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Modern methods of metal and metal-containing materials production involve a serious consideration of the impact on the environment. Emissions of greenhouse gases and the efficiency of energy use have been used as starting points for more sustainable production for several decades, but a more complete analysis can be made using life cycle assessment (LCA). In this paper, three examples are described: the production of precipitated calcium carbonate (PCC) from steelmaking slags, the fixation of carbon dioxide (CO2) from blast furnace top gas into magnesium carbonate, and the production of metallic nanoparticles using a dry, high-voltage arc discharge process. A combination of experimental work, process simulation, and LCA gives quantitative results and guidelines for how these processes can give benefits from an environmental footprint, considering emissions and use and reuse of material resources. CO2 mineralization offers great potential for lowering emissions of this greenhouse gas. At the same time, valuable solid materials are produced from by-products and waste streams from mining and other industrial activities.

Daytime passive radiative cooling (DPRC) has remained a challenge over the past decades due to the necessity of precisely defined materials with a significantly high emissivity of thermal radiation within the atmospheric transparent window wavelength range (8–13 μm) as well as high reflectivity in the solar spectrum (0.2–3 μm). Fortunately, recent advances and technological improvements in nanoscience and metamaterials are making it possible to create diverse metamaterials. This enables the production of DPRC in direct solar irradiation. The development of a material that is appropriate for effective DPRC is also a noteworthy development in this field of technology. This review gives a thorough introduction and discussion of the fundamental ideas, as well as the state-of-the-art and current trends in passive radiative cooling, and describes the cutting-edge materials and various photonic radiator structures that are useful in enhancing net cooling performance. This work also addresses a novel skylight window that offers passive cooling developed at the Åbo Akademi (ÅA) University, Finland. In conclusion, nanomaterials and nanoparticle-based coatings are preferred over all other approaches for commercialization in the future because of their low cost, the ability for large-scale production, simplicity in fabrication, and great potential for further increasing cooling performance.

Heat pumps are increasingly seen as efficient and cost-effective heating systems also in industrial applications. They can drastically reduce the carbon footprint of heating by utilizing waste heat and renewable electricity. Recent research on Stirling cycle-based very high temperature heat pumps is motivated by their promising role in addressing global environmental and energy-related challenges. Evaluating the environmental footprint of a heat pump is not easy, and the impacts of Stirling cycle-based heat pumps, with a relatively high temperature lift have received little attention. In this work, the environmental footprint of a Stirling cycle-based very high temperature heat pump is evaluated using a “cradle to grave” LCA approach. The results for 15 years of use (including manufacturing phase, operation phase, and decommissioning) of a 500-kW heat output rate system are compared with those of natural gas- and oil-fired boilers. It is found that, for the Stirling cycle-based HP, the global warming potential after of 15 years of use is nearly −5000 kg CO2 equivalent. The Stirling cycle-based HP offers an environmental impact reduction of at least 10% up to over 40% in the categories climate change, photochemical ozone formation, and ozone depletion when compared to gas- and oil-fired boilers, respectively.

Mineral carbonation routes have been extensively studied for almost two decades at Åbo Akademi University, focusing on the extraction of magnesium from magnesium silicates using ammonium sulfate (AS) and/or ammonium bisulfate (ABS) flux salt followed by carbonation. There is, however, a need for proper recovery and recirculation of chemicals involved. This study focused on the separation of AS, ABS and aqueous ammonia using different setups of bipolar membrane electrodialysis using both synthetic and rock-derived solutions. Bipolar membranes offer the possibility to split water, which in turn makes it possible to regenerate chemicals like acids and bases needed in mineral carbonation without excess gas formation. Tests were run in batch, continuous, and recirculating mode, and exergy (electricity) input during the tests was calculated. The results show that separation of ions was achieved, even if the solutions obtained were still too weak for use in the downstream process to control pH. Energy demand for separating 1 kg of NH4+ varied in the range 1.7, 3.4, 302 and 340 MJ/kg NH4+, depending on setup chosen. More work must hence be done in order to make the separation more efficient, such as narrowing the cell width.

Steelmaking industry faces urgent demands for both steel slag utilization and CO 2 abatement. Ca and Mg of steel slag can be extracted by acid solution and used to prepare sorbents for CO 2 capture. In this work, the calcium-based sorbents were prepared from stainless steel slag leachate by co-precipitation, and the initial CO 2 chemisorption capacity of the calcium-based sorbent prepared from steel slag with the Ca and Mg molar ratio of 3.64:1 was 0.40 g/g. Moreover, the effect of Ca/Mg molar ratio on the morphology, structure, and CO 2 chemisorption capacity of the calcium-based sorbents were investigated. The results show that the optimal Ca/Mg molar ratio of sorbent for CO 2 capture was 4.2:1, and the skeleton support effect of MgO in calcium-based sorbents was determined. Meanwhile, the chemisorption kinetics of the sorbents was studied using the Avrami-Erofeev model. There were two processes of CO 2 chemisorption, and the activation energy of the first stage (reaction control) was found to be lower than that of the second stage (diffusion control).

