Imidazolium-based ionic liquids (ILs) have garnered significant attention as foundational materials in sustainable chemical engineering, owing to their negligible volatility, exceptional thermal stability, and highly tunable structural properties. These characteristics make them particularly valuable for applications such as green solvents, advanced catalysis, and energy storage. This research detailed a comprehensive investigation into the development, optimization, and analysis of an industrial-scale green synthesis pathway for 1-butyl-3-methylimidazolium chloride ([Bmim]Cl), which was prepared through a quaternization reaction using N-methylimidazole and 1-chlorobutane as raw materials.Subsequently, reaction parameters were optimized and the implementation of process intensification strategies to enhance production efficiency and environmental sustainability. Experimental results combined with economic analysis identified the optimal synthesis conditions as a reaction temperature of 76℃, N-methylimidazole to 1-chlorobutane molar ratio of 1∶1.3, and a reaction time of 36 h. Under these optimized parameters, a consistently high single-pass yield of 95.6% was achieved. Kinetic studies revealed that there was a significant correlation between reaction temperature, reactant molar ratio, and conversion efficiency. The calculated activation energy (Ea≈135.7 kJ/mol) indicated a pronounced temperature dependence of the reaction rate. Building upon reaction optimization, a pivotal aspect of this work involved the design and implementation of an advanced closed loop material recycling system. This integrated internal recycling mechanism enabled the near-complete recovery and reuse of unreacted feedstocks and solvents, achieving high recovery rates of 99.5% for 1-chlorobutane and 98.1% for ethyl acetate. By significantly curtailing raw material consumption and waste generation, this approach aligned intrinsically with green chemistry principles and propelled the process toward near zero emissions. In conclusion, this pathway not only offers a scalable model for the manufacture of [Bmim]Cl, but also provides a transferable strategy for the synthesis of other value-added ionic liquids, thereby representing a substantial advancement in the field of sustainable process engineering.