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Increasing energy usage efficiency requires enhanced heat energy recuperation between process streams in the industry and civic sector with waste heat utilization. The condensation of different vapours is the process encountered in many industrial applications. Increasing the heat recuperation in this process is possible with efficient heat transfer equipment, among which a Plate Heat Exchanger (PHE) is at the leading position. A number of research works have been conducted in recent years concerning construction development and heat transfer enhancement in conditions of limited pressure drop to increase PHE performance in condensation processes. The results of studies on heat transfer and pressure drop in the two-phase condensing flow inside channels of PHE with different geometries of corrugations are discussed. In many implementations, the total pressure drop allowable for gaseous streams in heat exchangers is relatively small. The structure of two-phase flow in PHE channels of complex geometry is very different than in tubes and flat wall channels. The relative differences in approaches to enhance PHE performance in condensation processes based on its modelling, optimisation and design are analyzed. The directions and prospects for future developments are formulated, and potential savings for the economy and the environmental footprint is presented. [ABSTRACT FROM AUTHOR]

Pressure drop is an important consideration in Total Site Heat Integration (TSHI). This is due to the typically large distances between the different plants and the flow across plant elevations and equipment, including heat exchangers. Failure to consider pressure drop during utility targeting and heat exchanger network (HEN) synthesis may, at best, lead to optimistic energy targets, and at worst, an inoperable system if the pumps or compressors cannot overcome the actual pressure drop. Most studies have addressed the pressure drop factor in terms of pumping cost, forbidden matches or allowable pressure drop constraints in the optimisation of HEN. This study looks at the implication of pressure drop in the context of a Total Site. The graphical Pinch-based TSHI methodology is extended to consider the pressure drop factor during the minimum energy requirement (MER) targeting stage. The improved methodology provides a more realistic estimation of the MER targets and valuable insights for the implementation of the TSHI design. In the case study, when pressure drop in the steam distribution networks is considered, the heating and cooling duties increase by 14.5% and 4.5%. [ABSTRACT FROM AUTHOR]

Heat exchanger network (HEN) retrofit is a vital task in the process design to improve energy savings. Various types of heat exchangers such as shell and tube, double-pipe, compact plate, and spiral tube have their working temperature ranges and costs. Selecting suitable types of heat exchangers according to their temperature ranges and costs is a crucial aspect of industrial implementation. However, considering the type of heat exchangers in the HEN retrofit process is rarely seen in previous publications. This issue can be solved by the proposed Shifted Retrofit Thermodynamic Grid Diagram with the Shifted Temperature Range of Heat Exchangers (SRTGD-STR). The temperature ranges of six widely used heat exchanger types are coupled in the grid diagram. This diagram enables the visualisation of identifying the potential retrofit plan of HEN with heat-exchanger type selection. The retrofit design aims to minimise utility cost and capital cost. An illustrative example and a case study are presented to show the effectiveness of the method. [ABSTRACT FROM AUTHOR]

The strong demand for sustainable energy supplies had escalated the discovery, and intensive research into cleaner energy sources, as well as efficient energy management practices. In the context of the circular economy, the efforts target not only the optimisation of resource utilisation at various stages, but the products' eco-design is also emphasized to extend their life spans. Based on the concept of comprehensive circular integration, this review discusses the roles of Process Integration approaches, renewable energy sources utilisation and design modifications in addressing the process of energy and exergy efficiency improvement. The primary focus is to enhance the economic and environmental performance through process analysis, modelling and optimisation. The paper is categorised into sections to show the contribution of each aspect clearly, namely: (a) Design and numerical study for innovative energy-efficient technologies; (b) Process Integration—heat and power; (c) Process energy efficiency or emissions analysis; (d) Optimisation of renewable energy resources supply chain. Each section is assessed based on the latest contribution of this journal's Special Issue from the 21st conference on Process Integration, Modelling and Optimisation for Energy Saving and Pollution Reduction (PRES 2018). The key results are highlighted and summarised within the broader context of the state of the art development. [ABSTRACT FROM AUTHOR]

