Strategic Pathways for Magnesium–Aluminum‐Layered Double Hydroxides: Multidimensional Footprints of Production Routes

ABSTRACT Magnesium–aluminum‐layered double hydroxides (MgAl‐LDHs) are used in flame retardants, remediation, and catalysis. Sustainability comparisons of industrial routes are insufficient. This study couples techno‐economic analysis with life cycle assessment (LCA) to evaluate two routes (hydrothermal synthesis and modification) at 1000 t/a using industrial data. Both yield 99.9% pure products with distinct energy structures: Synthesis consumes more electricity but less gas/water; modification cuts electricity by 33.9% but needs more gas/water for grinding. Economically, synthesis costs 5984.81 CNY/t, 15.87% lower than modification (7113.78 CNY/t), dependent on regional energy prices. There are no direct CO 2 emissions, carbon footprints from gas‐based energy. Synthesis has 0.72 kg CO 2 /kg, 6.5% lower than modification, and heating decarbonization is key. This work clarifies techno‐economic and environmental boundaries, supporting process selection and green transformation.