802 BEYOND ENERGY: LIFE-CYCLE-BASED CARBON FOOTPRINT METRICS FOR SUSTAINABLE MINERAL PROCESSING * R. Powell1, N Mayfield2, K. Nell3 1Field and Expert Service, Optimization Services, Metso Minerals, Australia, (*Presenting author: roxana.powell@metso.com) 2Field and Expert Service, Optimization Services, Metso Minerals, USA 3Julius Kruttschnitt Mineral Research Centre, Sustainable Minerals Institute, The University of Queensland, Australia ABSTRACT Mineral processing has long excelled at optimising throughput and costs, with energy consumption emerging as the most important sustainability factor. With advances in the industry, particularly through renewable energy, new opportunities are emerging to further reduce operations' environmental footprint. This paper presents a complementary framework that integrates Life Cycle Assessment (LCA) into mineral processing optimisation and positions carbon footprint as a practical metric alongside cost and production efficiency. Rather than replacing existing approaches, this framework strengthens them by broadening the scope of analysis to include consumables, services, and equipment— elements that often remain hidden in traditional cost or energy assessments. For example, while shifting from grid electricity to renewable energy delivers an immediate reduction in carbon emissions, further gains can only be realised if the impacts of grinding media, linings, and ancillary processes are considered. By examining alternative flowsheets and operational conditions, we show how LCA provides new insights that enhance traditional process trade-off studies. This integration provides minerals processing professionals with an additional decision-making tool, helping to align optimisation practices with decarbonization goals while maintaining economic performance. The work, developed in collaboration between industry and academia, shows how sustainability metrics can be embedded into everyday process assessments. In this way, the carbon footprint analysis not only identifies new areas for innovation but also provides a common language for multidisciplinary teams to work towards common goals. The result is a more holistic approach to optimisation, one that retains the strengths of cost and production analysis while updating them to reflect today’s sustainability priorities. KEYWORDS Life Cycle Assessment, carbon footprint, mineral processing, optimisation, sustainability 1. INTRODUCTION Mineral concentrators have traditionally been optimised around throughput, cost, and energy. Energy intensity (kWh/t) is directly linked to grind targets (e.g., P80 in µm), circuit stability, product tonnage, recovery, and grade. Because comminution is often the largest energy consumer on site, reducing kWh/t has long supported both performance and environmental goals. This made energy an effective proxy for environmental impact when electricity-related emissions dominated the footprint. ¹ ² That proxy is weakening. As renewables expand and the CO₂ intensity of grid electricity decreases, the relative contribution of Scope 2 is declining in many regions, while Scope 1 (on-site fuels) and supply chain inputs – consumables, equipment, and services – account for a larger share in many operations. Recent power sector trends show record clean generation growth and a sustained drop in emissions intensity, reinforcing the need to look beyond energy alone when assessing carbon performance at concentrators. ³ ⁴ At the same time, regulatory transparency on value chain emissions is increasing. Europe now
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