In this work, process intensification and heat integration are applied to improve a palm oil biofuel production process using modularity analysis and evaluated through techno-economic analysis and life cycle assessment (LCA). The modularity analysis integrated with the safety indicator guided the scoping of intensification options and the application of the LCA at the level of process modules that facilitate the treatment of recycles. Two alternatives are presented: the first is the intensified one only and the second is the addition of heat integration. In both cases, there was an improvement in economic terms by decreasing utility costs by 2 and 70%, respectively. In environmental terms, the global warming potential obtained is 12.8 kg CO2 eq./GJ for the intensified design and 12.2 kg CO2 eq./GJ for the intensified and integrated design, which is a considerable improvement over other studies that have been carried out. In addition, process safety was improved as the fire and explosion damage rate decreased by 15% in the separation section. In conclusion, this work demonstrated a novel application of modularity to scope intensification opportunities, implement LCA models at the modular level, and identify hot spots.

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