Optimizing Environmental Performance in Chemical Manufacturing: A TRACI and USEtox-Based Life Cycle Approach to Waste Minimization
DOI:
https://doi.org/10.61978/catalyx.v2i2.1277Keywords:
Life Cycle Assessment, Process Mass Intensity, E-Factor, Chemical Process Design, Waste Minimization, TRACI, USEtoxAbstract
Chemical manufacturing is under increasing pressure to reduce its environmental footprint. Life Cycle Assessment (LCA), as defined by ISO 14040/14044, is an established method for evaluating such impacts. This study aims to integrate LCA with quantitative waste minimization metrics Process Mass Intensity (PMI) and E-Factor to evaluate the environmental benefits of process redesign. Two chemical process scenarios (baseline and improved) were assessed using a cradle-to-gate LCA approach. TRACI 2.1 and USEtox were employed to evaluate environmental impacts across categories such as climate change, human toxicity, and water use. PMI and E-Factor were calculated from foreground process data, and background inventory was sourced from the ecoinvent database. Allocation was based on mass, and uncertainty was assessed via Monte Carlo simulations and sensitivity analysis. The improved process demonstrated a 33% reduction in PMI and a 50% decrease in E-Factor, driven by solvent recovery and energy optimization strategies. Climate change impact dropped from 15.0 to 10.2 kg CO2-eq, while human toxicity and water footprint also saw substantial improvements. LCA findings provided actionable insights for process redesign, revealing that targeted waste minimization enhances overall environmental performance. While energy demands initially rose, optimization and heat integration neutralized trade-offs, supporting more sustainable operations. Integrating LCA with PMI and E-Factor offers a robust, standardized framework for evaluating waste minimization in chemical processes. This approach supports environmentally sound decision-making and can guide future innovations in green chemistry and sustainable manufacturing.
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