Life Cycle Assessment Methodology Research Articles

Cradle-to-gate life cycle assessment of heavy machinery manufacturing: a case study in Türkiye

Abstract Purpose Amidst accelerated industrialization and urbanization, the surge in heavy equipment production, crucial for construction, mining, industry, and transportation, necessitates a comprehensive examination of its environmental implications from a sustainability standpoint. This study aims to scrutinize the environmental impacts of manufacturing forklifts and semi-trailers in Türkiye, employing the life cycle assessment (LCA) methodology. Methods The life cycle assessment (LCA) methodology is the foundational framework for evaluating the environmental impacts associated with forklift and semi-trailer manufacturing. A cradle-to-gate approach was employed. CCaLC2 software alongside the Ecoinvent 3.0 database and CML LCIA methodology was used. Results The carbon footprint analysis reveals that the production of a single forklift and semi-trailer generates 10.8 tons CO2eq. and 24.9 tons CO2eq. of emissions, respectively. Considering the mass of the machinery, these figures translate to 2.8 ton CO2eq./ton machinery and 1.57 ton CO2eq/ton machinery for the forklift and semi-trailer, respectively. These results were found to be consistent with values reported for similar (but not identical) heavy machinery. Notably, the predominant share of environmental impact stems from raw material acquisition for both products, with subsequent contributions from various production stages. Steel utilization emerges as the primary contributor to all environmental impact categories, constituting an average contribution of 75%. Noteworthy exceptions include the acidification potential of forklift production, where the incorporation of the engine emerges as the primary hotspot with a significant 38% contribution. Conclusions The findings present the environmental footprint associated with forklift and semi-trailer manufacturing, emphasizing the pivotal role of raw material acquisition, particularly steel utilization. Insights derived from this environmental impact assessment provide invaluable guidance for enhancing environmental sustainability. Decision-makers and industry stakeholders can leverage these conclusions to implement targeted measures, such as exploring alternative materials or refining production processes, to mitigate the environmental consequences of resource-intensive heavy equipment manufacturing, aligning with broader sustainability objectives.

Environmental life cycle assessment (LCA) of oxidative desulfurization of gas condensate in novel oxidation system.

Environmental life cycle assessment (LCA) of oxidative desulfurization of gas condensate in novel oxidation system.

Sustainable Heat Production for Fossil Fuel Replacement—Life Cycle Assessment for Plant Biomass Renewable Energy Sources

This study aims to assess the environmental impact of using wood-based biomass as a high-efficiency fuel alternative to fossil fuels for heat production. To achieve this, the life cycle of biomass transformation, utilization, and disposal was analyzed using the life cycle assessment (LCA) methodology with SimaPro 9.5.0.2 PhD software. The system boundaries included extraction, processing, transportation, combustion, and waste management, following a cradle-to-gate approach. A comparative analysis was conducted between natural gas, the most widely used conventional heating fuel, and two biomass-based fuels: wood pellets and wood chips. The results indicate that biomass utilization reduces greenhouse gas emissions (−19%) and fossil resource depletion (−16%) while providing environmental benefits across all assessed impact categories analyzed, except for land use (+96%). Biomass is also to be preferred for forest waste management, ease of supply, and energy independence. However, critical life cycle phases, such as raw material processing and transportation, were found to contribute significantly to human health and ecosystem well-being. To mitigate these effects, optimizing combustion efficiency, improving supply chain logistics, and promoting sustainable forestry practices are recommended. These findings highlight the potential of biomass as a viable renewable energy source and provide insights into strategies for minimizing its environmental footprint.

Evaluating the use of eggshell powder and sawdust ash as cement replacements in sustainable concrete development

