Greening Foundation Industries: Shared Processes and Sustainable Pathways

Foundation industries, encompassing metals, ceramics, cement, paper, chemicals, and glass, play a vital role in driving industrial economies. Despite their pivotal role, a comprehensive understanding of shared processes and their impact on resource utilisation remains elusive. This study employs a novel approach, leveraging an adapted Dependency Structure Matrix (DSM), to unveil the core processes commonly utilised among these industries. These processes are then evaluated based on their influence on energy consumption and CO₂ emission. The investigation revealed 18 common processes categorised by their processing principles, their expected outcomes, and the equipment used. Remarkably, these processes emerge as significant contributors to both energy consumption and CO₂ emissions. Notably, pyroprocessing emerged as a prevalent practice in five out of the six sectors, while the production of dried products and crushers and mills were the most frequently encountered outcomes and equipment used, respectively. This paper discusses the implications of these findings for foundation industries, emphasising potential areas for enhancing manufacturing operations to reduce environmental damage and facilitate knowledge transfer among the various sectors. Furthermore, the study identifies shared abatement options that can be collectively implemented across industries to achieve more substantial reductions in environmental footprint. By identifying and prioritising the most impactful processes in foundation industries, this study provides a strategic footing for advancing sustainable and efficient manufacturing practices within these critical sectors.