Sustainable Industrial Processes Research Articles

Integrated Experimental and Mathematical Modeling to Guide Microbial Biocatalysis: Pseudomonas putida Conversion of L-Phenylalanine to trans-Cinnamic Acid.

trans-Cinnamic acid (tCA) can be produced by the deamination of L-phenylalanine using phenylalanine ammonia-lyase (PAL). In bioprocesses, optimizing production processes to improve key performance metrics such as titer, rate, and yield has proved challenging. This study investigates tCA production in Pseudomonas putida KT2440 using a whole-cell biocatalyst expressing four different PAL genes. Among these, RmXAL showed the highest titer and rate. Biocatalysis at pH 8.5 and 37°C were identified as the best conditions, giving a tCA concentration of 2.65 g L-1 and a production rate of 0.44 g L-1 h-1. To improve the metrics further, a decoupled bioprocess with various biocatalyst concentrations in the second stage was examined. With a whole-cell biocatalyst concentration of 30 gDCW L-1, optimal process parameters were achieved, giving a titer of 29.88 g L-1, rate of 5.99 g L-1 h-1, yield on glucose of 0.27 g tCA g glucose-1, and yield on L-phe of 0.75 g tCA g L-phe-1. This study is the first report of a model that enables performance metrics to evaluate a suitable process for tCA production and provides valuable insights into tCA production using a decoupled bioprocess. This would appear applicable to larger-scale production, paving the way for an efficient and sustainable industrial process.

Scaling up Trickle Bed Reactor for Gas Fermentation Technology: The Effect of Temperature and Reactor Characteristics on Mass Transfer

The increasing demand for efficient and sustainable industrial processes has accelerated research into green alternatives. Gas fermentation in a trickle bed reactor is a promising technology; however, optimal scaling up is still challenging. A mass transfer model is crucial for identifying bottlenecks and suggesting design improvements to optimize the scale-up of TBR for gas fermentation. This study explores the effects of temperature, reactor dimensions, and packing material size on the volumetric mass transfer coefficient (kLa) in a commercial-scale trickle bed reactor (TBR). Using dynamic mass transfer modeling, the research results highlight that thermophilic conditions (60 °C) significantly enhance kLa and mass transfer rates for H2, CO, and CO2, despite reduced gas solubility at higher temperatures. Additionally, packing material of smaller particles improves kLa by increasing the surface for gas–liquid interaction, while reactor dimensions, particularly volume and diameter, are shown to critically influence kLa. This study provides valuable insights into optimizing TBR design and scale-up, emphasizing the importance of thermophilic conditions, proper packing material selection, and reactor geometry for efficient gas–liquid mass transfer in syngas (a mixture of H2, CO, and CO2) biological conversion. Overall, the findings offer practical guidelines for enhancing the performance of industrial-scale TBR systems.

Structural Reorganizations and Nanodomain Emergence in Lipid Membranes Driven by Ionic Liquids.

Ionic liquids (ILs) have promising applications in pharmaceuticals and green chemistry, but their use is limited by toxicity concerns, mainly due to their interactions with cell membranes. This study examines the effects of imidazolium-based ILs on the microscopic structure and phase behavior of a model cell membrane composed of zwitterionic dipalmitoylphosphatidylcholine (DPPC) lipids. Small-angle neutron scattering and dynamic light scattering reveal that the shorter-chain IL, 1-hexyl-3-methylimidazolium bromide (HMIM[Br]), induces the aggregation of DPPC unilamellar vesicles. In contrast, this aggregation is absent with the longer alkyl chain IL, 1-decyl-3-methylimidazolium bromide (DMIM[Br]). Instead, DMIM[Br] incorporation leads to the formation of distinct IL-poor and IL-rich nanodomains within the DPPC membrane, as evidenced by X-ray reflectivity, differential scanning calorimetry, and molecular dynamics simulations. The less evident nanodomain formation with HMIM[Br] underscores the role of hydrophobic interactions between lipid alkyl tails and ILs. Our findings demonstrate that longer alkyl chains in ILs significantly enhance their propensity to form membrane nanodomains, which is closely linked to enhanced membrane permeability, as shown by dye leakage measurements. This heightened permeability likely underlies the greater cytotoxicity of longer-chain ILs. This crucial link between nanodomains and toxicity provides valuable insights for designing safer, more environmentally friendly ILs, and promoting their use in biomedical applications and sustainable industrial processes.

