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Green Hydrogen vs Conventional Energy Sources: A LCA Case Study of Aluminum Casting

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Abstract:

Aluminum components production is associated with significant greenhouse gas emissions due to both raw material extraction and energy-intensive manufacturing processes. In particular, the melting phase required high thermal energy and conventional energy sources (e.g. fossil fuels, national grids...) can result in relevant environmental impacts. This study evaluates the environmental sustainability of four different energy supply systems for aluminum die casting through a comparative Life Cycle Assessment (LCA). Four scenarios were analyzed: natural gas, national grid electricity, photovoltaic (PV) electricity with battery storage, and PV-powered hydrogen production with metal-hydride storage. A cradle-to-gate approach was adopted, including energy production, storage, raw materials extraction, tool manufacturing, casting operations and finishing. The environmental impacts were modelled using SimaPro, and Global Warming Potential (GWP) was calculated according to the Intergovernmental Panel on Climate Change (IPCC) methodology. The results show that renewable-based solutions represent the most sustainable alternatives, with impact reductions up to 62% compared with traditional approaches. PV electricity with battery storage achieves the lowest unitary impacts (0.15 kg CO₂ eq/kWh). Hydrogen produced from PV electricity also provides significant reductions relative to natural gas and grid electricity and offers high operational flexibility. The metal-hydride storage system shows slightly lower impacts than battery storage, due to its long service life and minimal hydrogen losses. These results highlight the potential of renewable energy and green hydrogen as alternative energy carriers for industrial production.

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Periodical:

Key Engineering Materials (Volume 1051)

Pages:

73-81

DOI:

https://doi.org/10.4028/p-Y0QEyo

Citation:

Cite this paper

Online since:

April 2026

Authors:

Iacopo Bianchi, Pietro Forcellese, Gioacchino Fratini, Thomas Lamberti, Tommaso Mancia*, Michela Simoncini

Keywords:

Aluminum Casting, Hydrogen Storage, Life Cycle Assessment, Sustainability

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Creative Commons CC BY 4.0

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* - Corresponding Author

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