We present an investigation on how economic and environmental assessment results change when different process options or evaluation settings are considered. As the main case study the production technology of methyl methacrylate (MMA) is investigated. Six commercial processes using different reaction routes are modelled and evaluated with respect to their economic and environmental performance. On these six base case models different process options and evaluation settings are considered and the resulting impacts on the assessment results are quantified. Major findings of the study are that the more decision-variables become fixed, the smaller becomes the impact of the decisions still to be taken-but not only with respect to the economic performance but also with regard to the environmental assessment result. Along the process development steps the potential impacts on the economic and environmental performance decrease to the same degree. The results obtained for the evaluation settings do not show such a systematic pattern as those for the process options. This finding indicates that decision makers face many options in the economic and especially the environmental assessment of chemical processes which might lead to quite different magnitudes in variability due to either the choice of method or the choice of method parameters. This paper demonstrates that the resulting variability might be crucial with respect to the decision making outcome. (C) 2009 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.