Concrete, the most widely utilized material in construction worldwide, contributes significantly to the consumption of natural resources and energy. The construction sector is a major source of waste and greenhouse gas (GHG) emissions, making it essential to improve the environmental impact of concrete to address climate change and pollution concerns. Evaluating the environmental footprint of concrete is crucial for advancing sustainable building practices. Cement, a key binder in concrete, is particularly responsible for GHG emissions due to its energy-intensive production process. This study applies the Life Cycle Assessment (LCA) methodology, using SimaPro software and the Ecoinvent database, to assess the environmental impact of concrete. A modified concrete mix was developed by replacing Portland Composite Cement with Eggshell Powder (ESP) (60% by weight) and Sawdust Ash (SDA) (40% by weight) at varying replacement rates of 10%, 20%, 30%, and 40%. The results showed up to 20% for replacement cement with ESP and SDA improved compressive strength in a 28-56 day period, with the highest strength growth rate of 29.58% observed for the mixes with replacement. However, higher replacement levels of 30% and 40% showed limited strength improvement during the same period. The enhanced compressive Strength and higher strength growth (compared to tra- ditional concrete) are observed withare0-20 % replacement of cement s. This suggests that this blend of materials could be used in projects with significant budget constraints, directly decreasing carbon emissions associated with concrete production. This aligns with global sustainability goals and can be used in projects aiming for green certifications like LEED (Leadership in Energy and Environmental Design). The study indicates that substituting cement with ESP and SDA reduces costs. This can sig- nificantly benefit low-budget housing projects or areas with high cement prices, providing a direct economic advantage. The environmental performance of the modified concrete was analyzed through LCA following the ISO 14040:2006 framework, focusing on the cradle-to-grave impacts, including raw material extraction, energy consumption, and water usage. One cubic meter of concrete was chosen as the functional unit. The analysis revealed significant reductions in the endpoint impact categories, including a 59% reduction in ecosystem impacts, 60% in human health, 61% in resource depletion, 59.79% in ozone depletion, and 54.32% in fossil fuel depletion. These results highlight the potential of ESP and SDA as sustainable alternatives for improving concrete's mechanical properties and environ- mental performance, supporting the development of more sustainable construction practices.

Social Life Cycle Assessment of Innovative Products from Solar Evaporation Iberian Saltworks: A Descriptive Approach to the Implementation of Halotolerant Crops and Microorganisms

Soil salinization and land abandonment pose significant socio-economic and environmental challenges, particularly in the Iberian Peninsula, where traditional saltworks and agricultural lands have been increasingly degraded. Innovative approaches, such as the implementation of halotolerant crops and microorganisms, offer a promising strategy to revitalize these underutilized areas. This study applies the Social Life Cycle Assessment (S-LCA) methodology to evaluate the socio-economic benefits of halotolerant agriculture in abandoned saltworks and salinized lands. Data were collected through interviews with key stakeholders, literature reviews, and case studies of four enterprises actively engaged in sustainable salina restoration. Key social indicators, including employment creation, community participation, and cultural heritage conservation, were assessed using an expert-based weighting system. The findings indicate that enterprises involved in these initiatives demonstrated strong contributions to local economic resilience and cultural heritage preservation. However, challenges related to scalability and external economic influences remain key considerations. These results highlight the potential of biosaline agriculture as a viable solution to address land abandonment and food security challenges, while also contributing to rural socio-economic development.

Waste Management in Tourism: a Study in an Environmental Conservation Park in Light of the Circular Economy

Objective: This study investigates the implementation of waste management practices in environmental conservation parks, focusing on applying circular economy principles to reduce CO₂ emissions and mitigate environmental impacts associated with tourism. Theoretical Framework: Based on a theoretical framework that integrates Circular Economy, Zero Waste, and Life Cycle Assessment (LCA), the research provides a comprehensive basis for analyzing challenges and opportunities in sustainable tourist destinations. Method: A case study was conducted at Parque Estadual de Vila Velha in Ponta Grossa (PR), Brazil, using document analysis, review of official reports, and the application of the Waste Reduction Model (WARM), which is based on Life Cycle Assessment (LCA) methodology. Both quantitative and qualitative data were systematically collected and analyzed to compare different waste management scenarios. Results and Discussion: The findings indicate that the adoption of zero waste practices substantially reduces greenhouse gas emissions, improves operational efficiency in waste management, and enhances visitor experience. Research Implications: The study shows that adopting waste management practices based on the circular economy and the zero waste concept can lead to a significant reduction in GHG emissions. The scenario that proposes the local treatment of organic waste, such as composting, presents a significant reduction in emissions. This indicates that investing in on-site treatment technologies can be an effective strategy to improve waste management and reduce the need for transportation, which is a significant source of emissions. Originality/Value: Discussion of emissions scenarios from waste treatment in an environmental preservation tourist park, based on the WARM methodology. Comparison of results from different treatments, implications for waste transportation and segregation.

