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Research on the environmental impacts from the global value chain of plastics has typically focused on the disposal phase, considered most harmful to the environment and human health. However, the production of plastics is also responsible for substantial environmental, health and socioeconomic impacts. We show that the carbon and particulate-matter-related health footprint of plastics has doubled since 1995, due mainly to growth in plastics production in coal-based economies. Coal-based emissions have quadrupled since 1995, causing almost half of the plastics-related carbon and particulate-matter-related health footprint in 2015. Plastics-related carbon footprints of China’s transportation, Indonesia’s electronics industry and India’s construction sector have increased more than 50-fold since 1995. In 2015, plastics caused 4.5% of global greenhouse gas emissions. Moreover, 6% of global coal electricity is used for plastics production. The European Union and the United States have increasingly consumed plastics produced in coal-based economies. In 2015, 85% of the workforce required for plastics consumed by the European Union and the United States was employed abroad, but 80% of the related value added was generated domestically. As high-income regions have outsourced the energy-intensive steps of plastics production to coal-based economies, renewable energy investments throughout the plastics value chain are critical for sustainable production and consumption of plastics.

This work provides a globally regionalized approach for quantifying particulate matter (PM2.5) health impacts. Atmospheric transport and pollutant chemistry of primary particulate matter, sulfur dioxide (SO2), nitrogen oxide (NO x ), and ammonia (NH3) from stack emissions were modeled and used to calculate monthly high-resolution maps of global characterization factors that can be used for life cycle impact assessment (LCIA) and risk assessment. These characterization factors are applied to a global data set of coal power emissions. The results show large regional and temporal differences in health impacts per kg of emission and per amount of coal power generation (5–1300 DALY TWh–1). While small emission reductions of PM2.5 and SO2 from coal power lead to similar health benefits across densely populated areas of Asia and Europe, we find that larger emission reductions result in up to three times higher health benefits in parts of Asia because of the nonlinear health responses to pollution exposure changes. Hence, many regions in Asia benefit disproportionately much from large coal power PM2.5 and SO2 emission reductions. NO x emission reductions can lead to equally high health benefits, where unfavorable atmospheric conditions coincide with elevated NH3 background pollution and large population (e.g., in Central Europe, Indonesia, or Japan but also numerous other places).

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