Sustainable innovation: Case studies from product development

AbstractAttempts to implement sustainable development in industry are hampered by the fact that production processes are often not environmentally sound. Therefore, there is a need for innovation processes that are sustainable. This means that they need to be durable on the one hand, but also with reduced materials consumption and a low carbon footprint, on the other. Current trends suggest that much could be gained, by undertaking research that may lead to more sustainable industrial production and processes. Against this background, this paper describes the characteristics of sustainable innovation, discusses what makes innovation sustainable, and introduces a set of case studies where different types of innovation in product development are described, drawing the lessons learned. The paper concludes by describing the items, which need to be considered in the future, to make a greater use of sustainable innovation principles in product development, as part of a systemic transformation.

Direct parallel electrosynthesis of high-value chemicals from atmospheric components on symmetry-breaking indium sites

To tackle significant environmental and energy challenges from increased greenhouse gas emissions in the atmosphere, we propose a method that synergistically combines cost-efficient integrated systems with parallel catalysis to produce high-value chemicals from CO2, NO, and other gases. We employed asymmetrically stretched InO5S with symmetry-breaking indium sites as a highly efficient trifunctional catalysts for NO reduction, CO2 reduction, and O2 reduction. Mechanistic studies reveal that the symmetry-breaking at indium sites substantially improves d-band center interactions and adsorption of intermediates, thereby enhancing trifunctional catalytic activity. Employed in a flow electrolysis system, the catalyst achieves continuous and flexible production of NH3, HCOO-, and H2O2, maintaining over 90% Faradaic efficiency at industrial scales. Notably, the parallel electrolysis device reported in this study effectively produces high-value products like NH4COOH directly from greenhouse gases in pure water, offering an economically efficient solution for small molecule synthesis and unique insights for the sustainable conversion of inexhaustible gases into valuable products. Therefore, this work possesses considerable potential for future practical applications in sustainable industrial processes.

Screening and Identification of Industrial Enzyme Producing Bacteria from Sheep and Goat Milk

Industrial enzyme producing bacteria are essential for advancements in biotechnology. This study aims to identify bacterial strains from sheep and goat milk capable of producing industrially valuable enzymes. Basic Gram’s Staining and motility tests were performed from the bacterial colony of samples. Milk samples yielded a colony of bacteria which were screened for protease and amylase production. IMVIC tests demonstrated the feasibility of utilizing sheep and goat milk as a rich source of industrially valuable enzyme producing bacteria. By using SDS – PAGE the presence of the protein molecules is found. This study contributes to the discovery of novel enzyme-producing bacteria from unconventional sources, providing opportunities for the development of sustainable and efficient industrial processes. In this case, the results suggest that sheep and goat milk can serve as a rich source of industrially relevant enzymeproducing bacteria, offering potential applications in food processing, textile, and pharmaceutical industries. This demonstrated that certain bacterial strains exhibited high enzyme activity, highlighting their potential for industrial applications. Further studies on optimizing enzyme production and understanding the genetics of these isolates could lead to the development of new microbial strains for efficient enzyme production in various industries.

Water pollution: causes, impacts and current efforts to address the issues of water pollution along river Meizimera-kihihi, Kanugu District,Uganda.

Pollution refers to the addition of harmful substances to that level where they cause an effect on the environment, it has three major categories such as water, soil, and air pollution but this report is on water pollution. It occurs when harmful substances contaminate water bodies such as, groundwater, rivers, lakes, and oceans rendering them unfavorable for various purposes for example drinking, recreation, and support to aquatic life. Globally, over 80% of wastewater worldwide is discharged into the water bodies without adequate treatment. In Africa, lack of clean water and sanitation is a significant challenge in many countries, affecting approximately 319 million people. Thus, water pollution is one of the types of pollution that has been threatening the lives of living organisms. Implementing effective policies and strategies can have a profound impact on the environment and local communities. By reducing pollution levels and improving water quality, we can create a healthier environment and decrease the incidence of waterborne diseases, leading to improved health and well-being for residents. The research on water pollution in the River Meizimera Kihihi has important implications for future research, policy and governance, human health, the environment, and communities and society. In conclusion, effective policies can foster community involvement, raise awareness, and promote collective action to address water pollution. By achieving clean water and sanitation (SDG 6), we can contribute to the broader sustainable development goals. This research has important ramifications for future research, policy and governance, human health, the environment, communities, and society. This study investigated the problems of water pollution, its causes, its impact, and the current effort to address the issues along the river of Meizimera-kihihi, Kanugu district, Uganda. Recommendations were made, which included encouraging the adoption of sustainable agricultural practices, industrial processes, and waste management strategies to minimize pollution.

