The optimal design of an energy-intensive process involves a compromise between costs and greenhouse gas emissions, complicated by the interaction between optimal process emissions and supply chain emissions. We propose a method that combines generic abatement cost estimates and the results of existing (LCA) life cycle assessment studies, so that supply chain emissions are properly handled during optimization. This method is illustrated for a (NGCC) natural gas combined cycle power plant model with the following design and procurement options: procurement of natural gas from low-emissions producers, fuel substitution with (SNG) synthetic natural gas from wood, and variable-rate CO2 capture and sequestration from both the NGCC and SNG plants. Using multi-objective optimization, we show two Pareto-optimal sets with and without the proposed LCA method. The latter can then be shown to misestimate CO2 abatement costs by a few percent, penalizing alternate fuels and energy-efficient process configurations and leading to sub-optimal design decisions with potential net losses of the order of $1/MWh. Thus, the proposed LCA method can enhance the economic analysis of emissions abatement technologies and emissions legislation in general. (C) 2011 Elsevier Ltd. All rights reserved.