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At least 163 records · Page 9

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DOE OSTI2022

CLARIFYING THE NEXUS BETWEEN LIFE CYCLE ASSESSMENT AND CIRCULARITY INDICATORS: A SETAC/ACLCA INTEREST GROUP

Purpose Improving the circularity of resources is important to the sustainability of consumer goods. Current research has indicated that circularity practices and circular economy (CE) methods do not always reduce environmental impacts. The aim of this research is to investigate the adoption of the life cycle assessment (LCA) methodology to improve the environmental impacts of circularity practices. Methods As part of the Society for Environmental Toxicology And Chemistry (SETAC) forum, an interest group (IG) on Circularity and LCA was formed in partnership with the American Center for Life Cycle Assessment (ACLCA) to tackle methodological and technical issues related to circularity in LCA. The IG’s research approach is summarized in four key steps: defining goals and objectives, literature review and gap analysis, ideation, and experimentation. The twelve active persons within this IG meet monthly and have been divided into four sub-working groups (sub-WGs) so that complementary tasks can be completed concurrently in an effective manner. Each sub-WG meets monthly and reports back to the main group for collaboration and brainstorming to meet the research objectives. Results and discussion First, the sub-WG #1, focusing on the “pool of circularity and LCA-based indicators”, analyzed the complementarity between two of the most used circularity indicators and LCA. Second, the sub-WG #2, working on the “evaluation of CE loops performance through LCA”, built a mind map of pain points that reflect the challenges that the LCA practitioners face when combining LCA with CE approaches. Third, the sub-WG #3, dealing with the “trade-offs between circularity and sustainability”, highlighted key alignments and/or conflicts between circularity and sustainability performance depending on the scope, product, industry, or system of analysis. Fourth, the sub-WG #4, focusing on “business and industrial cases”, plans to leverage the knowledge base developed within this IG to develop use cases documenting the benefits and challenges associated with CE-related loops modeling in LCA. Conclusions The first findings of this SETAC/ACLCA IG provide a state-of-the-art overview of the synergists of LCA methodology and the CE measurement frameworks reported in the literature. To move forward and capitalize on the first findings, one valuable point will be to discuss and provide concrete solutions to the pain points that emerged when considering circularity in LCA. Eventually, the knowledge base and resources created within this IG ultimately aim to support the proper application of LCA for practitioners in CE contexts, and could provide relevant inputs for the ISO Technical Committee ISO/TC 323 working on the upcoming standard for the measurement of CE performance.

Life cycle assessment, circular economy, circulari↗

DOE OSTI2021

Global urban growth between 1870 and 2100 from integrated high resolution mapped data and urban dynamic modeling

Long term, global records of urban extent can help evaluate environmental impacts of anthropogenic activities. Remotely sensed observations can provide insights into historical urban dynamics, but only during the satellite era. Here, we develop a 1 km resolution global dataset of annual urban dynamics between 1870 and 2100 using an urban cellular automata model trained on satellite observations of urban extent between 1992 and 2013. Hindcast (1870–1990) and projected (2020–2100) urban dynamics under the five Shared Socioeconomic Pathways (SSPs) were modeled. We find that global urban growth under SSP5, the fossil-fuelled development scenario, was largest with a greater than 40-fold increase in urban extent since 1870. The high resolution dataset captures grid level urban sprawl over 200 years, which can provide insights into the urbanization life cycle of cities and help assess long-term environmental impacts of urbanization and human–environment interactions at a global scale.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Cradle-to-gate life cycle assessment of advanced composite panels incorporating CO 2 -derived multi-walled carbon nanotubes and hemp fiber for sustainable building applications