The design of heat exchanger networks (HEN) in the process industry has largely focused on minimisation of operating and capital costs using techniques such as pinch analysis or mathematical modelling. Aspects of operability and flexibility, including issues of disturbances affecting downstream processes during the operation of highly integrated HEN, still need development. This work presents a methodology to manage temperature disturbances in a HEN design to achieve maximum heat recovery, considering the impact of supply temperature fluctuations on utility consumption, heat exchanger sizing, bypass placement and economic performance. Key observations have been made and new heuristics are proposed to guide heat exchanger sizing to consider disturbances and bypass placement for cases above and below the HEN pinch point. Application of the methodology on two case studies shows that the impact of supply temperature fluctuations on downstream heat exchangers can be reduced through instant propagation of the disturbances to heaters or coolers. Where possible, the disturbances have been capitalised upon for additional heat recovery using the pinch analysis plus-minus principle as a guide. Results of the case study show that the HEN with maximum HE area yields economic savings of up to 15% per year relative to the HEN with a nominal HE area. [ABSTRACT FROM AUTHOR]

Seawater desalination is considered a technique with high water supply potential and has become an emerging alternative for freshwater supply in China. The increase of the capacity also increases energy consumption and greenhouse gases (GHG) emissions, which has not been well investigated in studies. This study has analyzed the current development of seawater desalination in China, including the capacity, distribution, processes, as well as the desalted water use. Energy consumption and GHG emissions of overall desalination in China, as well as for the provinces, are calculated covering the period of 2006–2016. The unit product cost of seawater desalination plants specifying processes is also estimated. The results showed that 1) The installed capacity maintained increased from 2006 to 2016, and reverse osmosis is the major process used for seawater desalination in China. 2) The energy consumption increased from 81 MWh/y to 1,561 MWh/y during the 11 years. The overall GHG emission increase from 85 Mt CO2eq/y to 1,628 Mt CO2eq/y. Tianjin had the largest GHG emissions, following are Hebei and Shandong, with emissions of 4.1 Mt CO2eq/y, 2.2 Mt CO2eq/y. and 1.0 Mt CO2eq/y. 3) The unit product cost of seawater desalination is higher than other water supply alternatives, and it differentiates the desalination processes. The average unit product cost of the reverse osmosis process is 0.96 USD and 2.5 USD for the multiple-effect distillation process. The potential for future works should specify different energy forms, e.g. heat and power. Alternatives of process integration should be investigated—e.g. efficiency of using the energy, heat integration, and renewables in water desalination, as well as the utilization of total site heat integration. [ABSTRACT FROM AUTHOR]

A plate heat exchanger (PHE) is a modern, effective type of heat transfer equipment capable of increasing heat recuperation and energy efficiency. For PHEs, enhanced methods of heat transfer intensification can be further applied using the analysis and knowledge already available in the literature. A review of the main developments in the construction and exploration of PHEs and in the methods of heat transfer intensification is presented in this paper with an analysis of the main construction modifications, such as plate-and-frame, brazed and welded PHEs. The differences between these construction modifications and their influences on the thermal and hydraulic performance of PHEs are discussed. Most modern PHEs have plates with inclined corrugations on their surface that create a strong, rigid construction with multiple contact points between the plates. The methods of PHE exploration are mostly experimental studies and/or CFD modelling. The main corrugation parameters influencing PHE performance are the corrugation inclination angle in relation to the main flow direction and the corrugation aspect ratio. Optimisation of these parameters is one way to enhance PHE performance. Other methods of heat transfer enhancement, including improving the form of the plate corrugations, use of nanofluids and active methods, are considered. Future research directions are proposed, such as improving fundamental understanding, developing new corrugation shapes and optimisation methods and area and cost estimations. [ABSTRACT FROM AUTHOR]

