Mass, enthalpy, and chemical-derived emission flows in mineral processing

The production of materials from mineral resources is a significant contributor to anthropogenic CO₂ emissions. This contribution is driven primarily by chemical CO₂ emissions from the conversion of mineral resources and emissions tied to energy demands for material processing. In this work, we synthesize the thermodynamically required enthalpy and chemically derived emissions of mineral processing and consumption in the United States. We quantify mass, enthalpy, and emissions flows for minerals described by the US Geological Survey, with 882 mass flows and 155 chemical reactions analyzed. In total, 503 PJ of enthalpy is thermodynamically required for 398 Mt of chemically converted material consumption in the United States, resulting in 129 Mt of chemically derived CO₂ emissions. Additionally, 249 PJ of fuel resources such as coke are stoichiometrically required for the chemical conversion of minerals. These enthalpy requirements and CO₂ emissions are primarily from high-mass consumption materials such as cement, carbon steel, fertilizer, and aluminum. Cumulatively, the dataset synthesized in this work provides a complete view of the chemical requirements of mineral processing and can aid in guiding decarbonization or sustainable growth in critical minerals sectors, including construction materials and materials for energy storage or generation.