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 CO₂-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%).

While the production costs and logistical benefits of biomass pelleting have been widely discussed in the literature, the downstream economic and environmental benefits of processing pelleted biomass have been largely neglected. To investigate those benefits, we performed a comparative techno-economic analysis and life cycle assessment of producing ethanol using loose and pelleted forms of biomass. Analyses of a 2000 metric tons (dry)/d biorefinery showed that using pelleted biomass is more economical than using loose or baled biomass. The lowest minimum ethanol selling price (MESP) for pelleted biomass was USD 0.58/gal less than the lowest MESP for loose biomass. Among all processing conditions analyzed, MESP for ethanol produced with pelleted biomass was always lower than when produced with loose biomass. Shorter pretreatment and hydrolysis times, higher pretreatment solids loadings, lower ammonia requirements, and reduced enzyme loadings were the primary factors contributing to lower MESP with pelleted biomass. Similarly, pelleted biomass also demonstrated a 50% lower life cycle greenhouse gas emission compared to loose biomass. Emissions from higher pelleting energy were offset by downstream advantage in lower chemical needs.

Cellulosic biorefineries have attracted interest due to the growing energy security and environmental concerns related to fossil fuel-based energy and chemicals. Using pelleted biomass as a biorefinery feedstock can reduce their processing inputs while improving biomass handling and transportation. However, it is still questionable whether energy and emission savings from feedstock transportation and processing can justify pelletization. A life cycle assessment approach was used to compare energy consumption and greenhouse gas (GHG) emissions from pelleted and non-pelleted corn stover as a biorefinery feedstock. Operations considered were pelleting, transportation, and soaking in aqueous ammonia (SAA) pretreatment. Despite greater GHG emissions (up to 25 times higher than the transportation) generated from the pelleting process, the model showed a significant opportunity to offset and even reduce overall GHG emissions considering the pretreatment process benefits. Our process energy analysis showed that SAA pretreatment of pelleted biomass required significantly lower energy inputs (56%) due to the lower-severity pretreatment’s effectiveness. Higher pretreatment solid loadings are allowed when pelleted biomass is used and this reduces the process chemicals and water requirements by 56% and 49%, respectively. This study demonstrated that the SAA pretreatment of pelleted biomass might be a feasible option as the cellulosic biorefinery feedstock.