Fuzzy logic use case within the built environment for optimizing sustainability versus cost in the material selection process

This study aims to investigate the application of fuzzy logic in decision-making within the Built Environment. The research focuses on achieving a balance between reducing carbon emissions and increasing costs in the selection of materials and equipment. This balance is measured by Life Cycle Carbon Emissions (LCCE) and is evaluated using a Life Cycle Assessment (LCA) methodology. By modeling fuzzy logic against classical binary logic within MATLAB, the study demonstrates how fuzzy logic’s “degrees of truth” may be utilized to construct customized stakeholder buy-in profiles and also achieve increased mathematical precision. These decision-maker stakeholder profiles reflect different interpretations of linguistic expressions of value in terms of cost against carbon reduction trade-offs. The research develops a three-dimensional control surface by using the Fuzzy Logic Toolbox in MATLAB. This surface serves as a visual tool for purchasing professionals to optimize these trade-offs on a scale, which provides a practical strategy for large-scale construction projects.

Sustainable Additive Manufacturing of IN718 Blades: Powder Recycling Strategies for Reduced Carbon Footprint.

With the growing demand for aero-engine turbine blades, the resource consumption and environmental impact of superalloy powder in the manufacturing process have become increasingly significant. This study focuses on IN718 nickel-based superalloy powder and establishes a recycling method based on powder mixing. By mixing sieved recycled powder with new powder at a 1:1 mass ratio, comprehensive characterization tests, including powder morphology analysis, particle size distribution, blade printability evaluation, mechanical property tests (tensile strength at both 25 °C and 650 °C), and microhardness measurements, demonstrated that the blended powder maintained performance characteristics comparable to new powder, with no statistically significant differences observed. Furthermore, this study introduces the life cycle assessment (LCA) methodology into the field of superalloy powder recycling, providing a novel technical approach for sustainable development in aerospace manufacturing. A quantitative analysis of environmental impacts throughout the blended powder recycling process indicates that this method can reduce carbon emissions by 45% and energy consumption by 48%.

Life Cycle Assessment of Thermoelectrics: Ecological Viability in Intermittent Waste Heat Scenarios.

This study evaluates the ecological impacts of thermoelectrics (TEs) in stationary applications that periodically generate waste heat using life cycle assessment (LCA) methodology, a first of its kind. Six TE modules are analyzed for a periodic heat-emitting application: a natural gas-based power plant that meets only peak electricity demand. The analysis uses detailed inventories from an earlier study regarding the production and end-of-life stages of the TEs. The results show that while TEs are effective in conserving fossil fuels and lowering greenhouse gas emissions, they do not exhibit significant positive effects on other environmental impacts. These findings persist even when accounting for variations in TE conversion efficiency and lifetime and the implementation of a circular economy approach for recycling and repurposing TE modules. This suggests that the environmental suitability of TEs is predominantly influenced by the type of fossil energy source they replace, making current TEs unsuitable for stationary applications that periodically generate waste heat. The study also highlights the need for further research on the development of new, practical TEs that utilize nontoxic, abundant elements and are produced through less energy-intensive techniques.

Comparative toxicity and environmental impact assessments of sonochemically-synthesized CuO and Zn-doped CuO nanoparticles using zebrafish and LCA tools

Nanomaterials (NMs), including nanoparticles (NPs), offer promising potential in achieving the European Commission’s Green Deal goals of climate-neutral, zero-pollution and circular economy. Metal oxide NPs display antimicrobial properties, with efficacy also towards antimicrobial-resistant bacteria. Nevertheless, the increasing manufacture, use and unintended release of NMs particularly in aquatic compartments, raises concerns about their environmental sustainability and safety towards non-target organisms. Within the Safe and Sustainable by Design framework, this study compares toxicity and environmental impacts of sonochemically synthesized water-based CuO and Zn-doped CuO NPs. Zebrafish embryos were exploited in a high-throughput developmental and behavioral screening to investigate nanosafety. The Fish Embryo acute Toxicity test was used to assess the NPs aquatic toxicity potential, while behaviour was addressed by tracking embryos activity. The Life Cycle Assessment (LCA) methodology was implemented through the OpenLCA software to evaluate the environmental footprint of the NPs synthesis. Our findings showed no significative lethality at the tested concentrations (0.01–100 mg/L) (LC50 wCuO > > 100 mg/L), with the exception of ZnCuO NPs 100 mg/L (LC50 ZnCuO = 123 mg/L). Sub-lethality occurred as delayed hatching, partially recovered by Zn-doping, and embryo development. LCA highlighted the dominant role of electricity (which represented 47 to 98% of the total impacts) and copper acetate (37–94%) consumption in the environmental impacts of the NPs synthesis, emphasizing the importance of optimizing energy and chemical use to minimize environmental burden. This research supports the safe and sustainable design of nano-enabled antimicrobials and underscores the need for an approach comprehensive of both risk assessment and LCA in nanotechnology development.

