There are considerable challenges in developing new resource projects that meet the ideals of sustainability. The high-level principles of corporate sustainability policies cannot be easily integrated into project management systems. In addition, existing systems do not readily deliver innovative solutions to address key sustainability issues, such as significantly reduced carbon emissions, minimal environmental impacts, and maintaining the societal 'licence to operate'. SUSOP (R) (SUStainable OPerations) is an approach for the integration of sustainable development principles into the design and operation of industrial processes. Somewhat analogous to HAZOP (Hazard and Operability Studies), SUSOP (R) is a systematic and rigorous framework for identifying and evaluating sustainability opportunities and risks within the organising architecture of a sustainability framework. This approach has been tested and enhanced through application to real case studies in the minerals industry. The results, both at the conceptual and pre-feasibility phases, have led to significant insights for identifying and evaluating options that enhance an operation's contribution to sustainability and its long-term business case. This paper discusses the need for an approach such as SUSOP (R), presents the key outcomes from its development with particular reference to the case study learnings, and highlights the practical ways for incorporating sustainability into project management systems. (C) 2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.