Techno‐Economic and Lifecycle Analysis of Green Colloidal Silver: Moving toward Scale‐Up

Silver particles (AgPs) are increasingly used across a range of industries, including personal care, household, and food packaging, but conventional synthesis methods involve high production costs and negative environmental impacts. Green synthesis using plant extracts offers a sustainable alternative, though limited comparative data on economic and environmental performance exist. This study evaluates three green methods—BX3 (a patented extract), lemon juice (LJ), and green tea (GT)—against a conventional method using sodium borohydride (NaBH₄). Equal‐volume reactions are analyzed via ICP‐MS, UV–vis spectroscopy, and dynamic light scattering. Techno‐economic analysis and life cycle assessment (LCA) assessed costs and environmental impact. BX3 emerged as the most cost‐effective and environmentally friendly option, producing AgPs at $13,000/kg with a 75% yield and a global warming potential of 1,900 kg CO₂‐Eq/kg. In contrast, NaBH₄ yielded 7.35% at $195,000/kg, 15x more expensive than the BX3 method, and a global warming potential of 74,000 kg CO₂‐Eq/kg. GT, while a green method, has the highest cost $690,000/kg, the lowest yield (1.13%), and the worst environmental impact, including a human toxicity value of 92,000 kg 1,4‐DCB‐Eq/kg‐even surpassing the toxic NaBH₄ process. These findings highlight BX3's promise for scalable, low‐impact AgP production and broader industrial use.