Advanced composite panels represent a promising pathway to reducing carbon emissions in the construction industry, yet comprehensive environmental impact assessments remain limited. Here, in this study, we conduct a life cycle assessment (LCA) to evaluate the environmental impacts of innovative composite panels produced from multi-walled carbon nanotubes (MWCNTs), hemp fiber (HF), recycled carbon fiber (rCF), and recycled polypropylene (PP), exploring their potential as baseline structural equivalents to conventional gypsum board. MWCNTs and HF play a critical role in sequestering carbon during raw material production, while the recycling processes for CF and PP generally require less energy compared to virgin material production. The LCA evaluates environmental performance using the TRACI 2.1 method, covering global warming potential (GWP), ozone depletion, smog formation, acidification, eutrophication, carcinogenic and non-carcinogenic effects, respiratory impacts, ecotoxicity, and fossil fuel depletion. Compositional variations—resin type (virgin vs. recycled), rCF content (9–29 wt%), and HF content (10–30 wt%)—are introduced for sensitivity and hotspot analyses. Results demonstrate that, when compared on the basis of preliminary structural equivalence, increasing recycled PP, rCF, and HF content can significantly reduce global warming potential compared to gypsum board. Beyond carbon reduction, the composite panels show trade-offs across other environmental categories. With the growing demand for composite materials in interior panels, ceiling systems, and exterior claddings, these findings highlight the environmental benefits and potential trade-offs of the proposed composites, establishing a foundational framework to support their continued development toward full building-system integration.

Advanced composite manufacturing↗

DOE OSTI2023

Techno-Economic and life cycle assessment of standalone Single-Stream material recovery facilities in the United states

Material Recovery Facilities (MRFs) are crucial players in achieving a circular economy. MRFs receive complex waste streams and separate valuable recyclables from these mixtures. This study conducts techno-economic analysis (TEA) to estimate the net present value (NPV) and life cycle assessment (LCA) to estimate different environmental impacts of a commercial scale standalone, single-stream MRF to assess the economic feasibility and environmental impacts of recovering valuable recyclables from an MRF processing 120,000 tonnes per year (t/y). The TEA employs a discounted cash flow rate of return (DCFROR) analysis over a 20-year facility lifetime, along with a sensitivity analysis on the impact of different operating and economic parameters. Results show that the total fixed cost of building the MRF facility is $\$ $23 MM, and the operating cost is $\$ $45.48/tonne. Further the NPV of the MRF can vary from $\$ $3.57 MM to $\$ $60 MM, while 100-year global warming potential can range from 5.98 to 8.53 kg carbon dioxide equivalents (CO2-eq) per tonne of MSW. We have also found that MSW composition (arising from regional effects) significantly impacts costs, 100-year global warming potential, and other impact categories such as acidification potential, eutrophication potential, ecotoxicity, ozone depletion, photochemical oxidation, carcinogenic effects, and non-carcinogenic effects. Sensitivity and uncertainty analysis indicate that waste composition and market prices significantly impact the profitability of the MRF, and the waste composition mostly impacts global warming potential. Our analysis also indicates that facility capacity, fixed capital cost, and waste tipping fees are vital parameters that affect the economic viability of MRF operations.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Environmental life cycle impacts of small wastewater treatment plants: Design recommendations for impact mitigation

The objective of this study was to quantify potential mitigation of environmental impacts from the operation and construction of wastewater treatment plants (WWTP) from implementing specific design recommendations. The study investigated small WWTPs, many of which are serving slow growing or declining populations. Life Cycle Assessment methodology was used to evaluate and compare the inventory and environmental impacts of nine small WWTP case studies. Detailed inventory data was collected from the facilities’ engineering design plans and utility bills. One recommended practice was to avoid significant overdesign by planning for no lower than a 75% capacity utilization by the facilities’ end-of-life. A theoretical correction to a 75% capacity utilization was estimated to mitigate 0.4% of lifetime electricity usage and 1% of secondary process concrete for every 1% reduction in design average flow rate. Relatedly, a 0.4% mitigation in the Carcinogenic and Global Warming impacts could be achieved for every 1% reduction in design average flow toward a 75% capacity utilization. Other suggested practices were focused on conveyance, namely, to minimize non-process facility area and to use polyvinyl chloride pipe instead of ductile iron pipe where possible. Furthermore, the latter practice was estimated to mitigate between 1.1 and 4.8% of the Carcinogenic impact in the nine case studies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Combining Agent Based Modeling and System Dynamics to Investigate the Circularity of Plastics

