Rare earth elements (REE) exhibit particular and unique properties that render them essential to technological applications. Of particular interest is their involvement in the transition toward global sustainability and their military applications. The magnetic properties of the rare earth elements is of primordial importance to sustainable development. More specifically, terbium and dysprosium are two elements with no known substitutes in critical applications and with no domestic or allied sourcing available. These elements are currently mined by in-situ leaching of ion-absorbed clays, mostly from illegal operations in Myanmar financed by Chinese companies. The demand from both elements, and for the other magnet rare earths is projected to growth at very high rates through 2035 while the world undergoes a transition toward sustainability, and a drastic reduction in greenhouse gases emissions. Our team has been evaluating the potential of acid mine drainage (AMD) as a source of rare earth elements and critical materials (CM). Acid mine drainage is the result of in-situ generation of sulfuric acid due to the weathering of sulfide ores. It is a significant legacy environmental issue and one of the largest pollutants in many mining districts throughout the world. The objective of the present work is to provides a roadmap for the utilization of AMD as a critical material feedstock to preserve the independence of the United States of America with regards to these materials. To that effect, a fundamental economic assessment of REE/CM recovery from AMD using a network sourcing strategy in addition to a robust, flexible feedstock separations and refining facility was undertaken. A techno-economic analysis of the extraction, refining, separation and reduction to metal is presented along with a sensitivity analysis.The results of this analysis show that, with the exception of the minimum price scenario, all operational configurations have positive economic indicators with rates of return varying from 25% to 32% for the contemporary price scenario. This is primarily due to the very high enrichment in terbium and dysprosium of AMD. The optimal configuration was determined to be production of Co, Mn, and all REEs except for mischmetal, which is not recovered. Sensitivity analysis and Monte Carlo Simulation show that capital cost and HCl consumption are the two major factors influencing rate of return, thus indicating opportunities for future technology development and cost optimization. In order to reduce both the capital and operation cost of the facility, alternative ionic liquids extractants based on conventional acidic extractants where synthesized and investigated. The results show that the ionic liquids varied in performance, with [c101][D2EHP] and [c101][EHEHP] performing poorer than their conventional counterparts and [c101][c572] performing better. The performance of [c101][c572] was 13% superior to Cyanex 572, 20% superior to EHEHPA and 27% superior to D2EHPA the current commercially used extractants. Recommendations for further study on [c101][c572] include stripping tests, continuous pilot testing, and techno-economic analysis. The test work revealed that zinc and to a lesser extent calcium were significant deleterious elements in the solvent extraction circuit, and that selective removal would significantly reduce the acid-base consumption of the separation circuit. A process was developed to selectively remove calcium and zinc from AMD-derived feedstock and from REE products. The ammonium chloride leach process offer many advantages, including the possibility of closing the cycle by using carbon dioxide sequestration as a step to regenerate the ammonium chloride in a zero-discharge process. / Doctor of Philosophy / A younger me: - What are these elements in the bottom of the periodic table? My high school chemistry teacher: - "Don't waste time there, these are of no concern." Twenty years later, technological developments and the imperative to transition away from fossil energy to mitigate climate change have brought the rare earth elements, a series of 17 elements with unique properties to the forefront of the conversation. In addition to an organic increase in demand, the recent supply chain consolidation by China is adding a geopolitical risk to the equation. The magnetic properties of the rare earth elements is of primordial importance to sustainable development and to our military technology. More specifically, terbium and dysprosium are two elements with no known substitutes in critical applications and with no domestic or allied sourcing available. These elements are currently mined from illegal operations in Myanmar, with the support of Chinese companies. The demand from both elements, and for the other magnet rare earths is projected to growth at very high rates through 2035 while the world undergoes a transition toward sustainability, and a drastic reduction in greenhouse gases emissions. Given the important of the rare earth elements, and the absence of significant deposits in the united states, with the exception of the Bear Lodge and Elk Creek deposits, the Department of Energy has mandated academic institution of evaluating alternative sources of rare earth elements. Our team has been evaluating the potential of acid mine drainage as a source of rare earth elements and critical materials. Our team has surveyed many acid mine drainage sources and determined that many sites are highly enriched in terbium and dysprosium. Acid mine drainage is a legacy environmental issue related to past problematic mine development techniques. In the problematic mines. these acidic mine waters are permanently generated and if not treated can have severe impacts on water streams in which they flow. The toxicity of the acid mine drainage on the environment is due to its high acidity and significant levels of toxic metals. Acid mine drainage can be recognized by their yellow to red tint. It is treated by reacting it with a neutralization agent, which results in treated water and a sludge. The sludge is dewatered and stored in tailing impoundments. I have designed a process for the economical recovery of rare earth elements and critical materials from acid mine drainage. The cost to build and operate the facility was derived and it was determined that the project could be further enhanced by reducing the plant chemical reagent consumption. One specific category of chemical referred to as extractant, is central to the rare earth separation process. A novel variation on the standard extractants has been evaluated and promises to provide significant savings. While the extractants were investigated, it was noticed that some impurities such as zinc and calcium created issues in the circuit. I then developed a process for their selective removal. The process also provide a net carbon dioxide sequestration potential.

