Synergistic Carbon Mitigation through Electrification and Solvent Recovery in Process Intensification Frameworks
DOI:
https://doi.org/10.61978/catalyx.v2i2.1331Keywords:
Process Intensification, Electrification, Solvent Recovery, Carbon Emissions, Technology Readiness Level, Chemical IndustryAbstract
The chemical industry is under increasing pressure to decarbonize in response to global climate commitments and sustainability expectations. This study investigates the carbon reduction potential of electrification and solvent recovery within a Process Intensification (PI) framework, using a scenario-based analysis to model varying electricity emission factors and recovery efficiencies. The methodology combines Life Cycle Assessment (LCA), Techno-Economic Assessment (TEA), and Technology Readiness Level (TRL) evaluation to assess environmental performance and implementation feasibility. Results indicate that emission reductions are highly sensitive to electricity source, with low-carbon grids offering the greatest benefit. Electrification of thermal processes, when powered by renewable energy, significantly cuts greenhouse gas emissions, while solvent recovery contributes to waste minimization and material efficiency. Combined, these strategies produce synergistic effects, amplifying both environmental and economic benefits. However, diminishing returns in solvent recovery efficiency and high initial capital costs present challenges to widespread adoption. TRL assessments suggest that many technologies are near commercialization, though integration hurdles persist. The findings highlight the importance of policy incentives, regulatory frameworks, and stakeholder engagement in enabling PI adoption. This integrated approach offers a pathway for sustainable transformation in chemical manufacturing, aligning emission reductions with long-term economic viability.
References
Angelis, R. D. (2021). Circular Economy and Paradox Theory: A Business Model Perspective. Journal of Cleaner Production, 285, 124823. https://doi.org/10.1016/j.jclepro.2020.124823 DOI: https://doi.org/10.1016/j.jclepro.2020.124823
Buchner, G. A., Zimmermann, A., Hohgräve, A. E., & Schomäcker, R. (2018). Techno-Economic Assessment Framework for the Chemical Industry—Based on Technology Readiness Levels. Industrial & Engineering Chemistry Research, 57(25), 8502–8517. https://doi.org/10.1021/acs.iecr.8b01248 DOI: https://doi.org/10.1021/acs.iecr.8b01248
Caiardi, F., Azzaro‐Pantel, C., & Le-Boulch, D. (2024). Exploring Carbon Neutrality Scenarios Through the Life Cycle Assessment Lens: A Review of Literature and Methodological Challenges. Environment Development and Sustainability. https://doi.org/10.1007/s10668-024-05598-y DOI: https://doi.org/10.1007/s10668-024-05598-y
Chang, F., Zhang, X., Zhan, G., Duan, Y., & Zhang, S. (2020). Review of Methods for Sustainability Assessment of Chemical Engineering Processes. Industrial & Engineering Chemistry Research, 60(1), 52–66. https://doi.org/10.1021/acs.iecr.0c04720 DOI: https://doi.org/10.1021/acs.iecr.0c04720
Cillo, V., Petruzzelli, A. M., Ardito, L., & Giudice, M. D. (2019). Understanding Sustainable Innovation: A Systematic Literature Review. Corporate Social Responsibility and Environmental Management, 26(5), 1012–1025. https://doi.org/10.1002/csr.1783 DOI: https://doi.org/10.1002/csr.1783
Demirel, S. E., Li, J., El‐Halwagi, M. M., & Hasan, M. M. F. (2020). Sustainable Process Intensification Using Building Blocks. Acs Sustainable Chemistry & Engineering, 8(48), 17664–17679. https://doi.org/10.1021/acssuschemeng.0c04590 DOI: https://doi.org/10.1021/acssuschemeng.0c04590
Egli, L., Meyer, C., Scherber, C., Kreft, H., & Tscharntke, T. (2018). Winners and Losers of National and Global Efforts to Reconcile Agricultural Intensification and Biodiversity Conservation. Global Change Biology, 24(5), 2212–2228. https://doi.org/10.1111/gcb.14076 DOI: https://doi.org/10.1111/gcb.14076
Hartini, S., Ciptomulyono, U., Anityasari, M., & Sriyanto, S. (2020). Manufacturing Sustainability Assessment Using a Lean Manufacturing Tool. International Journal of Lean Six Sigma, 11(5), 943–971. https://doi.org/10.1108/ijlss-12-2017-0150 DOI: https://doi.org/10.1108/IJLSS-12-2017-0150
Hessel, V., Escribà‐Gelonch, M., Bricout, J., Tran, N. N., Anastasopoulou, A., Ferlin, F., Valentini, F., Lanari, D., & Vaccaro, L. (2021). Quantitative Sustainability Assessment of Flow Chemistry–From Simple Metrics to Holistic Assessment. Acs Sustainable Chemistry & Engineering, 9(29), 9508–9540. https://doi.org/10.1021/acssuschemeng.1c02501 DOI: https://doi.org/10.1021/acssuschemeng.1c02501
Jiang, L., Wang, H., Li, S., Dai, X., Meng, S., Fu, X., Yan, H., Zheng, J., Ma, N., & Kou, L. (2023). A ‘Get‐Save‐Return’ Process Continuum Runs on Phosphorus Economy Among Subtropical Tree Species. Journal of Ecology, 111(4), 861–874. https://doi.org/10.1111/1365-2745.14066 DOI: https://doi.org/10.1111/1365-2745.14066
