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The steel industry is responsible for a quarter of all industrial greenhouse gas emissions. So far, the environmental savings are mainly due to steel recycling. Besides recycling, the circular economy offers strategies to increase material efficiency and thus decrease the primary raw material demand. However, the potentials remain unexploited because circular economy concepts with a higher degree of circularity are not considered. The presented case study of an industrial machining knife illustrates how the production process can be improved by implementing various circular strategies. The environmental performance is analyzed by calculating and comparing the carbon footprint, the cumulative energy demand and the material footprint, and the material efficiency indicator. The results show that the implementation of the three overarching strategies of the circular economy - narrowing, closing, and slowing - contributes to a significant increase in material efficiency. The implementation also has a positive effect on the overall environmental performance. The circular production processes require less energy and resources and cause fewer emissions. Auxiliary processes such as additional transport routes are relevant, as they can reduce or even overcompensate for savings. These processes must be adequately considered and designed.
In material development processes, the question if a new alloy is more sustainable than the existing one becomes increasingly significant. Existing studies on metals and alloys show that their composition can make a difference regarding the environmental impact. In this case study, a recently developed air hardening forging steel is used to produce a U-bolt as an example component in automotive engineering. The production process is analyzed regarding the environmental performance and compared with the standard quench and tempering steels 42CrMo4 and 33MnCrB5-2. The analysis is based on results from applying the method of Life Cycle Assessment. First, the production process and the alterations on material, product, and process level are defined. The resulting process flows were quantified and attributed with the environmental impacts covering Carbon Footprint, Cumulative Energy Demand, and Material Footprint as they represent best the resource-, energy- and thus carbon-intensive steel industry. The results show that the development of the air hardening forging steel leads to a higher environmental impact compared to the reference alloys when the material level is considered. Otherwise, the new steel allows changes in manufacturing process, which is why an additional assessment on process level was conducted. It is seen that the air hardening forging steel has environmental savings as it enables skipping a heat treatment process. Superior material characteristics enable the application of lightweight design principles, which further increases the potential environmental savings. The present work shows that the question of the environmental impact does not end with analyzing the raw material only. Rather, the entire manufacturing process of a product must be considered. The case study also shows methodological questions regarding the specification of steel for alloying elements, processes in the metalworking industry and the data availability and quality in Life Cycle Assessment.