Air quality issues still affect the quality of life for people in industrialised cities around the world. The investigations should include the identification of the sources of the pollution and its distribution in space and time. This work is the first attempt to perform identification of the sources of pollution in Ust-Kamenogorsk city in Kazakhstan. Analysis of retrospective data (including ten variables (TSP, SO2, CO, NO2, phenol, HF, HCl, H2SO4, formaldehyde, H2S) from five monitoring stations for the period 2017–2021) using multivariate statistical methods and hierarchical cluster analysis has been performed to assess spatiotemporal patterns of air quality of the city. The results indicate that the contamination patterns can be grouped into two categories: cold and warm seasons. The study revealed the dangerous concentrations of NO2 and SO2 exceeded the limits by 2–3 and 1.5–2 times, independently of the seasonality. Averaged concentrations of TSP slightly exceeded the established limits for the most industrialised part of the city. Concentrations of HF and formaldehyde significantly rose during the cold seasons compared to the warm seasons. Other chemical parameters significantly depend on the seasonality and locations of the sampling points. The major reason for air pollution is twofold—the use of a burnt-coal throughout the year for electricity and heat generation (especially during the cold seasons) and the high density of the heavy metallurgy industry in the city. The principal component analysis confirms a high loading of industrial sources of air pollution on both spatial and seasonal dimensions. [ABSTRACT FROM AUTHOR]

Demographic factors, statistical information, and technological innovation are prominent factors shaping energy transitions in the residential sector. Explaining these energy transitions requires combining insights from the disciplines investigating these factors. The existing literature is not consistent in identifying these factors, nor in proposing how they can be combined. In this paper, three contributions are made by combining the key demographic factors of households to estimate household energy consumption. Firstly, a mathematical formula is developed by considering the demographic determinants that influence energy consumption, such as the number of persons per household, median age, occupancy rate, households with children, and number of bedrooms per household. Secondly, a geographical position algorithm is proposed to identify the geographical locations of households. Thirdly, the derived formula is validated by collecting demographic factors of five statistical regions from local government databases, and then compared with the electricity consumption benchmarks provided by the energy regulators. The practical feasibility of the method is demonstrated by comparing the estimated energy consumption values with the electricity consumption benchmarks provided by energy regulators. The comparison results indicate that the error between the benchmark and estimated values for the five different regions is less than 8% (7.37%), proving the efficacy of this method in energy consumption estimation processes. [ABSTRACT FROM AUTHOR]

To incorporate exchanger dimensions as a design objective in plate and fin heat exchangers, a variable that must be taken into consideration is the geometry of the finned surfaces to be used. In this work, a methodology to find the surface geometry that will produce the required heat transfer coefficient and pressure drop to achieve the design targets was developed. The geometry of secondary surfaces can be specified by the fin density, which represents the number of fins per unit length. All other geometrical features, as well as the thermo-hydraulic performance, can be derived from this parameter. This work showed the way finned surfaces are engineered employing generalised thermo-hydraulic correlations as a part of a design methodology. It also showed that there was a volume space referred to as volume design region (VDR) where heat duty, pressure drop, and dimensions could simultaneously be met. Such a volume design region was problem- and surface-specific; therefore, its limits were determined by the heat duty, the pressure drop, and the type of finned surface chosen in the design. The application of this methodology to a case study showed that a shell and tube heat exchanger of 227.4 m2, with the appropriate fin density using offset strip-fins, could be replaced by a plate and fin exchanger with any combination of height, width, and length in the ranges of 0–0.58 m, 0–0.58 m, and 0–3.59 m. The approach presented in this work indicated that heat exchanger dimensions could be fixed as a design objective, and they could effectively be achieved through surface design. [ABSTRACT FROM AUTHOR]

Energy is a fundamental element supporting societal development, particularly with the increasing dependency on the Internet of Things. It is also the main contributor to environmental impacts and subsequently, a potential sector for mitigation. Sustainable energy system design considers energy savings and energy efficiency, waste and consumption reduction, process efficiency enhancement, waste heat recovery, and integration of renewable energy. Emerging tools range from advanced Process Integration, modelling, simulation, and optimisation, to system analysis and assessment. This review covers selected emerging studies promoting sustainable system design, including the recent developments reported in the Special Issue (SI) of the 22nd Conference on Process Integration, Modelling and Optimisation for Energy Saving and Pollution Reduction (PRES'19). The primary emphasis was to enhance the economic and environmental performance. However, social factors were also highlighted as essential for future sustainable development. The discussion and analysis in this review focus on the most recent developments of (a) heat integration and heat transfer; (b) integrated and newly developed heat exchangers, (c) integration of renewables, and (d) roles in economic and environmental sustainability. The key results are highlighted, and future research ideas are suggested according to their links to a broader context. [ABSTRACT FROM AUTHOR]