The United States currently produces about 1 million metric ton of ocean plastic pollution annually. One proposed solution to combat plastic waste is a circular economy (CE), which aims to transition from today's take-make-waste linear pattern of production and consumption to a system where the value of resources is maximized over time. Two key methods in industrial ecology are useful in assessing the viability of CE: (1) System Dynamics (SD) and (2) Agent Based Modeling (ABM). In prior work, the plastic life cycle was modeled with SD and ABM. The two models calculate recycling rates and costs in different ways, making it difficult to pinpoint necessary next steps. We integrate the ABM and SD models - linking the emergent patterns from micro-level human decisions to system level processes - which allows a more comprehensive understanding of feedbacks, costs, and environmental impacts. The integrated model is more accurate, and can be used to visualize recycling rates and human health and environmental impacts over time. The difference between the integrated and original SD model prompts a Sobol sensitivity analysis, which is used to understand which behavioral factors most affect plastic recycling patterns. We find that the habitual component is typically the most influential in promoting positive recycling behavior. Additionally, we utilize the combined model to understand and visualize how various behavioral intervention scenarios, like improved access to recycling programs and cart tagging, influence recycling patterns; these results can guide future policy-making.

agent-based modeling↗

DOE OSTI2020

BioSTEAMDevelopmentGroup/biosteam

BioSTEAM is a fast and flexible package for the design, simulation, and techno-economic analysis of biorefineries under uncertainty. BioSTEAM’s framework is built to streamline and automate early-stage technology evaluations and to enable rigorous sensitivity and uncertainty analyses. Complete biorefinery configurations are available at the Bioindustrial-Park GitHub repository, BioSTEAM’s premier repository for biorefinery models and results. The long-term growth and maintenance of BioSTEAM is supported through both community-led development and the research institutions invested in BioSTEAM. Through the open-source and community-lead platform, BioSTEAM aims to foster communication and transparency within the biorefinery research community for an integrated effort to expedite the evaluation of candidate biofuels and bioproducts. Additionally, an agile life cycle assessment (LCA) platform has been designed to interface with BioSTEAM, BioSTEAM-LCA. This open-source, installable package allows users to perform streamlined LCAs of biorefineries. The focus of BioSTEAM-LCA is to streamline and automate early-stage environmental impact analyses of processes and technologies, and to enable rigorous sensitivity and uncertainty analyses linking process design, performance, economics, and environmental impacts.

Cortes-Peña, Yoel↗

DOE OSTI2020

BioSTEAMDevelopmentGroup/thermosteam

Cortes-Peña, Yoel↗

DOE OSTI2023

Energy Flexibility-Environmental Outcomes Tradeoffs Workshop Report and Research Roadmap

The U.S. Department of Energy (DOE) and Norway’s Royal Ministry of Petroleum and Energy signed an Annex to a previously signed memorandum of understanding (MOU) in February 2020 to collaborate on hydropower research and development (R&D). This MOU Annex has brought together the DOE’s Office of Energy Efficiency and Renewable Energy Water Power Technology Office and the Norwegian Research Center for Hydropower Technology (HydroCen) to plan and coordinate hydropower R&D activities to increase our understanding of hydropower’s role in the future energy grid and how to minimize and mitigate the subsequent environmental impacts. As part of this MOU Annex, hydropower researchers from the U.S. and Norway have come together to conduct collaborative research on hydropower markets and value, hydropower plant capabilities and constraints, monitoring and control technologies, environmental design solutions, environmental impacts and tradeoffs, flexible operation and planning, and technology innovations. This report presents background information on hydropower environmental regulation in the U.S. and Norway and summarizes content and conclusions from this series of two, three-hour workshops on hydropower generation flexibility and environmental outcomes, that included structured discussions used to identify research priorities and collaborative research opportunities.