Life cycle assessment of urea production: Environmental impact comparison of two fertilizer technologies in Northern India.

Life cycle assessment of urea production: Environmental impact comparison of two fertilizer technologies in Northern India.

Agri-food waste to phenolic compounds: Life cycle and eco-efficiency assessments.

Agri-food waste to phenolic compounds: Life cycle and eco-efficiency assessments.

Sustainability building materials and circularity score of residential buildings

Building materials used, approaches and technologies related to the operation of residential buildings influence the environment and climate change. For this purpose, an assessment of environmental impacts and circularity of 11 residential buildings (marked as A) was carried out using the life cycle assessment (LCA) methodology. LCA analysis consisted of four parts. First, the goal and scope were defined. Then, inventory analysis (LCI) entered the assessment using input data. They were needed to quantify inputs and outputs, resource and energy flows, emissions, and other leakages. Life cycle impact assessment (LCIA) quantified the pollutants into impact categories. The last part was the interpretation of the results. Investigated buildings were assessed within a moderate climate zone and "Cradle to Cradle" system boundaries over a lifetime of 60 years. The product and energy consumption phases generally contributed to the highest GHG emissions. In terms of materials, aerated concrete (up to 89.4%), concrete (20-51%) and clay brick (38-47%) caused the highest values for the GWP indicator. The end-of-life phase, including incineration, landfilling and reuse of materials, was quantified in the 0.1-74% range. Quantified global indicators are Global warming potential (GWP), Depletion potential of the stratospheric ozone layer (ODP), and Abiotic depletion potential for non-fossil resources (ADP-E). In this study, regional indicators are Acidification potential (AP), Eutrophication potential (EP) and Formation potential of tropospheric ozone (POCP). A building that achieves higher circularity is the building that makes the most use of renewable or reused resources, so it uses less raw materials. The circularity score representing materials recovery was 23% to 48%. The best circularity score of building E (48%) was due to downcycling (45.8%) and use as energy (32.1%) of applied materials. The lowest circularity score was found for building I, with a value of 23%. The most suitable building in terms of environmental impact and circularity was identified using multicriteria analysis.

Selection of Sol-Gel Coatings by the Analytic Hierarchy Process and Life Cycle Assessment for Concentrated Solar Power Plants

Sol-gel coatings are commonly used to prevent corrosion from molten salt mixtures in CSP plants. Until now, they have been driven primarily by cost considerations, without integrating environmental criteria into the modeling and decision-making process. The novelty of this study lies in the development of an evaluation framework that incorporates environmental impact alongside technical and economic factors, providing a more sustainable approach. This work assesses porosity, thermal shock resistance, and thickness to determine the optimal sol-gel coating. For this purpose, the multi-criteria decision-making technique “Analytic Hierarchy Process” (AHP) and the Life Cycle Assessment (LCA) methodology are implemented. The results show that the scores obtained for the 3YSZ-5A (5% mol) coating are higher than those of the 3YSZ (3% mol) and 3YSZ-20A (20% mol) coatings, between 1.52 and 1.69, respectively. The 3YSZ-5A coating (5% mol) is the optimal solution among all the systems analyzed, with a score of 0.61 AHP pt. The coating of the same type and higher molar concentration (20%) achieved 0.55 AHP pt. Finally, the 3YSZ type coating received the lowest rating, with a score of 0.36 AHP pt. The insights generated in this research will support decision-making in the design and maintenance of CSP plants.

Life cycle assessment of sandstone aggregate quarry activities—a case study in Istanbul, Türkiye