<div>With the rapid development of clean energy technologies, various bottlenecks on supplies of related critical materials emerged. Since supply chains of critical materials often involved with multiple layers of markets with different characteristics, to better identify bottlenecks and increase critical material availability, it is vital to have better understanding and projection on these markets.</div><div>Agent-based modeling is a bottom-up approach that can imitate heterogenous objects in a changing environment. Therefore, it is an excellent tool to simulate markets with fierce competition and fast revolution. This work demonstrates the application of agent-based modeling by discussing three different topics related to critical material demand and supply induced by clean energy products.</div><div>The first application focused on LED residential lighting market. LED lighting market grew rapidly and introduced potential demand on several critical materials including indium. The work modeled consumers as heterogenous and irrational agents in network purchasing new bulbs based</div>

This report has investigated the ethical issues associated with mining or processing of materials that make them considered as controversial. For each material, the main areas of use and the top producing countries are analysed, followed by social and/or environmental issues as well as potential problems in the future. In total, 13 materials are discussed, of which most are minerals. The overall issues, that are recurring throughout the report and are important to be aware of are: child labor, low safety standards, mining activity resulting in deforestation or harming biodiversity, mining processes that affect communities (e.g. because of large water consumption) and the risks associated with widespread illegal mining. The report also provides research about organisations and initiatives that aim to affect the problems, and gives a brief view over tools that can be used to increase awareness of these issues.

En la presente tesis se tiene como objetivo determinar cómo solucionar el problema de desabastecimiento de materiales críticos de la empresa Consorcio Cam Lima. Para ello, se tuvo que realizar una descripción general de la empresa, enfocándonos en los procesos logísticos ya existentes donde se pudo identificar las necesidades diarias de las líneas operativas de la empresa, los materiales que se encuentran en dichas necesidades y la frecuencia y cantidad que requieren los usuarios para poder realizar sus actividades eficientemente y en el periodo establecido. Se pudo analizar los procesos y procedimientos que los usuarios y las áreas de apoyo toman en cuenta para que se pueda realizar el abastecimiento de materiales críticos, además de los necesarios para una correcta reposición de materiales por parte del área logística, que involucra el área de almacén y compras, y mantener una completa exactitud de inventarios físicos y del sistema. Con dicho análisis, se pudo comprobar que los usuarios no se planifican y generan los requerimientos de materiales a última generando una incorrecta reposición del inventario, además se pudo comprobar que los errores y demoras en la digitación de entradas y salidas de materiales en el sistema no era una causa de la inexactitud de inventarios, obteniendo hallazgos como omisión de algunas actividades en el proceso de recepción de materiales físicos. En el planteamiento de la mejora se determinó que materiales críticos se comportan como una demanda estacional, por lo que para poder obtener el pronóstico de la demanda se utilizó el modelo de suavización exponencial. Finalmente, se propone implementar un plan de abastecimiento a partir del análisis del modelo de lote económico y un kardex físico por cada material registrando cada ingreso y salida del almacén. In the present investigation is intended to determine how to solve the problem of shortage of materials critical of the company Consortium Cam Lima. For this, had to carry out a general description of the company, focusing on existing logistics processes which were unable to identify the daily needs of the operation guidelines of the company, what are those needs and frequency and amount that require users to be able to carry out its activities efficiently and in the set period of time. I could analyze the processes and procedures that users and support areas taken into account so that the supply of critical materials, in addition to those necessary for a correct replacement of materials by the logistics area, can be that it involves the warehouse and shopping area, and maintain a complete physical inventory and system accuracy. With this analysis, it was proven that users not planned is and generate the requirements of latest materials generating an incorrect replacement of the inventory, also failed to check the errors and delays in the fingering of inputs and outputs of material in the system was not a cause of the inaccuracy of inventories, obtaining findings as omission of certain activities in the process of receiving physical materials. On the approach of improving was determined that critical materials behave as a seasonal demand, so for demand forecasting model of exponential smoothing was used. Finally, intends to implement a plan of supply from the analysis of the model of the economic lot and a physical kardex by each material registering every entrance and exit the warehouse.

