A Proposed Methodological Considerations for Sustainable Chemical Process Design

This research focuses on sustainable process design of ethanol from lignocellulosic biomass in Thailand. Feedstocks used to produce bioethanol are cassava rhiome, corn stover and sugarcane bagasse as they are agricultural residues that are abundantly available, avoid competition with food industries, reduce CO2 emission because of open burning, and independent of fossil fuel resources. For each feedstock, process design alternative cases were first established. Each case was investigated through a four-part method. The first part dealt with simulation to evaluate different process design alternatives. The second part dealt with economic evaluation in term of, total capital investment, total operating cost, net revenue and so on. The third part dealt with sustainability analysis to analyze three main factors (mass, energy and water usage) in the process and through the analysis identify the process bottleneck. The fourth part dealt with life cycle assessment (LCA) to analyze environmental impacts of the process such as acidification, eutrophication, global warming potential, and else. A sustainability metrics was generated after finishing the four main parts. Results from the studies were divided into two sections, one where each feedstock was considered separately and another where the feedstocks were combined into an optimal mixed feed. Attention was given to the second combined feed option because it enhances long-term security of feedstocks supply for sustainable bio-ethanol production, which is a critical factor for sustainability of biofuels. Finally, alternatives for the combined cases were generated and improved to determine the best sustainable process design.

Sustainable Process Synthesis-Intensification

Re-engaging with the process and materials of making is a form of transparency common in sustainable design approaches. The current academic studio model, wherein a student chooses a retail fabric for a one-off design or stand-alone collection, does not reflect resilient circular models of apparel production. An opportunity exists to model ways in which the designer might be empowered to designing out waste and keep materials in use by re-utilization<br>(Ellen MacArthur Foundation, 2017). This project focuses on sustainable material selection, creative ideation and design process as strategies toward a considered and sustainable design solution. As design researchers exploring sustainable design in our own scholarship, we were eager to embed resilience and circular strategy into our teaching.

Design and optimization of an inherently safe and sustainable process for the separation of anisole

In recent years the need for the design of more sustainable processes and the development of alternative reaction routes to reduce the environmental impact of the chemical industry has gained vital importance. Main objectives especially regard the use of renewable raw materials, the exploitation of alternative energy sources, the design of inherently safe processes and of integrated reaction/separation technologies (e.g. microreactors and membranes), the process intensification, the reduction of waste and the development of new catalytic pathways. The present PhD thesis reports results derived during a three years research period at the School of Chemical Sciences of Alma Mater Studiorum-University of Bologna, Dept. of Industrial Chemistry and Materials (now Dept. of Industrial Chemistry “Toso Montanari”), under the supervision of Prof. Fabrizio Cavani (Catalytic Processes Development Group). Three research projects in the field of heterogeneous acid catalysis focused on potential industrial applications were carried out. The main project, regarding the conversion of lignocellulosic materials to produce monosaccharides (important intermediates for production of biofuels and bioplatform molecules) was financed and carried out in collaboration with the Italian oil company eni S.p.A. (Istituto eni Donegani-Research Center for non-Conventional Energies, Novara, Italy) The second and third academic projects dealt with the development of green chemical processes for fine chemicals manufacturing. In particular, (a) the condensation reaction between acetone and ammonia to give triacetoneamine (TAA), and (b) the Friedel-Crafts acylation of phenol with benzoic acid were investigated.

PurposeA recent study has asserted that businesses need to adopt “eco‐advantage”. This paper aims to explore the viability of small and medium enterprises (SMEs) achieving “eco‐advantage” by exploring their understanding of sustainability issues, how they adopt and innovate in terms of sustainability and the benefits and obstacles they face.Design/methodology/approachThe research approach is exploratory, comprised of 15 SME embedded cases based in the UK. The cases are participants in short interventions in sustainable product and process design as a part of a university knowledge transfer project, representing the overall case. Cases are based on interviews with company participants and collaborating academics, supplemented by documentary and observational evidence.FindingsThe results build on the work on “eco‐advantage” found in a recent study, highlighting marketing, rather than compliance issues as a catalyst for change. The newly aware SME enters a development process which involves cumulative capabilities, gaining a nascent inner confidence, which includes espousing wider sustainable values.Research limitations/implicationsThe results reveal the scope and challenges for SMEs to adopt more sustainable practices, encompassing innovations and a broad set of capabilities. Further research points to the need to monitor benefits as well as inputs in evaluating sustainability improvements and to consider longitudinal business sustainability issues.Originality/valueThe paper informs the emerging debate on sustainability in SMEs, providing a rich source of data to enhance the provision of business support and knowledge transfer activities, where a more holistic and customised approach is required to realise the real environmental and economic benefits accrued from implementing sustainable improvements.

Integration of life cycle assessment software with tools for economic and sustainability analyses and process simulation for sustainable process design

This paper aim to conduct a pilot study in India process industry for sustainable machining process design. A survey questionnaire was framed at five point likert type scale. Respondents were asked to five elements related to sustainable machining process design (SMPD) Fifty responses was collected from various process industries. Simple statistics mean, standard deviation, correlation and t test is applied for the analyse survey responses. It is evident that the Energy efficiency during the process, Vegetable based cutting fluid and machining process utilisation are more emphasised by the companies and the other factors like Waste minimization and cryogenic machining require more focused on it. One sample t test it is evident that Energy efficiency during the process (SMPD5) (t = 6.194) is the most important factor which is highly adopted by the process industry in practice.

