- and emission-intensive process. Researchers have been exploring alternatives to reduce CO 2 emissions including producing ethylene from biobased feedstocks. This paper evaluates the cradle-to-gate greenhouse gas (GHG) emissions of bioethylene produced from U.S. corn ethanol. The analysis includes different pathways for the dehydration of corn ethanol to ethylene and co-processing routes via fluid catalytic cracking (FCC) processes. For the FCC co-processing route carbon-14 analysis is used to determine bioethanol yields. A 127% reduction in life cycle GHG emissions of bioethylene is estimated compared to fossil-derived ethylene for the base case. Additional case studies are also discussed to understand the reduction of GHG emissions due to sustainable corn farming and renewable power use, biogenic carbon capture, and fuel switch with biofuels at the ethanol plant, and its impact on bioethylene GHG emissions.

carbon footprint↗