Economic and Environmental Impact Analysis of MWCNT Lithium Nickel Manganese Cobalt Oxide Batteries Manufacturing Considering Worker Safety

Development of safe, economically competitive, and environmentally responsible nano-enabled products, is a desired outcome to avoid unintended consequences for the use of nanomaterials. Carbon nanotubes (CNTs) offer great potential for improving the conductivity and capacity of lithium-ion batteries, but concern for potential impacts on human health and the environment could delay implementation. Given the uncertain risks, additional precautions for exposure prevention may be warranted, although not yet regulated. Companies working with engineered nanomaterials (ENMs) may need to explore decision tradeoffs for additional occupational safety costs and the environmental impacts.;Currently under research, multi-walled carbon nanotube lithium nickel manganese cobalt oxide batteries (MWCNT NMC batteries) show greater energy density and product life than existing lithium-ion batteries. To explore the economics for manufacturing scale-up, a stochastic process based cost model was developed to investigate the cost drivers for manufacture of MWCNT NMC batteries, targeted for satellite and computer applications. In the model, various occupational safety scenarios were considered to analyze the effect of different levels of prevention for worker exposure on the total manufacturing cost. Multi-criteria decision analysis (MCDA) methodology was applied to prioritize a range of alternatives for decision makers, using AHP techniques to recommend best alternatives for each stakeholder. A benefit-cost ratio analysis was also performed to categorize the most desirable product for the decision makers.;To assess the environmental impacts of the manufacturing of CNT lithium-ion batteries, a life cycle assessment (LCA) methodology was applied. Inventories were generated using scenarios from the cost model and used to evaluate the environmental impacts in the manufacturing stage with SimaPro(TM) software. Results provided 1) a first order environmental footprint on the manufacturing process for scale-up, and 2) insights on potential process improvements given the uncertainty in regulatory constraints for nanomaterials. Further, by adjusting the input assumptions, sustainable manufacturing practices for MWCNT NMC batteries with renewable energy (solar energy) use were explored.;Using various methodologies, concurrent assessment of the economic and the environmental health and safety tradeoffs for manufacturing scale-up was explored for MWCNT lithium-ion batteries to determine the economic feasibility, given the uncertain exposure effects of CNTs. The results not only allow consideration of strategies to reduce the manufacturing costs and to utilize sustainable manufacturing practices, but also help manufacturers to estimate the economic viability associated with alternative processing methods to avoid worker exposures. Results from this work offer economic, environmental, health and safety tradeoff analyses to promote sustainable nanomanufacturing.