Circular economy implementations tend to decrease the human pressure on the environment, but not all produce footprint reductions. That observation brings the need for tools for the evaluation of recycling processes. Based on the Exergy Footprint concept, the presented work formulates a procedure for its application to industrial chemical recycling processes. It illustrates its application in the example of cotton waste recycling. This includes the evaluation of the entire process chain of polyethylene synthesis by recycling cotton waste. The chemical recycling stages are identified and used to construct the entire flowsheet that eliminates the cotton waste and its footprints at the expense of additional exergy input. The exergy performance of the process is evaluated. The identified exergy assets and liabilities are 138 MJ/kg ethylene and 153 MJ/kg ethylene, reducing the Exergy Footprint by 75% and the greenhouse gas footprint by 43% compared to the linear pattern of polyethylene production. The exergy requirements for producing raw cotton constitute a large fraction of the liabilities, while the polyethylene degradation provides the main asset in the reduction of the Exergy Footprint. [ABSTRACT FROM AUTHOR]

The process of material removal from a workpiece to obtain the desired shape is termed machining. Present-day material removal technologies have high spindle speeds and thus allow quick material removal. These high-speed spindles are highly exposed to vibrations and, as a result, the accuracy of the final workpiece's dimensions is compromised. To overcome this problem, the motion of the tool is restricted, and multiple degrees of freedom are given through the motion of the workpiece in different axes. A machining bed configured as a parallel manipulator capable of giving six degrees of freedom (DOF) to the workpiece is proposed in this regard. However, the proposed six DOF machining bed should be energy efficient to avoid an increase in machining cost. The benefit of using the proposed configuration is a reduction in dimensional error and computational time which, as a result, reduces the energy utilization, vibrations, and machining time in practice. This paper presents kinematics, dynamics and energy efficiency models, and the development of the proposed configuration of the machining bed. The energy efficiency model is derived from the dynamics model. The models are verified in simulation and experimentally. To minimize error and computation time, a PID controller is also designed and tested in simulation as well as experimentally. The resulting energy efficiency is also analyzed. The results verify the efficacy of the proposed configuration of the machining bed, minimizing position error to 2% and reducing computation time by 27%, hence reducing the energy consumption and enhancing the energy efficiency by 60%. [ABSTRACT FROM AUTHOR]

Heat storage with thermochemical (TC) materials is a promising technology for solar energy storage. In this paper, a solar-driven desiccant evaporative cooling (DEC) system for air-conditioning is proposed, which converts solar heat energy into cooling with built-in daily storage. The system utilises thermochemical heat storage along with the DEC technology in a unique way. Magnesium Chloride (MgCl2·6H2O) has been used, which serves as both a desiccant and a thermochemical heat storage medium. The system has been designed for the subtropical climate of Lahore, Pakistan, for a bedroom with 8 h of cooling requirements during the night. MATLAB has been employed for modelling the system. The simulation results show that 57 kg of magnesium chloride is sufficient to meet 98.8% of cooling demand for the entire month of July at an elevated cooling requirement. It was found that the cooling output of the system increased with increasing heat exchanger effectiveness. The heat exchangers' effectiveness was increased from 0.7 to 0.8, with the solar fraction increased from 70.4% to 82.44%. The cooled air supplied to the building meets the fresh air requirements for proper ventilation. [ABSTRACT FROM AUTHOR]

This study proposes a multi-objective approach for the optimal design of a sustainable Integrated Biodiesel/Diesel Supply Chain (IBDSC) based on first- (sunflower and rapeseed) and second-generation (waste cooking oil and animal fat) feedstocks with solid waste use. It includes mixed-integer linear programming (MILP) models of the economic, environmental and social impact of IBDSC, and respective criteria defined in terms of costs. The purpose is to obtain the optimal number, sizes and locations of bio-refineries and solid waste plants; the areas and amounts of feedstocks needed for biodiesel production; and the transportation mode. The approach is applied on a real case study in which the territory of Bulgaria with its 27 districts is considered. Optimization problems are formulated for a 5-year period using either environmental or economic criteria and the remainder are defined as constraints. The obtained results show that in the case of the economic criterion, 14% of the agricultural land should be used for sunflower and 2% for rapeseed cultivation, while for the environmental case, 12% should be used for rapeseed and 3% for sunflower. In this case, the price of biodiesel is 14% higher, and the generated pollutants are 6.6% lower. The optimal transport for both cases is rail. [ABSTRACT FROM AUTHOR]

