Ab Initio Life-Cycle Analysis Assisting the Selection of Eco-Friendly Additives in Bio-Based Coatings

The formulation of eco-friendly coatings with protective properties against corrosion and/or mechanical degradation requires the selection of appropriate bio-based binders and functional additives. Although the concentration of additives remains limited, the replacement of fossil-based additives with bio-based additives may deliver an important contribution to improving the carbon footprint of a coating, in parallel with their influences on coating performance, lifetime, and processing. However, the role of bio-based additives in life-cycle analysis (LCA) is often neglected and minorly considered in current literature. Reasons for this include the complexity of the full system, together with a lack of data, methodological inconveniences, and appropriate design of realistic scenarios. Within this work, an approach of simplified LCA is followed by ab initio cradle-to-gate analysis of coating formulations focusing on the replacement of specific fossil additives (e.g., carbon black, silicates, and calcium carbonate) with bio-based additives (e.g., biochar, bio-based wax, recovered calcium carbonate, and nanocellulose). The different environmental impact parameters (human health, eco-toxicity, resource scarcity, and carbon footprint) for bio-based additives and coating formulations are calculated from eco-cost analysis (Idemat 2024 v2.2 database), indicating a 15 to 30% gain in carbon footprint for coatings with bio-based additives. In a particular case study for improving coating performance by substituting cellulosic additives into nanocellulose from different sources, the reduction in environmental impact parameters is positively associated with their high performance at low concentration. The need for intermediate processing of bio-based additives is a main parameter contributing to their environmental impact, but environmental benefits are abundantly compensated by their carbon storage credit and performance improvement.