PVC has become an indispensable material worldwide. However, its production method (suspension) presents significant sustainability challenges, such as negative environmental impacts and high operational costs due to energy consumption. For this reason, a combined analysis was conducted involving energy integration using Aspen Energy Analyzer™ V14 software and a technical process analysis. This methodology aims to reduce industrial utility consumption and assess the sustainability performance of this alternative. The integration through pinch analysis revealed that it is possible to reduce the energy consumption of the process by 29% in heating utilities and 6% in cooling utilities. The minimum utility requirements were 21 GJ/h for heating (down from 29 GJ/h) and 131 GJ/h for cooling (down from 139 GJ/h). This reduction resulted in approximately a 41% decrease in utility costs. Additionally, the reduction in burner energy consumption led to lower greenhouse gas emissions, with a decreased natural gas consumption of approximately 279 m³. However, only two streams could be integrated due to technical process limitations; therefore, it is recommended to explore integrations with complex operations such as reactors and phase-change processes. In addition to this, the WEP technical evaluation yielded promising results showing a decrease in the specific energy intensity by 3219.506 MJ/t (being 4681.8 MJ/t), which represents an economic saving in industrial services (energy purposes) of approximately USD 886.000 per year, satisfying the optimization of the process despite the limitations when integrating it energetically. Finally, a more in-depth analysis should be conducted to further integrate other streams of the process to reduce utilities consumption.

Biofuels, such as biodiesel, bioethanol, and biohydrogen produced from organic waste, constitute a sustainable alternative to non-renewable fuels and drive the energy transition. In this work, the inherent safety methodology was implemented to quantify and evaluate the intrinsic risks of obtaining hydrogen from African palm stems through direct gasification with Selexol. The methodology indicators were calculated with reference to databases, the literature, and safety data sheets, considering critical stages of the process. The total inherent safety index (I_SI) was 38, classifying the process as intrinsically unsafe, with the chemical component scoring 21 points, with hydrogen being the main chemical risk (8 points), along with hazards generated by chemical reactions. Likewise, high temperature and pressure conditions indicate the presence of potentially unsafe equipment such as reactors and heat exchangers, giving the process index 17 points. Based on the results, it is recommended to reduce raw material inventories and optimize operating conditions to reduce the potential for hazardous events and improve overall inherent safety.

Polyvinyl chloride (PVC) is the third most widely produced plastic on an industrial scale, due to its diverse applications and physicochemical properties. Its production through suspension polymerization presents significant safety challenges due to the handling of hazardous substances. To assess the impact of energy integration on process risks, the inherent safety analysis was implemented to determine the characteristic hazards of PVC suspension production. The methodology’s indicators were quantified by reviewing databases, literature, and safety data sheets, considering process steps such as vinyl chloride monomer recovery, PVC purification, and drying. The results revealed that the PVC production process under energy integration conditions is intrinsically unsafe, with a total inherent safety index (ISI) of 34. The chemical component would contribute 19 points, with VCM being the main chemical risk given its flammable and carcinogenic nature, contributing a value of 15, along with the heat released by the reactions. Process safety would contribute 15 points, associated with hazardous equipment such as furnaces, burners, and dryers, as well as risks related to inventories and similar plant accidents. To improve process safety, it is recommended to reduce VCM inventories, optimize operating conditions, and implement advanced control systems for possible accidental releases.