Development of Madura Batik MSME HR as a Catalyst for Green Entrepreneurship in Indonesia

The purpose of this study is to look at how human resource (HR) development in Batik Madura micro, small, and medium-sized enterprises (MSMEs) might act as a catalyst for green entrepreneurship in Indonesia. Green entrepreneurship is becoming the primary emphasis for decreasing negative environmental consequences while enhancing competitiveness in a global market that is more concerned with sustainability. HR plays a crucial role in implementing technical innovation and environmentally sustainable industrial processes. This study takes a qualitative method, with in-depth interviews with the owners, managers, and employees of MSME Batik Madura, as well as a literature analysis on green entrepreneurship.According to the study's findings, sustainable human resource development through training and education that emphasizes sustainability can boost productivity and efficiency in batik manufacturing. Furthermore, human resources with environmental consciousness and digital marketing abilities help Madurese batik products compete more effectively in national and international marketplaces. This study promotes collaboration among government, academics, and industry stakeholders to strengthen the development of human resources for Madura Batik MSMEs, which is the primary pillar in the transition to green entrepreneurship.

Non-Isothermal Thermogravimetric Analysis of Carbonation Reaction for Enhanced CO2 Capture

An in-depth investigation into CaO-based carbonation reaction kinetics for CO2 sorption is being conducted using simultaneous thermal analysis (STA), with the application of advanced thermogravimetric and differential scanning calorimetry techniques. Utilizing advanced thermal analysis system for real-time monitoring of simultaneous measurements of mass changes and thermal effects are conducted, ensuring precision and versatility in data acquisition. The study explores the intricacies of the non-isothermal carbonation process across a wide range of temperatures, shedding light on the temperature-dependent trends in reaction rates. Innovative statistical methods, combining regression techniques and Arrhenius equation, are employed to determine energy and reaction kinetics. The sensitivity of carbonation process to varying pressure conditions is meticulously examined in the study, providing pivotal discernment for optimization of reaction parameters across diverse applications. The integration of STA with statistical modeling alongside systematic analysis of temperature-dependent trends and pressure-order relationships not only enhances the understanding of CO2 capture efficiency but also improves the robustness and accuracy of the findings. Furthermore, meticulous cross-validation with existing studies provides a critical evaluation of the experimental approach’s precision and limitations. This study enhances understanding of CaO carbonation kinetics, providing practical implications for carbon capture processes and contributing to sustainable industrial processes.

Preparation of V2O5 using Pb5(VO4)3OH recovered from Bayer vanadium sludge through H2SO4 pre-treatment, H2O2 leaching, V5O12∙6H2O and V10O24∙12H2O precipitation and oxidative roasting at 400 °C

Bayer vanadium sludge (BVS), discharged during the Bayer alumina production, is a promising secondary resource for the supply of vanadium. Previous vanadium extraction process involving Pb5(VO4)3OH precipitation by PbSO4, H2SO4 and (NH4)2SO3 leaching, (NH4)2S2O8 oxidation followed by ammonium vanadate precipitation, suffered from large amounts of reagent consumption and discharge of ammonia-containing waste. In this study, a cleaner and cost-efficient process based on H2SO4 pre-treatment, H2O2 leaching, hydrolytic precipitation, and preparation of V2O5 through oxidative roasting was proposed to reduce reagent consumption and waste. Results show that the maximum vanadium leaching efficiency reached 99.7 % under the most suitable conditions of H2SO4 pre-treatment with H2SO4/Pb5(VO4)3OH molar ratio of 6.5, pulp density of 250 g/L at 90 °C for 4 h followed by H2O2 leaching with H2O2/V molar ratio of 3.0 at 15 °C for 10 min. Furthermore, 96.5 % of vanadium was precipitated in the forms of V5O12∙6H2O and V10O24∙12H2O by heating the leach liquors to 100 °C for 60 min, followed by the oxidative roasting at 400 °C for 2 h to prepare V2O5 product with a purity of 99.2 %, with only H2O as a by-product. This research provides new insights into vanadium extraction in a cleaner, cost-efficient, and sustainable industrial process which saves 147.4 $/t Pb5(VO4)3OH.