First ideas of applications design using magnesium (hydro) carbonates mixed with silica gel for day/night and seasonal thermal energy storage are presented. The application implies using solar (or another) heat source for heating up the thermal energy storage (dehydration) unit during daytime or summertime, of which energy can be discharged (hydration) during night-time or winter. The applications can be used in small houses or bigger buildings. Experimental data are presented, determining and analysing kinetics and operating temperatures for the applications. In this paper the focus is on the hydration part of the process, which is the more challenging part, considering conversion and kinetics. Various operating temperatures for both the reactor and the water (storage) tank are tested and the favourable temperatures are presented and discussed. Applications both using ground heat for water vapour generation and using water vapour from indoor air are presented. The thermal energy storage system with mixed nesquehonite (NQ) and silica gel (SG) can use both low (25–50%) and high (75%) relative humidity (RH) air for hydration. The hydration at 40% RH gives a thermal storage capacity of 0.32 MJ/kg while 75% RH gives a capacity of 0.68 MJ/kg.

The increased global demand for metallic nanoparticles for an ever growing number of applications has given rise to a need for larger scale and more efficient nanoparticle (NP) production processes. In this paper one such process is evaluated from the viewpoints of scalability and energy efficiency. Multiple setups of different scale of an arc/spark process were evaluated for energy efficiency and scalability using exergy analysis, heat loss evaluation and life cycle impact assessment, based on data collected from EU FP7 project partners. The energy efficiency of the process is quite low, with e.g., a specific electricity consumption (SEC) of producing ~80 nm copper NP of 180 kWh/kg while the thermodynamic minimum energy need is 0.03 kWh/kg. This is due to thermal energy use characteristics of the system. During scale-up of the process the SEC remained similar to that of smaller setups. Loss of NP mass in the tubing of larger setups gives a lower material yield. The variation in material yield has a significant impact on the life cycle impact for the produced NP in both the Human Health and Ecosystem Quality categories while the impact is smaller in the Global Warming and Resource Depletion categories.

The use of Stirling-cycle-based heat pumps in high-temperature applications and waste heat recovery at an industrial scale is of increasing interest due to the promising role in producing thermal energy with zero CO2 emissions. This paper analyzes one such technology as developed by Olvondo Technology and installed at the pharmaceutical company AstraZeneca in Sweden. In this application, the heat pump used roughly equal amounts of waste heat and electricity and generated 500 kW of steam at 10 bar. To develop and widen the use of a high-performance high-temperature heat pump that is both economically and environmentally viable and attractive, various analysis tools such as exergy analysis and life cycle assessment (LCA) can be combined. The total cumulative exergy loss (TCExL) method used in this study determines total exergy losses caused throughout the life cycle of the heat pump. Moreover, an LCA study using SimaPro was conducted, which provides insight into the different emissions and the overall environmental footprint resulting from the construction, operation (for example, 1, 8, and 15 years), and decommissioning phases of the heat pump. The combined results were compared with those of a fossil fuel oil boiler (OB), a bio-oil boiler (BOB), a natural gas-fired boiler (NGB), and a biogas boiler (BGB).

The separation of ammonium bisulfate (ABS) from ammonium sulfate (AS) in aqueous solutions by monovalent ion selective membranes was studied. Optimised usage of these chemicals is both an important and challenging step towards a more efficient CO2 mineralisation process route developed at Åbo Akademi University (ÅA). The membranes were placed in a three or five-compartment electrodialysis stack. Silver, stainless steel and platinum electrodes were tested, of which a combination of Pt (anode) and stainless steel (cathode) electrodes were found to be most suitable. Separation efficiencies close to 100% were reached based on ABS concentrations in the feed solution. The tests were performed with an initial voltage of either 10 V–20 V, but limitations in the electrical power supply equipment eventually resulted in a voltage drop as separation proceeded. Exergy calculations for energy efficiency assessment show that the input exergy (electrical power) is many times higher than the reversible mixing exergy, which indicates that design modifications must be made. Further work will focus on the possibilities to make the separation even more efficient and to develop the analysis methods, besides the use of another anode material.

Fluorine-bearing refining slag (FBS) is used to produce axle steel for electric multiple unit vehicles. To avoid environmental pollution caused by fluorine, a fluorine-free ladle furnace slag (FFS) was designed based on an industrial FBS. The effects of main components on the physical and metallurgical properties of slag were investigated via theoretical analysis and laboratory tests. The composition range of components of the designed FFS are w(CaO) = 40–55 wt.%, w(SiO2) = 2–6 wt.%, w(Al2O3) = 30–40 wt.%, w(MgO) = 6–8 wt.%, and w(CaO)/w(Al2O3) = 1.25–1.50. Industrial-scale test results indicate that the FFS has similar deoxidation and desulfurization capabilities to industrial FBS.