Environmental impacts of three high-performance thermoplastics (HPTPs) and associated glass-fiber reinforced grades from different processing technologies

Abstract

To guide the design of effective mitigation strategies for high performance thermoplastics (HPTPs) we assessed the environmental impacts of three varieties: polyetherimide (PEI), polyphenylene sulphide (PPS), and polybutylene terephthalate (PBT) and related glass-fiber reinforced grades. Using data collected from different sources and the life cycle assessment (LCA) method, we showed that direct CO₂ emissions from HPTP production were low and that the environmental performance of HPTPs was primarily driven by feedstock sourcing and the processing method. Feedstocks were responsible for 35–93% of non-renewable energy (NRE) usage followed by the processing energy (4–49%) and glass fiber (0–12%). HPTP manufacturing processes using thermoforming consumed the most NRE, and those using compounding or extrusion consumed the least. Total NRE consumption ranged from 248–370 MJ kg⁻¹ for PEI, 103–183 MJ kg⁻¹ for PPS, and 101–115 MJ kg⁻¹ for PBT. Glass-fiber reinforced grades reduced NRE use by 13–36% relative to unfilled HPTPs. GHG emissions showed a similar trend and ranged from 12–17 kg CO_2eq kg⁻¹ for PEI, 7–9 kg CO_2eq kg⁻¹ for PPS, and 4–5 kg CO_2eq kg⁻¹ for PBT. Eutrophication (EP) and acidification (AP) were low and followed the PEI > PPS > PBT trend. Low direct CO₂ emissions from HPTP manufacturing limit the potential for point source carbon capture and storage as a mitigation strategy. However, developing recyclable, green feedstocks and adopting eco-friendly processes are key for improving the sustainability of HPTPs. Our findings serve as an important reference for HPTP stakeholders and policy makers.