Enhanced catalytic performance of Candida rugosa lipase through immobilization on zirconium-2-methylimidazole: A novel biocatalyst approach

Immobilization of enzymes on suitable supports is a critical approach for enhancing enzyme stability, reusability, and overall catalytic efficiency. This study explores the immobilization of Candida rugosa lipase on zirconium-based 2-methylimidazole (ZrMI) nanoparticles, aiming to develop a stable and reusable biocatalyst. The ZrMI was produced via a solvothermal technique and analyzed using various characterization methods. Candida rugose lipase was immobilized using cross-linking agents, achieving an 87 % immobilization efficiency. The immobilized enzyme exhibited significantly enhanced thermal stability, broader pH tolerance, and increased catalytic efficiency compared to free C. rugose lipase. The ZrMI@lipase retained 69 % of its enzymatic activity following a 60-day storage period at 4 °C. Notably, it displayed significant reusability, maintaining 65 % of its original activity after undergoing 15 catalytic cycles. Examination of the kinetics revealed that the immobilized enzyme possessed a heightened substrate affinity (Km of 4.1 mM) and maximal reaction rate (Vmax of 85.7 μmol/ml/min) in comparison to the free enzyme (Km of 5.4 mM and Vmax of 69 μmol/ml/min), indicating enhanced catalytic efficiency. Validation through zeta potential and hydrodynamic size assessments verified the successful binding of the enzyme and the consistent colloidal characteristics. These results suggest that ZrMI is a promising support for C. rugose lipase immobilization, offering improved stability and reusability for various industrial applications. The study highlights the potential of ZrMI@lipase as an efficient and durable biocatalyst, contributing to advancements in enzyme immobilization technology and sustainable industrial processes.

The INSIGHT platform: Enhancing NAD(P)-dependent specificity prediction for co-factor specificity engineering

Enzyme specificity towards cofactors like NAD(P)H is crucial for applications in bioremediation and eco-friendly chemical synthesis. Despite their role in converting pollutants and creating sustainable products, predicting enzyme specificity faces challenges due to sparse data and inadequate models. To bridge this gap, we developed the cutting-edge INSIGHT platform to enhance the prediction of coenzyme specificity in NAD(P)-dependent enzymes. INSIGHT integrates extensive data from principal bioinformatics resources, concentrating on both NADH and NADPH specificities, and utilizes advanced protein language models to refine the predictions. This integration not only strengthens computational predictions but also meets the practical demands of high-throughput screening and optimization. Experimental validation confirms INSIGHT's effectiveness, boosting our ability to engineer enzymes for efficient, sustainable industrial and environmental processes. This work advances the practical use of computational tools in enzyme research, addressing industrial needs and offering scalable solutions for environmental challenges.

Efficient Recovery of Rare Earth Elements from Acidic Wastewater by a Green β-CDs-Functionalized Nanosponge.

The recovery of rare earth elements (REEs) from acidic wastewater is crucial to sustainable development, industrial processes, and human health. In this research, β-cyclodextrin-based nanosponges (β-CD/PVA-SA NSs) have been proposed as potential adsorbents for europium (Eu), dysprosium (Dy), and gadolinium (Gd) recovery. The nanosponges are synthesized by cross-linking β-cyclodextrin (β-CD) functionalized polyvinyl alcohol (PVA) and sodium alginate (SA). Experimental results indicate that β-CD/PVA-SA NSs exhibit favorable selectivity for Eu, Dy, and Gd, with the maximum adsorption capacity of 222, 217, and 204 mg/g, respectively, in addition to stability and cyclicity. β-CD/PVA-SA NSs maintain selective adsorption effects towards RE ions that are present in acidic mine drainage (AMD), thereby highlighting their potential for practical applications. Furthermore, density functional theory (DFT) simulations have unveiled the fundamental interactions between the functional groups anchored in β-CD/PVA-SA NSs and the REEs, providing vital insights into their adsorption mechanism. Hence, the utilization of β-CD/PVA-SA NSs has the potential to advance initiatives in remediating acidic water pollution and facilitating the sustainable recycling of RE resources.