13 HYDRO ENERGY↗

DOE OSTI2025

A cradle-to-grave life-cycle-assessment of dry-processed Li-ion batteries for electric vehicles

Maxwell-type dry processing has emerged as a promising manufacturing technology for high-areal-loading Li-ion battery electrodes, offering a significant advantage by eliminating the use of the toxic and costly NMP solvent. This study developed a cradle-to-grave life-cycle-assessment model to evaluate the environmental impacts of this innovative technology, benchmarking the results against the conventional NMP-based technique for a configured 42 kWh NMC622-graphite battery pack. Furthermore, the findings reveal that the dry-processing method merits a 4.8% lower energy consumption and achieves environmental impacts up to 47.5% lower in 12 out of 13 categories, highlighting its environmental benefits compared with the NMP-based manufacturing processes.

Electrode↗

DOE OSTI2024

Carbon intensity of mass timber materials: impacts of sourcing and transportation

Mass timber construction is widely considered a promising alternative construction method to reduce buildings’ total life-cycle carbon emissions because wood is a carbon sink. Cross-laminated timber (CLT) panels, manufactured by gluing lumber layers with grains at right angles, are potential low-carbon alternatives to carbon-intensive concrete and steel construction. However, most environmental impact assessment studies do not consider variation in transportation impacts within the CLT supply chain when calculating life-cycle impacts. This study investigates the embodied primary energy and the global warming potential (GWP) of CLT supply chain decisions regarding the type of timber species used, the U.S. region it is sourced from, and the location of the CLT mill. Longer transport distances in the supply chain for timber and CLT panels can contribute as much as 923 MJ/m 2 (20%) of the embodied primary energy of a CLT building, and the use of a higher-density timber species increases this contribution to 1246 MJ/m 2 (24%), with most of that energy derived from fossil energy sources. For perspective, the GWP of a building whose CLT panels and timber have been transported by truck over 6,000 km (252–270 kgCO 2 /m 2 ) is greater than the GWP of an equivalent reinforced concrete (RC) building (245 kgCO 2 /m 2 ). Thus, factors like the location of CLT processing facilities and the type of timber species can significantly impact the overall life-cycle assessment and, if chosen appropriately, can mitigate the environmental impacts of CLT construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Life-cycle costing assessment of back contact doping and encapsulation alternatives for increasing the life expectancy of CdTe PV modules (Final Report)

Contribution of Research to the State-of-Knowledge This research produced comparative sustainability evaluations of back contact doping and encapsulation alternatives considered by First Solar for decreasing degradation and increasing the life of the cadmium telluride (CdTe) photovoltaic (PV) modules. Technical Effectiveness and Economic Feasibility of Methods Investigated A holistic life-cycle-assessment of the alternatives considered for longer module operational lives, showed that they add between 0.2% and 2% to environmental impact indicators at the cradle-to-gate module level, but at the cradle-to-grave system level, alternative materials offer only benefits (i.e., environmental impact indicator decreases) to the public and the environment. Parallel experimental studies at First Solar showed that the use of the considered alternative materials did not impact the effectiveness of the current module recycling separations and material recovery processes. Furthermore, the increment on the module manufacturing cost due to using alternative materials was estimated to be negligible (i.e., >1%) and longer module lives more than compensate cost increases. Specifically, increase of the current warranted module life of 30 years to 50 years, would decrease the levelized cost of electricity (LCOE) from $40/MWh to $24/MWh for utility-scale installations in the US-SW, the economic feasibility of the considered alternatives is assured. Benefit to the Public With decreasing degradation from the current ~0.3%/year of Series 6 modules to less than 0.2%/year, the public will be benefited by longer photovoltaic operational lives, and therefore. In addition, the requirement for end-of-life management is shifted from 30 years to 40 or 50 years, with profound benefits to the public and the environment.

