Life cycle optimization for sustainable product footprint management: A comprehensive approach to coupling economic, environmental, and energy factors on a large scale

This study proposes an integrated analytical framework designed to evaluate and optimize the sustainability performance of refinery operations across economic, environmental, and energy dimensions. Unlike traditional models that analyze these aspects independently, the proposed method captures their dynamic interdependencies through a modular, subprocess-level decomposition of the production chain. The framework employs Life Cycle Costing (LCC) for detailed economic analysis, Life Cycle Assessment (LCA) for emissions tracking, and Multi-Regional Input-Output (MRIO) modeling to quantify energy use. These components are cohesively linked through a graph-theoretic multi-objective decision model that enables optimization of production pathways based on cost, energy intensity, and carbon emissions. Empirical validation using data from a high-capacity petrochemical refinery demonstrates that the approach effectively identifies critical emission and cost hotspots, particularly in diesel and naphtha processing routes. Implementation of the optimized layout resulted in over 70 % emissions reduction in key subprocesses while improving energy efficiency and reducing costs. The results underscore the value of integrated footprint coupling and optimization strategies in steering refinery systems toward carbon-resilient and economically sustainable futures.