Life cycle assessment of a new industrial process for sustainable construction materials

•Biomass Fly Ash from pulp-paper industry were used in the geopolymers production.•The energy consumption due to the innovative GC production process was calculated.•The LCA showed a lower environmental impact in respect to traditional concrete.•The use of a cogeneration system could provide a significant cost reduction. One of the key sectors for the green transition of European countries is construction, that is more and more asked to evolve towards innovative ecological binders and green cost-effective processes. The construction sector is highly energy intensive, and the cement production is one of the main sources of environmental pollution in the world. In this regard, GeoPolymers (GP) seem to be promising for a sustainable replacement of cementitious materials. Therefore, the Life Cycle Assessment (LCA) of the industrial production of different formulations of Geopolymer Concrete (GC) was performed in this study after scaling up the Life Cycle Inventory (LCI) from a laboratory scale to an industrial one. Based on LCA results, the Global Warming Potential (GWP) indicator demonstrated a lower greenhouse gas emission of the proposed GC production in respect to the CC manufacturing process, while no significant difference was observed in the GWP scores of the considered GC formulations when referring to the functional unit. Nevertheless, the usage of the innovative GC formulations, on an industrial scale, would avoid a significant reduction of sand and kaolin extracted, with a consequent decrease on the environmental impact. Finally, the economic assessment showed that the combined production of thermal and electrical energy by a cogeneration system could provide a significant cost reduction when the percentage of electricity fed into the public network is higher than 39%.