The School of Mechanical, Industrial, and Manufacturing Engineering at Oregon State University is home to one of the largest academic Mechanical Design groups in the country. As a leader in undergraduate design education, we have been able to keep in touch with a large group of mechanical design graduates, and as such are capable of assessing how students retain information learned in undergraduate coursework to see how this understanding is employed in real-world engineering practice. However, the principles governing the design of sustainable products and processes are relatively novel and are only now being integrated into the undergraduate and graduate mechanical design curriculum. It is our hypothesis that particular means of learning and understanding sustainable design — via lectures, homework assignments, design projects, and the use of various sustainability-related LCA tools — will enable the highest retention of sustainable design understanding, and a higher likelihood that this sustainable design knowledge will be propagated into design practice in industry. Multiple curricular studies that explore dissemination and retention of sustainable design skills are being explored, including a junior-level introductory mechanical design course and a graduate level sustainable product development course. In the junior-level course, baseline sustainability knowledge is tested by allowing students to make sustainable design decisions by applying varied skill sets, including general principles, a list of sustainable design guidelines, and an innovative online survey (The GREEn Quiz). The graduate-level course, which employs sustainable design principles within a larger product development architecture, will capitalize on more “expert” knowledge. Future work will also be discussed, including planned validation studies and curriculum improvements, as well as the means of quantifying the retention of sustainable design information.

Process lifecycle has several stages, including process design covered in multiple stages. Process economics is a vital factor in finalizing the process design. Besides economics, inherent safety is an important concept contributing to sustainable process design generation. The inherent safety concept has been applied via equipment characteristics for individual equipment. Since a method considering inherent safety with equipment aspects and process economics has not been available, therefore, a new method has been proposed, namely sustainable process design for heat exchanger network (SPDHEN), to integrate inherent safety, equipment aspects, and process economics. SPDHEN uses indexing to identify the critical heat exchanger, which is then examined via hazard analysis for an explosion. For unacceptable hazards, inherent safety principles are engaged to generate design alternatives for which process economics is examined too. The final design would be inherently safer with the best profit margin. The proposed method has been studied for the ammonia synthesis loop. It is concluded that the explosion hazard has been reduced to a tolerable level by using inherent guide words with a marginal compromise on quantity of ammonia produced, that is, 0.32%. This method is straightforward and can be useful for process engineers to generate sustainable process designs for heat exchanger networks considering safety and process economics simultaneously.

Sustainable Process Design and Synthesis for HDPE Recycling

This article explores the role of digital fashion as an innovative tool for sustainable design and garment production. The primary aim is to examine how digital fashion can help reduce the use of natural resources, minimize waste generated in traditional production processes, and promote environmentally responsible approaches to fashion development. Today, the fashion industry is widely recognized as one of the leading contributors to environmental degradation, particularly due to its heavy consumption of materials, high energy usage, and generation of non-biodegradable waste. However, advances in digital technology have introduced new tools that can support more sustainable design processes in the fashion industry. This study focuses on the potential of digital fashion, especially through the use of 3D design software such as CLO3D, which enables the creation of realistic virtual prototypes. These digital models can replace the need for physical samples in the early design stages, significantly reducing material usage and production waste. The main objective of this research is to evaluate how digital fashion technology can support sustainable design practices, particularly by shortening design timelines, lowering costs, and reducing material consumption. Additionally, the study considers how digital fashion enhances the ability to present design concepts in realistic and engaging ways. To investigate this, the article presents a case study on the design of a football uniform using CLO3D, a widely adopted 3D software in the international fashion industry. Football uniforms are a useful subject due to their need for precision in terms of proportion, pattern accuracy, and responsiveness to body movement. Therefore, the use of 3D software in this context clearly demonstrates the capabilities of digital fashion. The findings show that applying CLO3D in the design process significantly reduces redundant steps typically involved in traditional prototyping. Designers can accurately simulate fabric properties such as elasticity, folds, and how garments move in response to body motion. Results from this experiment reveal that digital fashion can generate outputs that closely resemble physical products, while also offering immediate flexibility to adjust design elements—such as color, material, or pattern—without the need to physically produce multiple sample versions. This allows for tangible reductions in time, cost, and resource use throughout the design and production process. From the case study, three main advantages of digital fashion are highlighted: (1) The ability to reduce the need for physical prototypes by relying on highly accurate digital garment simulations; (2) The reduction of costs and waste associated with iterative sampling and design refinement common in traditional methods; and (3) The acceleration of the design, testing, and revision cycle, enabling more agile responses to market demands—especially important in commercial fashion contexts where designs change rapidly by season. Nevertheless, the article also discusses current limitations of digital fashion. These include the costs associated with acquiring and maintaining necessary software and hardware, the complexity of learning the technology for designers unfamiliar with digital tools, and certain technical constraints such as the inability to fully replicate physical properties like texture, tactile sensation, or the effects of actual sewing techniques. Despite these limitations, digital fashion still demonstrates strong potential for both academic exploration and practical application, especially in equipping new-generation designers with innovative skills. Moreover, digital fashion serves as a foundational knowledge base for integrating related technologies such as artificial intelligence (AI) and virtual reality (VR). Based on the findings, this study recommends incorporating digital fashion into fashion design curricula at the higher education level, to better prepare future designers to adapt to the evolving global landscape of sustainable fashion. Furthermore, collaboration among academia, industry, and technology sectors should be promoted in order to mainstream digital fashion practices in commercial garment production. Establishing a new ecosystem that supports the widespread adoption of digital fashion could serve as a key mechanism to drive the fashion industry toward long-term sustainability, benefiting both economic and environmental dimensions.

Integrating Market Models and Price Effects in a Multiscale Sustainable Process Design Framework

Sustainable Chemical Process Development through an Integrated Framework

Sustainable process synthesis, design, and analysis: Challenges and opportunities