Highly parallelized laboratory evolution of wine yeasts for enhanced metabolic phenotypes

Adaptive Laboratory Evolution (ALE) of microorganisms can improve the efficiency of sustainable industrial processes important to the global economy. However, stochasticity and genetic background effects often lead to suboptimal outcomes during laboratory evolution. Here we report an ALE platform to circumvent these shortcomings through parallelized clonal evolution at an unprecedented scale. Using this platform, we evolved 104 yeast populations in parallel from many strains for eight desired wine fermentation-related traits. Expansions of both ALE replicates and lineage numbers broadened the evolutionary search spectrum leading to improved wine yeasts unencumbered by unwanted side effects. At the genomic level, evolutionary gains in metabolic characteristics often coincided with distinct chromosome amplifications and the emergence of side-effect syndromes that were characteristic of each selection niche. Several high-performing ALE strains exhibited desired wine fermentation kinetics when tested in larger liquid cultures, supporting their suitability for application. More broadly, our high-throughput ALE platform opens opportunities for rapid optimization of microbes which otherwise could take many years to accomplish.

ENTROPY-OPTIMIZED FLOW OF COUPLE STRESSES IN AN POROUS INCLINED PIPE WITH UNIFORM MAGNETIC FIELD AND MIXED CONVENTION

Abstract The research aims to investigate the entropy-optimized flow of couple stresses in a porous inclined pipe exposed to a transverse constant magnetic field and mixed convection. It focuses on understanding the thermodynamic efficiency and fluid behaviour under convective boundary conditions, contributing to improved designs in engineering applications where such flows are relevant. The aim is to enhance heat transfer efficiency in industrial processes such as chemical reactors, heat exchangers, and geothermal systems, while also improving filtration systems for applications like water purification and oil recovery. By subjecting the flow to a uniform magnetic field and mixed convection, nonlinear governing equations arise due to mixed convection. We linearize these equations using a quasi-linearization approach and solve them using Chebyshev spectral collocation. Our analysis focuses on thermodynamic phenomena like entropy generation and the Bejan number, which have implications for the efficiency and sustainability of industrial processes. We visualize temperature and axial velocity profiles across various parameter ranges to understand the fluid's behaviour under the influence of magnetic fields and porous materials. As the magnetic parameter increases, there is a decrease in fluid velocity and temperature. However, the opposite tendency is seen for the couple stress viscosity ratio parameter. We also observe irreversibility dominating heat transfer at the pipe wall, while fluid friction irreversibility dominates around the pipe's centre. This research contributes to advancing our understanding of thermodynamic processes in complex fluid systems and has practical implications for optimizing industrial processes and developing more efficient filtration systems.

Sustainable industrial process design for derived CO2 adsorbent from municipal solid wastes: Scale-up, techno-economic and parametric assessment

Climate change and carbon emissions attributed to anthropogenic activities is getting alarming dimensions. On the other hand, the overwhelming progress of industrialization and urbanization contributed to an explosion in the municipal solid waste (MSW), as one of the other global challenges. However, developing a cost-effective adsorbent with appealing textural properties for CO2 capture is still one of the main challenges. Lately, carbon-based solid waste materials of biogenic origin have received a major interest to this end, owing to the renewability, availability and low-cost. Routinely, academic research mainly focuses on lab-scale development of activated carbons derived from waste materials. However, there is a significant gap concerning the industrial production of activated carbon from such materials. Accordingly, in this work, an industrial plant has been designed for producing activated carbon derived from digestate of MSWs in the industrial scale by presenting all scale-up details, engineering assumptions and process specifications. The results indicated that the plant has a potential to process 90,273 ton MSW annually, which consumes 1367.8 MWh net electricity and 20,134.4 GJ net heat, also produces 4788.10 ton CO2 adsorbent, per year. The economic assessment specified that the plant capital cost is around $14.112 million with the net price of 0.61 $/kg for produced activated carbon. Further, the sensitivity analysis and parametric study determined that the sample level in the drum is the determinative parameter on the energy consumption and net price of adsorbent. Finally, Response Surface Methodology was employed to maximize the plant profitability concerning the designing factors.

Sustainable innovation: Economic valuation of wood waste for sustainable development at PT Wapoga Mutiara Industries