Abstract Purpose In this study, a life cycle assessment (LCA) of aggregate quarry activities in Istanbul, Türkiye, based on energy and raw material consumption was carried out. The Cebeci quarry plays a vital role in Istanbul’s aggregate production, contributing significantly to economic development and infrastructure projects. Methods LCA methodology was applied using GaBi Education software. An analysis from cradle-to-gate analysis was performed. EN 15804 + A2 impact assessment method was used to evaluate twelve impact categories including climate change, acidification, and eutrophication potential. Results and discussion Results show that the main contributor to all impact categories is the crushing and sieving plant. Electricity consumption is the major factor in the crushing and sieving process. The calculated climate change potential was about 2.30 kg CO2 eq/ton sandstone aggregate product. The alternative scenarios demonstrate the potential environmental improvements, with the use of wind energy in crushing-sieving plants showing a substantial improvement in many impact categories compared to the use of conveyor belts in transportation. Integrating wind energy into the conveyor belt system as a third scenario reveals the lowest environmental load, with climate change and acidification potential values of 0.146 kg CO2 equivalent and 3.20E-04 mol of H + equivalent, respectively. Conclusions This LCA study provides valuable insights into the environmental footprint of sandstone aggregate production and suggests alternative scenarios for mitigating its impacts. The findings can inform decision-making processes in the mining industry and contribute to the development of more sustainable practices in aggregate production. Renewable energy is the best option to mitigate the environmental burden. The main novelty of this study is that it is the first initiative to apply LCA in the Turkish aggregate mining industry.

Biogas Energy Usage Through the Co-Digestion of the Organic Fraction of Urban Solid Waste with Lime Mud: An Environmental Impact Analysis

This study evaluates the energy recovery from biogas generated through the anaerobic co-digestion of the Organic Fraction of Urban Solid Waste (OFUSW) with lime mud (LM). This approach aims to mitigate environmental impacts such as greenhouse gas emissions and pollution while promoting energy recovery for a diversified power matrix. Life cycle assessment (LCA) methodology, in accordance with the NBR ISO 14040 and 14044 standards, was used to compare five scenarios for the disposal of LM. The results highlight that the co-digestion scenario showed significant environmental benefits in 8 out of the 18 categories evaluated, such as reductions in eutrophication, acidification, and climate change. Additionally, the digestate produced helped avoid further environmental impacts. The integration of urban and industrial waste demonstrates the potential to enhance biogas productivity, generate savings for the pulp and paper industry, and promote sustainable practices. The innovation lies in the synergistic use of LM as a co-substrate, improving the efficiency of the anaerobic process and maximizing biogas production. This research provides a solid scientific foundation for decision-making in public policies and industrial practices, positioning itself as a viable and innovative proposal for the integrated management of solid waste and sustainable energy.

Life Cycle Assessment of Tinplate Aerosol Cans: Evaluating the Role of Photovoltaic Energy and Green Hydrogen in Environmental Impact Reduction

This study assesses the environmental impacts of producing 1000 tinplate aerosol cans at a Portuguese packaging company using the life cycle assessment (LCA) methodology. The inventory analysis is based on real industrial data collected from the company for foreground processes, complemented with the literature data for background processes. Two energy scenarios are compared: the current production setup, which relies on electricity from the Portuguese grid and 100% natural gas, and an optimized renewable energy scenario powered entirely by photovoltaic electricity, with thermal energy supplied by a mix of 20% green hydrogen and 80% natural gas. The ReCiPe 2016 Midpoint (E) method was applied to assess 18 environmental impact categories. For the production of 1000 cans, the associated impacts are as follows: 287.11 kg CO2 eq for GWP, 1.01 × 10−4 kg CFC-11 eq for ODP, 16.52 kBq Co-60 eq for IRP, 51.59 kg 1,4-DCB for FETP, 0.69 kg PM2.5 eq for PMFP, 77.20 kg oil eq for FFP, and 2.57 m3 for WCP. Tinplate exhibits the highest environmental burden across most impact categories, particularly in HTPc (96%) and SOP (98%). Offset aluminum printing plates have the greatest impact on FETP (33%), while wood pallets significantly contribute to LOP (81%). The renewable energy scenario resulted in significant reductions in IRP (60.9%), LOP (50.3%), ODP (39.8%), FFP (26.1%), and GWP (24.4%). However, it also led to notable increases in other impact categories, including FETP (135.3%), METP (130.8%), FEP (128.8%), MEP (114.3%), HTPnc (112.0%), SOP (107.8%), TETP (103.4%), and WCP (75.2%), primarily due to green hydrogen production and photovoltaic systems. Among the renewable options, wind electricity stands out as the most environmentally favorable choice for hydrogen production, outperforming both photovoltaic and hydroelectricity.

