From Green Chemistry to Sustainable Manufacturing: A Systems Framework for Low-Carbon and Circular Technologies

Abstract

Green chemistry has evolved from a pollution-prevention concept into a practical framework for sustainable chemical manufacturing. To address climate change, resource depletion, and environmental pollution, chemical processes must be redesigned beyond end-of-pipe treatment toward low-carbon, safer, and circular manufacturing systems. This mini-review develops a systems framework for low-carbon and circular technologies in chemical manufacturing by organizing green chemical technologies into four interrelated pathways: feedstock transition, catalysis and reaction engineering, process intensification and electrification, and circular product design. Quantitative metrics such as atom economy, E-factor, process mass intensity, carbon footprint, and life-cycle assessment are emphasized as essential tools for evaluating real sustainability benefits and avoiding burden shifting. The review further highlights the enabling roles of biocatalysis, artificial intelligence, predictive modeling, digital twins, automation, and systems engineering as cross-cutting tools for translating technological advances into industrial-scale sustainable manufacturing. Future green chemical technology should move from isolated greener reactions toward integrated molecular, process, and system design for low-carbon and circular chemical manufacturing.

Keywords

Green chemistry / Green chemical technology / Sustainable chemical manufacturing / Life-cycle assessment / Safe-and-sustainable-by-design

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