(101g) Towards Net-Zero CFRP By Integrating LCA, Circular Economy, and Innovation: Method and Software

Achieving net-zero emissions is a key element of global strategies to combat climate change and promote sustainable economic growth [1]. Reaching this goal requires a holistic, interdisciplinary approach that leverages innovative methods, advanced tools, and practical applications across various sectors [2]. Approaches like life cycle assessment (LCA), process synthesis, and multi-objective optimization offer valuable means to assess environmental impacts, identify key hotspots, and improve resource efficiency within supply chains and production systems [3, 4].

This study examines emissions from the U.S. transportation sector, with a focus on materials used in vehicle manufacturing. Plastics and polymer composites already common in interiors, exteriors, and lighting are increasingly being used in other automotive components [5]. However, their substantial contribution to greenhouse gas emissions and plastic waste poses a challenge to net-zero targets [6]. In response, automakers are investigating alternative materials to develop vehicles aligned with net-zero objectives. Carbon fiber-reinforced polymer (CFRP) has gained attention as a strong candidate due to its lightweight nature, which enhances vehicle efficiency by reducing mass [7]. To support life cycle assessment (LCA), this work investigates the trade-offs between cost and emissions using innovative strategies.

Hotspot analysis reveals that electricity generated from bituminous coal and over-all energy production are the major sources of emissions in the process. To overcome these challenges and move toward net-zero emissions in the automotive sector, this study explores the integration of renewable energy sources and carbon capture technologies. Utilizing renewable energy leads to an 81% reduction in emissions compared to the business-as-usual (BAU) scenario. Moreover, incorporating carbon capture and utilization technologies results in a 97.3% reduction relative to the BAU. In addition, the adoption of emerging technologies and the use of future scenario modeling can support the development of a strategic roadmap for long-term, sustainable emission reductions [8].

End-of-life (EoL) considerations focus on recovery, recycling, and down cycling of carbon fiber for sustainable material management. This study identifies solvolysis as the most effective EoL approach, reducing global warming potential (GWP) by 38.90% compared to the BAU. Additionally, analysis of recovery and recycling processes reveals that as the number of recycling cycles increases, emissions are progressively reduced. Sensitivity analysis further indicates that emissions decrease over time with minimal degradation in fiber quality, highlighting solvolysis as a highly promising and effective EoL solution. Effectively implementing this comprehensive approach will support the adoption of sustainable technologies in the automotive industry, leading to substantial reductions in CO2 emissions and plastic waste.

The above CFRP analysis is integrated into a user-friendly software interface, specifically designed for CFRP applications, with the potential to be adapted for other polymer systems in the future.

This comprehensive and user-friendly platform enables companies to systematically evaluate the environmental footprint and financial performance of CFRP products across their entire life cycle. This tool empowers stakeholders to compare various supply chain scenarios with ease, enabling informed decision-making that promotes both sustainability and economic efficiency. By leveraging this tool, companies can effectively navigate the complex trade-offs between environmental performance, circularity, and profitability supporting the alignment of their operations with global sustainability objectives. This tool represents a significant step toward making sustainable business practices more accessible, actionable, and beneficial for stakeholders across the automobile industries. The initial version focuses on the CFRP supply chain, specifically a case study involving compression molding. This tool consists of two main components analysis and design. In the Analysis module, users can explore various end-of-life scenarios for CFRP waste, emphasizing product recovery with deterioration factors. The tool allows users to select and compare different scenarios against a BAU baseline, assessing performance across environmental and circularity.

Users can customize assessments by choosing impact methods, life cycle inventory databases, and relevant indicators based on their goals. Once inputs are set, the tool runs simulations to generate results, including total environmental impacts, circularity metrics, and cost breakdowns. Additional insights include major contributors to environmental impacts and detailed Sankey diagrams showing material and energy flows.

The design module employs a multi-objective optimization framework to identify optimal end-of-life strategies for CFRP waste. It balances environmental, circularity, and economic objectives, providing users with trade-off insights and optimized supply chain configurations. Users can compare these solutions with the BAU case to identify opportunities for improvement.

The tool is currently being expanded to map the CFRP supply chain within the automobile industry, with the aim of developing roadmaps for achieving a sustainable net-zero carbon economy by 2050. This ongoing development highlights the tool’s versatility and its potential to address sustainability challenges across a wide range of industrial sectors.

References

[1] IEA, Net zero by 2050, 2021. URL: https://www.iea.org/reports/net-zero-by-2050.

[2] S. Barbhuiya, B. B. Das, D. Adak, Roadmap to a net-zero carbon cement sector: Strategies, innovations and policy imperatives, Journal of Environmental Management 359 (2024) 121052.

[3] R. Sharma, H. Kodamana, M. Ramteke, Multi-objective dynamic optimization of hybrid renewable energy systems, Chemical Engineering and Processing-Process Intensification 170 (2022) 108663.

[4] V. Thakker, B. R. Bakshi, Designing value chains of plastic and paper carrier bags for a sustainable and circular economy, ACS Sustainable Chemistry & Engineering 9 (2021) 16687–16698.

[5] M. A. Fentahun, M. A. Savas, Materials used in automotive manufacture and material selection using ashby charts, Int. J. Mater. Eng 8 (2018) 40–54.

[6] V. V. Rajulwar, T. Shyrokykh, R. Stirling, T. Jarnerud, Y. Korobeinikov, S. Bose, B. Bhattacharya, D. Bhattacharjee, S. Sridhar, Steel, aluminum, and frp-composites: The race to zero carbon emissions, Energies 16 (2023) 6904.

[7] W. Zhang, J. Xu, Advanced lightweight materials for automobiles: A review, Materials & Design 221 (2022) 110994.

[8] V. Thakker, B. R. Bakshi, Toward sustainable circular economies: A computational framework for assessment and design, Journal of Cleaner Production 295 (2021) 126353.