Large-scale deployment of low-carbon energy technologies is important for counteracting anthropogenic climate change and achieving universal energy access. This thesis explores potential growth rates of technologies necessary to reach a more sustainable global energy system, the material and energy flows required to commission these technologies, and potential future availability of the required resources. These issues are investigated in five papers. Potential future growth rates of wind energy and solar photovoltaics, and the associated material requirements are explored, taking the expected service life of these technologies into account. Methodology for assessing net energy return and natural resource use for wind energy systems are analyzed. Potential future availability of lithium and phosphate rock are also investigated. Estimates of energy and materials required for technologies such as wind energy and photovoltaics vary, and depend on the assumptions made and methods used. Still, it is clear that commissioning of low-carbon technologies on the scale required to reach and sustain a low-carbon energy system in coming decades requires significant quantities of both bulk materials and scarcer resources. For some technologies, such as thin film solar cells and electric vehicles with lithium-ion batteries, availability of materials could become an issue for potential growth rates. Future phosphate rock production could become highly dependent on few countries, and potential political, social and environmental aspects of this should be investigated in more detail. Material and energy flows should be considered when analyzing growth rates of low-carbon technologies. Their estimated service life can indicate sustainable growth rates of technologies, as well as when materials are available for end-of-life recycling. Resource constrained growth curve models can be used to explore future production of natural resources. A higher disaggregation of these models can enable more detailed analysis of potential constraints. This thesis contributes to the discussion on how to create a more sustainable global energy system, but the methods to assess current and future energy and material flows, and availability of natural resources, should be further developed in the future.

The increasing demand for mineral-based resources that face supply risks calls for managing the supply chains for these resources at the regional level. Cobalt is a widely used cathode material in lithium-ion batteries, which form the major portion of batteries used for renewable energy storage - a necessary technology for electrifying mobility and overcoming the challenge of intermittency, thus making renewable energy more reliable and energy generation more sustainable. This necessitates understanding cobalt's supply risks and for the Untied States, identifying sources of cobalt available for future use via recycling or mining. These needs are addressed in this work using single and multiregional input-output (MRIO) analysis in combination with graph theory. An MRIO-based approach is developed to obtain the trade network of cobalt and offer a more expedient way to identify potential critical material sources embodied in commodities made domestically. Commodities containing cobalt were disaggregated from two input-output (IO) models and the trade structure of cobalt at the national and state level was observed and compared. The significance of identified key sectors is measured according to several criteria and differences in sectors highlighted in the national versus subnational networks suggests that analysis at the two regional aggregation levels provides alternative insights. Results from mining the IO networks for cobalt highlight the geographical distribution of its use and industries to further investigate as potential sources for secondary feedstock.

