Cradle-to-Grave Life Cycle Assessment and Techno-Economic Analysis of Polylactic Acid Composites with Traditional and Bio-Based Fillers

This research focused on life cycle assessment (LCA) and techno-economic analysis (TEA) comparisons of polylactic acid (PLA) composites, in order to compare organic to inorganic fillers. Organic fillers included DDGS, flax, hemp, rice husks, and wood, and were compared against inorganic fillers (glass and talc) for PLA-based composites. This study utilized LCAI and TEA methodology to estimate and quantify costs, emissions, and energy intensity (EI) associated with material acquisition, processing, transport, and end-of-life treatment used during plastic composite production. Emission categories analyzed include global warming potential (GWP), air acidification (AA), air eutrophication (AE), water eutrophication (WE), ozone layer depletion (OLD), air smog (AS), high carcinogens (HC), and high non-carcinogens (HNC). To achieve a “Cradle-to-Grave” perspective, two models were meshed, the plastic comparator (PC) and EIO-LCA (EIO), to simulate the EI and emissions associated over the entire life cycle. Based assumptions used, this research has shown that utilizing land fill end-of-life treatment and glass filler composite was the most environmentally harmful option, and maintained the highest economic impact, for all impact categories during PLA composite production. Alternatively, both DDGS and wood filler composites paired with recycling end-of-life treatment were shown to be the least environmentally damaging method and incurred the lowest cost of all PLA composites considered. This study also suggests that utilization of organic bio-based fillers produces a lower economic/environmental impact, and EI, compared to utilization of inorganic fillers in PLA composites. Accordingly, this research has demonstrated the impact of LCA/TEA paired analysis when assessing the bioplastic and biocomposite processing, which may be utilized as a precursor for parallel research undertakings.