14 SOLAR ENERGY↗

DOE OSTI2021

An investigation of hard-disk drive circularity accounting for socio-technical dynamics and data uncertainty

The installed data storage capacity in the U.S. will reach 2.2 Zettabytes by 2025, generating about 50 million units of end-of-life (EOL) hard-disk drives (HDDs) per year. Due to data security concerns, most EOL HDDs are currently shredded (even when still functioning), representing an economic loss. Moreover, raw material extraction linked to the increased demand for storage causes environmental impacts. Besides mitigating the threat posed by sudden restrictions of raw materials, the circular economy (CE) offers to maximize value retention in the economy and reduce the environmental impacts of human activities. Common CE strategies are reusing and recycling products. However, the reuse of hard disk drives is currently burdened by the lack of trust HDD end-users have toward other non-physical means of data removal than shredding. Here, an agent-based modeling (ABM) approach is proposed to explore how techno-economic and social factors affect end-users' decisions to adopt EOL management practices other than shredding. The proposed method also accounts for data uncertainty by applying a semi-quantitative approach. Results demonstrate how increased green procurement and more robust standards could spur end-users' trust toward data-wiping technologies. Even when accounting for uncertainty, HDDs' reuse brings better environmental and economic benefits than HDD shredding followed by material recovery. The semi-quantitative approach proposed in this study could be more universally applied in future ABM, especially given the often-stochastic nature of such models. The developed ABM is also the first to represent several HDD industry stakeholders and demonstrate how the HDD shredding lock-in situation could be resolved.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Use of Captured CO2 for Production of Sustainable Polyurethane Foams in Automotive Applications

Captured CO2 has been investigated as a feedstock for the production of polyurethane (PU) foams for automotive applications. Previous work has shown successful incorporation of CO2 into polyols via three distinct reaction pathways. These CO2-derived polyols, as well as several commercially available polyols with varying CO2 content, were used to produce PU foams for automotive seating and NVH (noise, vibration, and harshness) applications. Foam formulations were optimized to maximize sustainable content while maintaining manufacturability constraints and performance requirements for each end use application. PU foams were first formulated at lab scale to confirm free rise and molded foam properties, then scaled up to pilot and industrial scales to evaluate production manufacturing feasibility. Finally, CO2-derived foams were used to produce molded components for end use product validation. Life cycle assessment (LCA) was used to quantify the environmental impact of using captured CO2 and bio-renewable content into polyols and PU foams through the metrics of global warming potential and embodied energy. Tradeoffs among environmental impacts, energy usage, manufacturability, and PU foam performance from the incorporation of CO2 and bio-renewable content will be discussed.

Lee, Ellen [Ford Motor Company]↗

DOE OSTI2023

Task 12 PV Sustainability - Life Cycle Assessment of Crystalline Silicon Photovoltaic Module Delamination with Hot Knife Technology

The objective of this study is to complete a life cycle assessment (LCA) of a novel technology that separates the crystalline silicon (c-Si) photovoltaic (PV) module front glass from the backsheet using hot knife technology. This is known to be the most challenging step in module recycling, where the choice of delamination approach can determine the process selection for the next steps of the recycling process, the economic value of the recovered materials, and environmental performance. The life cycle inventory (LCI) reported here is based on primary data from the technology manufacturer. Different LCIs are established following the cut-off approach and the end-of-life (EOL) approach. The environmental impacts of the hot knife delamination process are analysed based on six indicators, and the main contributors to delamination efforts are identified. For the EOL approach, the potential environmental benefits from the recovered materials are compared to the environmental impacts caused by the delamination process. The functional unit of this analysis is the delamination of 1 kg of used framed c-Si PV modules at the place of installation.

14 SOLAR ENERGY↗

DOE OSTI2025

Are quantum materials economically and environmentally sustainable?

