This paper proposes a methodology to improve the sustainability of industrial processes combining two tools: BAT Analysis and process simulation. Both tools are jointly applied to identify the IF of the analyzed process, so that the most appropriate candidate techniques from an inventory can be selected. The selected alternatives are tested in different scenarios that are evaluated using simulation, which would determine the configuration that best improves the sustainability of the process. The combination of both tools in an integrated methodology will help decision makers to select the most sustainable configuration for a given process. The methodology is validated in a case study: a hydrogen production plant. After analysing several scenarios where different candidate techniques are implemented, results show that the IF identified can be highly improved when the appropriate combination of BAT is applied. (c) 2014 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.