A Pareto approach to Environmentally-Conscious Design and 
Manufacturing (ECDM) was developed and implemented for 
design of first-stage chloroorganics formation and lignin 
removal processes in Cl2/ClO2 softwood kraft pulp bleaching. 
A new model, the "(C+D) Model", was developed to 
quantitatively simulate first-stage chemical reactions leading 
to chloroorganics formation and lignin removal. This model was 
parameterized against published chemical speciation data from 
Cl2/ClO2 pulp bleaching experiments and commonly-observed 
qualitative delignification trends. The parameterized model
predicted experimental measurements used in parameterization 
with accuracy similar or superior to other published bleaching 
models and realistically depicted global bleaching trends. A 
(C+D)EDED bleach plant simulation was developed using the (C+D) 
Model to predict first-stage processes and literature models to 
simulate latter stages. This plant simulation predicted design 
criteria of first-stage chloroorganics formation, chemical cost, 
brightness, and production rate arising from first-stage design 
specifications and production and brightness targets. Pareto 
design investigations identified design configurations yielding 
concurrent improvements in design criteria. Improved Pareto sets 
of design alternatives were generated using a Pareto Genetic 
Algorithm. Pareto sets how design of first-stage processes dictated 
tradeoffs between criteria. Final selection of preferred design
alternatives within Pareto sets requires relative valuation of 
objectives to be specified. Valuation is uncertain when comparing 
incommensurate objectives, such as in environmental valuation. 
Tradeoff analysis was developed to assist explicit valuation of 
bleaching design criteria by identifying ranges of objective 
valuations for which each alternative in a Pareto set was preferred. 
Potentially-preferred alternatives could then be identified based 
on robustness against valuation uncertainty. This research realized 
a specific application of a general Pareto-based vision of ECDM. 
This general vision targets three common issues in ECDM: (i) directly 
addressing all processes influencing criteria during design, (ii) 
searching for design alternatives that are concurrently-improved in 
all criteria, and (iii) decoupling search and valuation to facilitate 
sensitivity analysis of alternative preference against valuation 
uncertainty. Future applications in other specific design cases may 
ultimately show the value of this vision in explicitly addressing 
these three ECDM issues.