Inverse vulcanized sulfur polymers: A greener and cost-effective alternative to conventional polymers - A cradle-to-gate life cycle analysis

Inverse vulcanized sulfur polymers offer an ecofriendly alternative to conventional petrochemical-based polymers by utilizing elemental sulfur, a waste product from petroleum refining. This study evaluates their synthesis, characterization, and potential applications, focusing on their environmental impact through a cradle-to-gate life cycle analysis (LCA). Monte Carlo simulations were utilized to include uncertainty analysis, reinforcing the robustness of the results. Through 10,000 simulations, sulfur polymers, both non-catalyzed and catalyzed, required less energy in 9942 simulations, and showed lower global warming potential (GWP) and production costs in 8891 and 9857 simulations, respectively, compared to conventional polymers like polyurethane and polyepoxy resins. Projections for industrial-scale production showed a potential reduction of 86.2% in total energy consumption, 20.5% in GWP, and 60.9% in costs compared to laboratory-scale production. While catalyzed sulfur polymers demonstrated even more favorable LCA metrics, the energy required for raw material extraction for catalysts, which was not fully accounted for due to a lack of availability, may impact the final LCA metrics, reducing their benefits. The properties of the final polymer, such as mechanical strength, thermal stability, and chemical resistance, were affected by the use of catalysts and crosslinking agents and should be considered when selecting a polymerization method. In conclusion, sulfur polymers present a compelling alternative to conventional petrochemical-based polymers, with potential reductions in energy consumption, GWP, and production costs. However, further research to fully understand the implications of catalyst use and the potential impacts on polymer properties is needed. • Sulfur polymers (SPs) as a promising alternative to petrochemical-based polymers (PbP). • Cradle-to-gate life cycle analysis highlights sustainable approach of SPs. • The use of catalyst reduced up to 64.8% the energy requirements for SPs synthesis. • SPs required less energy in 99.96% of simulations (Monte Carlo) compared to PbP. • SPs were cheaper than PbP in 99.85% of the simulations (Monte Carlo).