Kim, Y., Park, L. K., Yiacoumi, S., & Tsouris, C. (2017). Modular Chemical Process Intensification: A Review. Annual Review of Chemical and Biomolecular Engineering, 8(1), 359–380. https://doi.org/10.1146/annurev-chembioeng-060816-101354 DOI: https://doi.org/10.1146/annurev-chembioeng-060816-101354
Klein, B. C., Silva, J. F. L., Junqueira, T. L., Rabelo, S. C., Arruda, P. V. d., Ienczak, J. L., Mantelatto, P. E., José Geraldo da Cruz Pradella, Vaz, S., & Bonomi, A. (2017). Process Development and Techno‐economic Analysis of Bio‐based Succinic Acid Derived From Pentoses Integrated to a Sugarcane Biorefinery. Biofuels Bioproducts and Biorefining, 11(6), 1051–1064. https://doi.org/10.1002/bbb.1813 DOI: https://doi.org/10.1002/bbb.1813
Kumar, S. S., & Lim, H. (2023). Recent Advances in Hydrogen Production Through Proton Exchange Membrane Water Electrolysis – A Review. Sustainable Energy & Fuels, 7(15), 3560–3583. https://doi.org/10.1039/d3se00336a DOI: https://doi.org/10.1039/D3SE00336A
Luthra, S., & Mangla, S. K. (2018). Evaluating Challenges to Industry 4.0 Initiatives for Supply Chain Sustainability in Emerging Economies. Process Safety and Environmental Protection, 117, 168–179. https://doi.org/10.1016/j.psep.2018.04.018 DOI: https://doi.org/10.1016/j.psep.2018.04.018
Moni, S., Mahmud, R., High, K., & Carbajales‐Dale, M. (2019). Life Cycle Assessment of Emerging Technologies: A Review. Journal of Industrial Ecology, 24(1), 52–63. https://doi.org/10.1111/jiec.12965 DOI: https://doi.org/10.1111/jiec.12965
Müller, J. M., Kiel, D., & Voigt, K. (2018). What Drives the Implementation of Industry 4.0? The Role of Opportunities and Challenges in the Context of Sustainability. Sustainability, 10(1), 247. https://doi.org/10.3390/su10010247 DOI: https://doi.org/10.3390/su10010247
Neves, Â., Godina, R., Azevedo, S. G., & Matias, J. (2020). A Comprehensive Review of Industrial Symbiosis. Journal of Cleaner Production, 247, 119113. https://doi.org/10.1016/j.jclepro.2019.119113 DOI: https://doi.org/10.1016/j.jclepro.2019.119113
Orsini, F., Bellavia, D., Schettini, F., & Foglia, E. (2025). The Impact of Automation and Digitalization in Hospital Medication Management: Economic Analysis in the European Countries. Healthcare, 13(13), 1604. https://doi.org/10.3390/healthcare13131604 DOI: https://doi.org/10.3390/healthcare13131604
Priyono, P., Alihudien, A., & Fiendyo, H. (2025). Review Study of Foundation Structure of Belawan Medan Crane Electrification Substation Building Regarding Bearing Capacity and Settlement. Jurnal PenSil, 14(3), 508–517. https://doi.org/10.21009/jpensil.v14i3.59104 DOI: https://doi.org/10.21009/jpensil.v14i3.59104
Qian, L. K., & Huey, S. J. (2023). Process Simulation and Economic Assessments for Biodiesel Production Catalyzed by Green Nanocatalysts. Asia-Pacific Journal of Chemical Engineering, 18(6). https://doi.org/10.1002/apj.2994 DOI: https://doi.org/10.1002/apj.2994
Ramírez‐Márquez, C., Al-Thubaiti, M., Martı́n, M., El‐Halwagi, M. M., & Ponce‐Ortega, J. M. (2023). Processes Intensification for Sustainability: Prospects and Opportunities. Industrial & Engineering Chemistry Research, 62(6), 2428–2443. https://doi.org/10.1021/acs.iecr.2c04305 DOI: https://doi.org/10.1021/acs.iecr.2c04305
Rodríguez, J. F. F., Picardo, A., Aguilar-Planet, T., Martín-Mariscal, A., & Peralta-Álvarez, M. E. (2025). Data Transfer Reliability From Building Information Modeling (BIM) to Life Cycle Assessment (LCA)—A Comparative Case Study of an Industrial Warehouse. Sustainability, 17(4), 1685. https://doi.org/10.3390/su17041685 DOI: https://doi.org/10.3390/su17041685
Sosa-Martínez, J. D., Morales‐Oyervides, L., Montañez, J., Contreras‐Esquivel, J. C., Balagurusamy, N., Gadi, S. K., & Salmerón, I. (2024). Sustainable Co-Production of Xylanase, Cellulase, and Pectinase Through Agroindustrial Residue Valorization Using Solid-State Fermentation: A Techno-Economic Assessment. Sustainability, 16(4), 1564. https://doi.org/10.3390/su16041564 DOI: https://doi.org/10.3390/su16041564
Trollip, B., & Merckel, R. (2025). Production of a Nutrient Enriched Biochar: A Techno‐economic Feasibility Analysis. Biofuels Bioproducts and Biorefining. https://doi.org/10.1002/bbb.2812 DOI: https://doi.org/10.1002/bbb.2812
Williams, A., & Simpson, R. (2009). Pico hydro - Reducing technical risks for rural electrification. Renewable and Sustainable Energy Reviews, 13(8), 2488–2494. https://doi.org/10.1016/j.rser.2008.12.020 DOI: https://doi.org/10.1016/j.renene.2008.12.011
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2026 Catalyx : Journal of Process Chemistry and Technology
This work is licensed under a Creative Commons Attribution 4.0 International License.