Decarbonizing Near-Zero-Energy Buildings to Zero-Emission Buildings: A Holistic Life Cycle Approach to Minimize Embodied and Operational Emissions Through Circular Economy Strategies

The decarbonization of the building sector is essential to mitigate climate change, aligning with the EU’s Energy Performance of Buildings Directive (EPBD) and the transition from near-Zero-Energy Buildings (nZEBs) to Zero-Emission Buildings (ZEBs). This study introduces a novel and streamlined Life Cycle Assessment (LCA) methodology, in accordance with EN 15978, to holistically evaluate the Global Warming Potential (GWP) of buildings. Our approach integrates a calibrated dynamic simulation of operational energy use, performed with DesignBuilder, to determine precise operational CO2 emissions. This is combined with a comprehensive assessment of embodied emissions, encompassing construction materials and transportation phases, using detailed Environmental Product Declarations (EPDs). Applied to the IndUVa nZEB case study, the findings reveal that embodied emissions dominate the life cycle GWP, accounting for 69%, while operational emissions contribute just 31% over 50 years. The building’s use of 63.8% recycled materials highlights the transformative role of circular economy strategies in reducing embodied impacts. A comparative analysis of three energy-efficiency scenarios demonstrates the IndUVa building’s exceptional performance, achieving energy demand reductions of 78.4% and 85.6% compared to the ASHRAE and CTE benchmarks, respectively. This study underscores the growing significance of embodied emissions as operational energy demand declines. Achieving ZEBs requires prioritizing embodied carbon reduction through sustainable material selection, recycling, and reuse, targeting a minimum of 70% recycled content. By advancing the LCA framework, this study presents a pathway for achieving ZEBs, driving a substantial reduction in global energy consumption and carbon emissions, and contributing to climate change mitigation.

Development of OptiCon: A Mathematical Model with a Graphical User Interface for Designing Sustainable Portland Cement Concrete Mixes with Budget Constraint

The production of Portland Cement Concrete (PCC) generates significant environmental impacts that increase climate change and decrease people’s quality of life. Recent studies highlight the potential to reduce these environmental burdens by partially replacing Portland cement with Supplementary Cementitious Materials (SCMs) and coarse aggregates with Recycled Concrete Aggregate (RCA). However, designing PCCs with simultaneous contents of SCMs and RCA is not easily manageable because current design procedures fail to adjust all of the variables involved. In order to overcome these limitations, this research introduces a novel mathematical model designed to develop operationally efficient PCC mixes that are both environmentally sustainable and cost-effective. The proposed model, denominated OptiCon, employs the Life-Cycle Assessment and Life-Cycle Costs Analysis methodologies to evaluate the incorporation of three different SCMs (i.e., fly ash, silica fume, and steel slag) and RCA into PCC mixes. OptiCon is also integrated within a graphical user interface in order to make its implementation straightforward for potential users. Thus, OptiCon is operationalized through an algorithm, offering a replicable approach that can be adapted to various contexts, providing both a theoretical framework and a practical tool for state agencies, engineers, suppliers, and other stakeholders to adopt more environmentally friendly practices in concrete production. Furthermore, a case study from northern Colombia analyzed thirty mix design scenarios with varying supplier conditions (foreign, local, or mixed), calculating costs and CO2 emissions for a fixed concrete volume of 1 m3. The findings demonstrated that utilizing OptiCon can achieve substantial reductions in both CO2 emissions and production costs, underscoring the model’s efficiency and practical impact.

When Technology Meets Sustainability: Microplastic Removal from Industrial Wastewater, Including Impact Analysis and Life Cycle Assessment

Microplastics (MPs) that are ubiquitous in aquatic environments and industrial wastewater streams have been identified as key hotspots of MP contamination. It is significantly more effective to remove MPs at these points before they enter municipal wastewater streams. This study is an environmental assessment of a novel pilot plant for the removal of MPs and the chemical oxygen demand (COD) from wastewater with a high MP contamination from a plastics manufacturer in Germany. MP removal is based on physical–chemical agglomeration–fixation by organosilanes. Formed agglomerates are separated using a belt filter. The COD is removed by an adsorption process. The resulting MP removal was 98.0 ± 1.1% by mass and 99.9987 ± 0.0007% by particle count, while the COD was reduced by 96 ± 2.7%. The system’s sustainability is evaluated using the Life Cycle Assessment methodology, evaluating system construction, operation, and end-of-life considerations. The current pilot plant is also compared to an optimized circular and sustainable upgrade, where drivers of environmental burdens are eliminated and collected MPs are reused. Significant reductions in environmental impact categories are achieved and the global warming potential is reduced by 96%. This study provides a sustainability assessment of a novel technology and circular solution to remove MPs from highly polluted industrial wastewater.