Solar energy industries are one of the fastest-growing industries in the global energy market. Between 2018 and 2019, installed capacity in Sweden increased by 70%. This is due to a combination of declining PV module and inverter costs, as well as  increased conversion to fossil-free energy production to mitigate greenhouse gas emissions. In fact, solar PVs have a 25-year life span, and soon many deployed PVs would soon reach their end of life (EoL), it is, therefore, important to organize for the EoL of PVs in order to recover precious resources and recycle PV modules in a sustainable manner. Currently, less than 10% of global solar cell waste is recycled, due to the lack of incentives for recycling in most countries. In the European Union, used-up modules are governed by the WEEE (Waste Electrical and Electronic Equipment) Directive, which requires the collection of 85% of solar cell waste, with at least 80% of the waste being prepared for reuse or recycling. Solar cell waste has not amounted to significant volumes in Sweden, due to the lack of no known systems for recycling. Used-up modules are currently collected and managed as electronic waste in one of two approved collection systems in Sweden. The aim of this thesis is to analyze and assess methods of recycling waste solar panels in Sweden and is it economically viable to set up a solar waste recycling center before it reaches the right amount of waste. Moreover, the main focus is on the analysis and comparison of the environmental impacts of various recycling methods for crystalline silicon (c-Si) and cadmium telluride (CdTe) panels. To recycle solar panel waste, the elements of these panels must be assessed from both an economic point of view as well as environmental impacts. Today, the most common PV panels in the global market and also Sweden are c-Si and CdTe types. The results showed except for the pyrolysis method, the environmental impacts of both c-Si and CdTe PV panels from the thermal-based recycling methods, are lower than chemical methods. Furthermore, the extraction of Al, Si, and glass from c-Si and the extraction of glass from CdTe has a less environmental impact than the current techniques used in the recycling of PV panels. Finally, in this study, we revealed which materials can be prioritized for maximum economic and environmental advantages from recycling. In c-Si modules, these are Ag, Al, Si, and glass and in CdTe modules, these are Te, Cu, and glass. Currently, investing in a new solar module recycling center in Sweden is not economically viable. Because the possibility of such an investment requires economic and political incentives. Given that by 2042 the volume of Swedish solar waste will not reach the minimum level of profitability to build a new specialized center for the recycling of solar modules, the best decision is to modify the existing plants in Sweden to recover expensive and vital materials.

<p>Critical materials are crucial to the wide deployment of clean energy technologies and advanced technology such as electric vehicles (EVs), smartphones, high-efficiency lighting, and wind turbines. Particularly, rare earth elements (REEs) and lithium are key elements for clean energy and EVs. However, higher REEs and lithium demand for clean energy transformation, extreme supply reliance on certain area exports, and severe environmental issues during mining and processing cause uncertainty for future clean energy and transportation development. Our study aims to develop dynamic LCA with scenario analysis to simulate the future possible sustainability pathways for critical materials for stakeholders and apply life cycle assessment (LCA) to evaluate the latest REEs and lithium extraction and recycling technologies. Dynamic LCA (DLCA) integrates the temporal datasets to predict the future environmental impact of a product. The databases are mainly from Ecoinvent and Critical Materials Life Cycle Assessment Tool (CMLCAT). Python package Brightway2 and Temporalis are used to simulate the DLCA.</p> <p>The study of DLCA on the REEs industry reveals the future predictive REEs environmental impact trend, providing a clear policy strategy to reach sustainability goals for stakeholders. The results show that shifting REEs resources from China to Australia and increasing the recycling rate are key factors in reducing environmental impact in the future. Considering the degradation of rare earths ore and storage depletion in China, such as the decreased production of heavy REEs from Ion adsorption clay in southern China, exploration, and inclusion of potential REEs production projects will be the possible sustainable way in the following decade. </p> <p>LCA of RE recovery from room temperature ionic liquid (RTIL) electrochemical process helps us explore the benefits of recycling RE from the e-waste. Although RTIL contributes a higher impact on ozone depletion and global warming, close-loop recycling RTIL could reduce substantial environmental impact. Lithium recovery from geothermal brine provides the great source for fulfilling the domestic demand of the U.S. Compared to the conventional Li compounds production, this method is efficient and has 25-41% lower global warming potential. The government, researchers, and industry could benefit from this study for exploring advantage and drawback strategies for the future environmental footprint of NdFeB magnet production and identifying environmental hotspots of the latest recycling and extraction process of REEs and lithium.</p>