Background: This study describes the economic valuation of wood waste at PT Wapoga Mutiara Industries using the Market Price Approach to calculate the Total Economic Value (TEV) derived from utilising production waste. This research uses qualitative methods to explore how processed wood waste contributes economically to the company and the local community. Wood waste in industrial processes is often an underutilised asset. However, at PT Wapoga Mutiara Industries, innovative practices have turned this by-product into a significant economic opportunity. Method: This research investigated the direct use value of wood waste - mainly wood chips and sawdust - converted into local charcoal products, a resource increasingly recognized for its environmental and economic benefits. The research assessed the monthly economic impact of these waste products, measuring their market value to quantify the total benefits accruing to the local economy. Findings: The findings from this study are considerable, showing that wood chips alone contribute IDR 42,300,000 to the economy each month. Sawdust was processed in the same way, adding IDR 72,860,000 per month. Combined, these waste materials contribute a total direct use value of IDR 166,160,000 per month to the local economy, which on average provides a potential income of IDR 1,350,700 per person per month, suggesting there is significant economic potential from sustainable wood waste management practices. Conclusion: In addition, the study provides insight into the broader implications of such valuation practices, demonstrating that with the right innovations, what is often considered industrial waste can be re-evaluated as a viable economic resource. This aligns with the global shift towards more sustainable industrial processes, where waste minimisation and reuse contribute to environmental sustainability, economic resilience, and community well-being. Novelty/Originality of this study: This study presents a comprehensive analysis of the economic valuation of wood waste in the processing industry, demonstrating the significant potential of innovative waste management practices. This research opens up new perspectives on how industrial 'waste' can be transformed into valuable economic resources, supporting environmental sustainability and the well-being of local communities.

Advances in Aureobasidium research: Paving the path to industrial utilization.

We here explore the potential of the fungal genus Aureobasidium as a prototype for a microbial chassis for industrial biotechnology in the context of a developing circular bioeconomy. The study emphasizes the physiological advantages of Aureobasidium, including its polyextremotolerance, broad substrate spectrum, and diverse product range, making it a promising candidate for cost-effective and sustainable industrial processes. In the second part, recent advances in genetic tool development, as well as approaches for up-scaled fermentation, are described. This review adds to the growing body of scientific literature on this remarkable fungus and reveals its potential for future use in the biotechnological industry.

Energy-efficient production of sustainable industrial process heat with a parabolic dish-conical cavity solar collector

Industrial decarbonization in response to global carbon neutrality requires vast process heat to be supplied in a low-carbon manner. Solar energy is regarded as one of the most promising alternatives to fossil fuel applied for heat-driven industrial processes, however, lack of effective approaches to improve the solar-thermal conversion efficiency is a longstanding issue. Here, we propose an efficient approach to produce industrial process heat based on a novel concentrated solar collector, mainly consisting of a parabolic dish concentrator and a conical cavity receiver. Results showed that the collector was competent to supply the process heat meeting various low-temperature industrial occasions, and there was an optimum flow rate to achieve a trade-off between the outlet temperature of working fluid and thermal efficiency of the solar collector. The thermal efficiency of the proposed solar collector was 2.7%–27.5% higher than that of most other existing collectors used for production of low-temperature process heat, and such a superior solar-thermal conversion efficiency was a consequence of the reduction in energy losses between the solar receiver and surroundings as confirmed by the comprehensive energy analysis performed in this study.

CFD and RSM Assist in Reducing the LPG Consumption of Burners for Agarwood Oil Production in Thailand

ABSTRACT This research aimed to optimize LPG consumption in Thai commercial burners used in agarwood oil production, specifically focusing on the KB-10, S-10, and EB-10 burners. Enhancing burner efficiency is crucial due to rising energy costs and environmental concerns. A dual approach using Response Surface Methodology (RSM) and Computational Fluid Dynamics (CFD) was employed in order to achieve the best burner. Central Composite Design (CCD) within the RSM framework determined the optimal swirl and inclination angles combinations. Modified burners with variant combination angles, as suggested by RSM, were numerically investigated. CFD simulations with Ansys Fluent, utilizing the k-ε turbulence and discrete ordinates (DO) radiation models, provided detailed insights into the combustion and heat transfer processes of those modified burners. The modified burners, SB10–1, SS10–3, and SEB10–7, demonstrated significant improvements. Laboratory and field tests indicated energy savings of 16.15%, 23.74%, and 20.75%, respectively. Statistical analysis confirmed these savings with p-values < .05. The 95% confidence intervals for LPG savings were 31.31 ± 0.8%, 33.42 ± 0.7%, and 31.84 ± 0.6%, corresponding to payback periods of approximately 2.99, 4.21, and 8.95 months. Additionally, CO and NOx emissions were kept below 350 ppm and 100 ppm, respectively. The novelty of this study lies in the combined use of RSM and CFD to optimize burner performance, leading to significant energy savings and emission reductions. These findings highlight the potential of these methods for burner optimization, offering both economic and environmental benefits. This research underscores the importance of integrating advanced modeling techniques to achieve sustainable and cost-effective industrial processes.