Quantum materials have revolutionized energy, information, and healthcare technologies, yet their development has largely prioritized performance over economic and environmental impacts—key factors for industrial adoption. Using topological materials as a case study, we present a data-driven framework that evaluates over 16,000 materials based on cost, supply chain resilience, energy demand, toxicity, and environmental footprint. By integrating the recently proposed quantum weight – a metric quantifying quantum behavior – we reveal a striking trend: materials with stronger quantum effects often exhibit higher environmental impact, posing challenges for scalability and industrial adoption. To address this, we identify a small set of materials that achieve a balance between quantum functionality and sustainability. Furthermore, our approach enables high-throughput, AI-driven materials discovery that incorporates economic and environmental influences from the outset, guiding the development of quantum materials for next-generation microelectronics and energy harvesting technologies.

AI↗

DOE OSTI2025

Future grid mix impacts on whole-building life cycle assessment

Building construction and operation are a significant contribution to global greenhouse gas emissions, so understanding and mitigating emissions is crucial for reliable and realistic emissions accounting. Whole-building Life Cycle Assessment (WBLCA) is an emissions accounting method that considers lifetime environmental impacts of a building during its construction, operation, and eventual end-of-life. When performing WBLCAs, emission calculations from the building's operation over the entire building lifespan are typically based on today's energy grid mixes. This method does not consider changes or advancements in the clean energy proportion within the grid mix and can over or under-inflate results, skewing the ratio of embodied vs. operational environmental impacts. While a variety of prediction tools estimate what future grid emissions might be, predictions can vary widely. To predict the clean energy ratio within future grid mixes and the potential impact these changes might have on WBLCA, annual data from several existing U.S. grid models was averaged and probabilistic modeling was used to extend the usable projections of shorter forecasts. Results show that clean energy sources will likely continue to increase over time, although the rate of growth varies by model. On average, by 2085, the clean energy penetration of the grid is projected to reach ~81% and renewable energy is projected to reach ~71%, although no widespread consensus is reached. To understand how the future grid mix impacts lifetime building emissions within a WBLCA context, the team analyzed two 2021 IECC-compliant all-electric residential buildings: one built from traditional materials and construction processes and the other built with carbon sequestering materials and modular assembly, with a portion of energy generated on site. The results indicate that a moderate estimate of future electricity grid mixes shows a reduction of yearly operational emissions for traditional residential buildings of 55% between 2025 and 2085, and a corresponding reduction of 48% of total emissions over a 60 year building lifespan. This study offers a nuanced approach to account for the variability of future grid mix models and provides an average trend-line based on a robust collection of scenarios.

Life Cycle Assessment (LCA)↗

DOE OSTI2020

Integrated Energy System Investigation for the Eastman Chemical Company, Kingsport, TN Facility

The industrial manufacturing industry is looking to implement new methods of energy production to ensure a consistent energy supply while reducing economic costs and environmental impacts. Much of the manufacturing industry relies on fossil fuels—primarily coal and natural gas—of which there are finite resources subject to price volatility due to an inelastic demand. These resources also come with significant negative environmental impacts related to emissions. While complete independence from fossil fuels is not immediately realistic, options are available to significantly reduce dependency on fossil fuel supplies, including integrated energy systems (IESs) which tightly couple nuclear energy source generators with energy consumers (i.e., industrial factories) to fulfill power and energy requirements. Once realized, optimized IESs may yield significant economic and environmental benefits over traditionally isolated generator and consumer facilities. This report presents a feasibility study for siting an IES to meet the steam and electricity needs of Eastman Chemical Company’s facility in Kingsport, Tennessee. This study explored reactor technology options, evaluation,and optimization,with a focus on meeting the facility’s operational and reliability requirements. This work is part of an ongoing effort by Eastman to be good environmental stewards and meet the demands of their customers by shifting to more environmentally sustainable solutions for their energy needs. Outcomes of this report are also of general interest and value to any design or development team seeking to deploy an IES,as many topics described herein are generally applicable to any nuclear power facility.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