<p>As society works to reduce its reliance on fossil fuels, the demand for renewable energy and clean energy technologies continues to grow rapidly. Lessons learned from the ongoing electronics waste crisis necessitate closing material loops to secure supply chains and redirect valuable resources away from the landfills.</p><p> </p><p>Inspired by the principles of industrial ecology, the circularization of renewables is demonstrated by applying the notion of Life Cycle Symbiosis (LCS), an extension of Industrial Symbiosis (IS). This is achieved by identifying waste streams that may have value as potential raw material/feedstock and the subsequent development of industrial synergies in the context of end of life (EoL) photovoltaics (PVs). Per metric ton of EoL PVs, the avoided global warming potential (GWP) and ecotoxicity impacts were calculated to be as high as 2750 kg CO₂ eq and 32,000 CTUe respectively, while the water savings and electricity savings were over 37,000 m³ and 3600 MJ. Building upon this work, a hybrid multi objective optimization (MOO) method was proposed to support the creation of industrial synergistic networks or eco industrial parks (EIPs). The hybrid method addresses the challenges associated with the early design and development stages of EIPs (supply, demand, potential synergies, etc.), and also those in relation to considering multiple conflicting sustainability objectives.</p><p> </p><p>Apart from addressing material scarcity, rising pollution levels and exposure to toxins, recovery and circularization may also contribute towards stabilizing feedstock prices. Supply chains for renewables and clean energy technologies are brittle because of risks associated with possible supply deficits stemming from complex geo-political situations and oligopolies. This can translate to price fluctuations among high-value, critical materials on which clean energy technologies rely. In order to ensure a smooth transition to a clean energy technologies, and one that is also sustainable, it is vital to assess the impact of these very complexities on the market dynamics for the critical material feedstocks. To this end, a system dynamics model has been developed to capture price trends of rare earth elements (REEs) used in EVs under varying market scenarios. The proposed model aims to aid automobile manufacturers in developing effective business strategies as they work towards electrifying their vehicle fleets.</p><p>This thesis reports on the development of some strategies rooted in industrial ecology to prevent renewables and clean energy technologies from themselves becoming environmental liabilities in the future.</p>

<p dir="ltr">In our daily lives, we rely on a multitude of discrete products to meet our needs. Traditional product design approaches have primarily focused on economic and technical aspects, often overlooking the pressing environmental and social challenges facing society. Recognizing the limitations of our ecological systems to cope with the waste generated by our current industrial processes, there is a growing need to anticipate the potential consequences of product design across technical, economic, environmental, and social dimensions to pave the way for a sustainable future. One promising strategy within this context is the integration of sustainability principles into optimization-based design models that consider a product's entire life cycle. While there have been previous efforts to optimize product life cycles, a comprehensive exploration of optimization-based design methods with a focus on multiple objectives for discrete products is essential. This dissertation explores the integration of sustainability principles with optimization-based design by taking the electric traction motor used in electric vehicles as a case study. This complex and environmentally significant technology is ideal for investigating the tradeoffs and benefits of incorporating sustainability objectives into the design process.</p><p dir="ltr">The key tasks undertaken in this study are as follows:</p><ul><li>Development of a parametric design and optimization framework for a surface-mounted permanent magnet synchronous motor. In this task, a special emphasis is placed on reducing reliance on materials with a high supply risk, such as rare earth elements.</li><li>Creation of a parametric life cycle assessment model that combines life cycle assessment and optimization-based design to minimize a single-score environmental impact. This model offers insights into the environmental performance of product design and underscores the importance of minimizing environmental impact throughout a product's life cycle.</li><li>Integration of a life cycle costing model, incorporating techno-economic assessment and total cost of ownership perspectives, into the parametric life cycle assessment and optimization-based design models. This model is used to minimize levelized production and driving costs, shedding light on the trade-offs within this family of cost metrics and the optimization of manufacturing systems for motor production.</li><li>Proposal of a circular economy model/algorithm to assess the advantages of integrating the circular economy paradigm during the early design phase. All the mentioned objective functions are considered to study the impacts of applying the circular economy paradigm.</li></ul><p dir="ltr">The contributions of this research can be summarized as follows:</p><ul><li>Utilized a diverse array of analytical methodologies to parameterize the design process of a motor, incorporating the integration of Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA) models, as well as the incorporation of disassembly planning for informed decision-making in the early stages of design.</li><li>Proposed a generalized objective function denoted as the Supply Risk-equivalent (SR-eq.), aimed at mitigating the risks associated with the dependency on critical materials in product manufacturing.</li><li>Introduced a novel approach for visualizing non-dominated solutions within a multi-objective framework, with experimentation conducted on up to six distinct objectives.</li><li>Substantiated the significance of decarbonizing the electric grid while maintaining competitive cost structures, the importance of advancing non-destructive evaluation (NDE) procedures for assessing the condition of end-of-life (EoL) subassemblies, and optimizing the collection rate of EoL motors.</li></ul><p dir="ltr">Demonstrated that the optimization of technical metrics as surrogate indicators for economic and environmental performance does not necessarily yield designs that are concurrently optimal in economic and environmental terms.</p>