Background: Why Industrial Waste Treatment Needs a New Approach
Rapid industrial growth has led to a sharp rise in liquid, solid, and gaseous waste. Traditional “end-of-pipe” waste treatment focuses on pollution control after production, often consuming large amounts of energy and leaving valuable heat, water, and materials unused. This approach is increasingly misaligned with global sustainability goals, stricter environmental regulations, and net-zero emission commitments.
Chemical engineering research now emphasizes system-level solutions that treat waste as a potential resource rather than a burden. Process integration, a design approach that optimizes energy and material flows across an entire system, has gained attention as a way to improve efficiency while reducing environmental impact. The research by Netty Herawati places this concept directly in the context of industrial waste treatment, where energy losses and material inefficiencies are common.
How the Research Was Conducted
The study used a combined qualitative and quantitative analysis grounded in process systems engineering. Instead of testing a single factory, the research examined conceptual models and case-based examples of industrial waste treatment technologies.
Key elements of the methodology included:
· System mapping to identify waste sources, energy flows, and material streams
· Mass and energy balance analysis to detect inefficiencies
· Pinch analysis to evaluate opportunities for heat recovery and internal energy reuse
· Resource recovery evaluation focusing on water reuse and material recycling
· Sustainability indicators covering energy intensity, resource reuse, and potential emission reduction
This integrated approach allowed the researcher to compare conventional waste treatment systems with process-integrated alternatives in a clear and measurable way.
Key Findings: Energy, Resources, and Sustainability Gains
The results show that process integration delivers consistent improvements across multiple performance indicators.
Major findings include:
· Lower energy consumption: Integrated systems significantly reduce external heating and cooling needs by reusing internal heat streams.
· Improved energy efficiency: Heat exchanger networks designed using pinch analysis maximize internal energy utilization.
· Higher resource recovery: Process water recycling rates increase, reducing dependence on fresh water supplies.
· Reduced residual waste: Better integration between treatment units lowers the volume of waste requiring final disposal.
· Lower emissions: Reduced energy demand leads directly to lower emissions associated with utilities and fuel use.
Compared with non-integrated systems, integrated waste treatment systems show lower energy intensity and higher overall sustainability performance. These gains are not limited to energy savings but extend to material efficiency and environmental outcomes.
Turning Waste into a Resource
One of the most important insights from the study is the shift in how industrial waste is viewed. Through process integration, waste streams can be connected back to production or support processes. Heat can be reused for pre-heating, treated water can be recycled internally, and valuable materials can be recovered through integrated separation and purification steps.
This aligns closely with circular economy principles, where materials and energy remain in use for as long as possible. The study demonstrates that process integration is a practical enabler of circular industrial systems, not just a theoretical concept.
Real-World Impact for Industry and Policy
For industry, the findings highlight a clear pathway to improving competitiveness. Although integrated systems may require higher upfront design effort and investment, the long-term benefits include lower operating costs, improved compliance with environmental regulations, and reduced exposure to energy price volatility.
For policymakers and regulators, the research supports policies that encourage system-level efficiency rather than isolated pollution control measures. Incentives for energy recovery, water reuse, and integrated process design can accelerate the transition toward sustainable industrial operations.
For engineering education and practice, the study reinforces the importance of training engineers to think in terms of systems, not individual units. Sustainable waste treatment depends on understanding interactions between energy, materials, and environmental impacts.
Author Insight
Netty Herawati of the University of Muhammadiyah Palembang emphasizes that process integration changes the role of waste treatment in industry. She explains that integrated systems “allow waste streams to be transformed into sources of energy and valuable materials, supporting both environmental protection and industrial efficiency.” This perspective positions process integration as a strategic design philosophy rather than a technical add-on.
Author Profile
Netty Herawati, M.Eng. Netty Herawati is a lecturer and researcher in chemical engineering at the Faculty of Engineering, University of Muhammadiyah Palembang, Indonesia. Her expertise includes process integration, sustainable industrial systems, waste treatment engineering, and energy efficiency. Her work focuses on applying systems engineering principles to support circular economy and sustainable development in industrial processes.
Source
Journal Article: Exploring Process Integration Practices in Sustainable Industrial Waste Treatment Systems
Journal: Formosa Journal of Science and Technology (FJST)
Publication Year: 2026
DOI: https://doi.org/10.55927/fjst.v5i1.386
Official URL: https://traformosapublisher.org/index.php/fjst
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