Abstract

This study presents an integrated framework combining thermal pinch analysis and life cycle assessment to evaluate energy-intensive industrial processes, addressing the need to capture both operational efficiency and environmental impacts. The goal is to determine whether energy savings from process integration justify associated environmental burdens. The method links utility targets and heat exchanger network designs to life-cycle inventory data, while explicitly including heat exchanger manufacturing impacts. Three industrial cases - ammonia, bioethanol, and hydrogen production from biomass-based resources - were analysed. Results show energy use reductions of 62.27–76.05% and cost savings of 45.81–65.38%. Environmental impacts, including global warming and resource depletion, decreased significantly, although minor trade-offs appeared in ozone depletion and mineral resource use due to added equipment. The framework reveals hidden burden shifting and supports transparent decision-making for industrial decarbonization strategies.