<![CDATA[Efficient management of water and hydrogen resources is a critical aspect of sustainable chemical process design. This study aims to develop a systematic methodology that integrates Water Pinch Analysis and Mass Exchange Network (MEN) optimization to reduce freshwater consumption and wastewater discharge in multi-unit chemical plants. The methodology begins with constructing a source–sink matrix from detailed process data, followed by water pinch targeting to identify minimum freshwater and wastewater flows. MEN synthesis is then formulated as a Mixed-Integer Nonlinear Programming (MINLP) model to allocate resources optimally across multiple units, considering multi-contaminant constraints. The optimization results reveal a freshwater reduction exceeding 30%, achieved through efficient reuse strategies validated by pinch-based targeting. Composite curves guided theoretical targets, while the MEN model provided actionable reuse pathways. Sensitivity analysis confirmed the robustness of the system to variations in contaminant thresholds and economic conditions. Real-world case studies in petrochemical, textile, and food sectors support the feasibility and adaptability of the proposed framework. Overall, the integration of Water Pinch and MEN methods demonstrates a scalable and cost-effective approach to sustainable resource optimization. This framework aligns with circular economy principles and sets the stage for future enhancements through real-time control and digitalization.]]>
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