Technoeconomic analysis (TEA) is an approach for conducting process design and simulation, informed by empirical data, to estimate capital costs, operating costs, mass balances, and energy balances for a commercial scale biorefinery. TEA serves as a useful method to screen potential research priorities, identify cost bottlenecks at the earliest stages of research, and provide the mass and energy data needed to conduct life-cycle environmental assessments. Recent studies have produced new tools and methods to enable faster iteration on potential designs, more robust uncertainty analysis, and greater accessibility through the use of open-source platforms. There is also a trend toward more expansive system boundaries to incorporate the impact of policy incentives, use-phase performance differences, and potential impacts on global market supply.

Mechanical recycling of polymers downgrades them such that they are unusable after a few cycles. Alternatively, chemical recycling to monomer offers a means to recover the embodied chemical feedstocks for remanufacturing. However, only a limited number of commodity polymers may be chemically recycled, and the processes remain resource intensive. We use systems analysis to quantify the costs and life-cycle carbon footprints of virgin and chemically recycled polydiketoenamines (PDKs), next-generation polymers that depolymerize under ambient conditions in strong acid. The cost of producing virgin PDK resin using unoptimized processes is ~30-fold higher than recycling them, and the cost of recycled PDK resin ($1.5 kg⁻¹) is on par with PET and HDPE, and below that of polyurethanes. Virgin resin production is carbon intensive (86 kg CO₂e kg⁻¹), while chemical recycling emits only 2 kg CO₂e kg⁻¹. This cost and emissions disparity provides a strong incentive to recover and recycle future polymer waste.

The current methodological approach for developing sustainable biofuel processes and supply chains is flawed. Life cycle principles are often retrospectively incorporated in the design phase resulting in incremental environmental improvement rather than selection of fuel pathways that minimize environmental impacts across the life cycle. Further, designing sustainable biofuel supply chains requires joint consideration of economic, environmental, and social factors that span multiple spatial and temporal scales. However, traditional life cycle assessment (LCA) ignores economic aspects and the role of ecological goods and services in supply chains, and hence is limited in its ability for guiding decision-making among alternatives—often resulting in sub-optimal solutions. Simultaneously incorporating economic and environment objectives in the design and optimization of emerging biofuel supply chains requires a radical new paradigm. This work discusses key research opportunities and challenges in the design of emerging biofuel supply chains and provides a high-level overview of the current “state of the art” in environmental sustainability assessment of biofuel production. Additionally, a bibliometric analysis of over 20,000 biofuel research articles from 2000-to-present is performed to identify active topical areas of research in the biofuel literature, quantify the relative strength of connections between various biofuels research domains, and determine any potential research gaps.