Membrane is the most important element of extrinsic Fabry-Perot interferometer sensors. Studying the relationship between working medium viscosity and membrane vibration characteristics are critical to the sensor design because the transformer oil viscosity will cause viscous loss during membrane vibration. The numerical investigation of membrane vibration characteristics in transformer oil is performed based on the finite element method. Besides, the effect of energy loss caused by viscosity is examined. It is firstly showed that the membrane has the highest sensitivity for the first-order vibration mode, and the transformer oil reduces the fundamental frequency by 60%. Subsequently, when viscosity and heat loss are considered, the amplitude is less than one-fifth of that without energy loss. The viscosity has a more significant effect on the velocity and temperature fields when the vibration frequency is close to the natural frequency. Finally, viscosity has a remarkable impact on the time domain response. Mechanical energy is converted into thermal energy during the vibration and the amplitude will gradually decrease with time. The effect of energy loss caused by viscosity on the membrane vibration characteristics is revealed, which would be important for an oil-immersed membrane design. [ABSTRACT FROM AUTHOR]

A study was carried out to determine in-tube evaporation and condensation performance of enhanced heat transfer tubes (EHT) using R410A, with the results being compared to a plain tube. The test tubes considered in the evaluation include: plain, herringbone (HB) and spiral (HX) microgrooves, herringbone dimple (HB/D), and hydrophobic herringbone (HB/HY). Experiments to evaluate the condensation were conducted at a saturation of 318 K, and at 279 K for evaporation. Mass flux (G) ranged between 40 to 230 kg m−2s−1. Condensed vapor mass decreased from 0.8 to 0.2; and the mass of vaporized vapor increases from 0.2 to 0.8; heat flux increased with G. Inlet and outlet two-phase flow patterns at 200 kg m−2s−1 were recorded and analyzed. Enhanced tube heat transfer condensation performance (compared to a plain tube) increased in the range from 40% to 73%. The largest heat transfer increase is produced by the herringbone–dimple tube (HB/D). In addition to providing drainage, the herringbone groove also helps to lift the accumulated condensate to wet the surrounding wall. Evaporation thermal performance of the enhanced tubes are from 4% to 46% larger than that of smooth tube with the best performance being in the hydrophobic herringbone tube (HB/HY). This enhancement can be attributed to an increase in the number of nucleation sites and a larger heat transfer surface area. Evaporation and condensation correlations for heat transfer in smooth tubes is discussed and compared. [ABSTRACT FROM AUTHOR]

Reliability-Centred Maintenance (RCM) is a strategic process to improve the maintenance planning of companies which contributes to sustainable production. This method has been applied by numerous industries to achieve an efficient maintenance process, but many have not fully completed their goals. The reason for this failure is that RCM implementation is complex, and organisations need to have adequate preparations before they implement it. In the pre-implementation phase, it is necessary to know the number of Critical Success Factors (CSFs) as a critical measure for implementing the RCM method successfully. Therefore, it is important for practitioners to apply a symmetric mechanism involving fuzzy systems to achieve the desired RCM implementation. There are a limited number of studies that have observed these factors regarding the characteristics of oil and gas companies, especially in the pre-implementation phase. Addressing RCM pre-implementation issues is of high importance from the economic perspective of sustainability for oil and gas organisations. The objective of this study is to investigate significant items in RCM pre-implementation through a combination of quantitative and qualitative analyses. The Nominal Group Technique (NGT) method is applied by gaining the opinion of experts to determine the factors and prioritising them using mathematical modelling. A group of related experts from the oil and gas industry were initially interviewed and surveyed to determine the critical success factors. These identified factors were then analysed using quantitative analysis to identify the important degrees and scored using Fuzzy Analytic Network Process (FANP). Fifteen major factors affecting the criticality of successful RCM implementation have been identified and prioritised, based on their weights. The model proposed in this study could be used as a guideline for assessing CSFs in other countries. To apply the proposed model in different contexts, it needs to be modified according to the needs, policies, and perspectives of each country. [ABSTRACT FROM AUTHOR]

The energy and power sectors are critical sectors, especially as energy demands rise every year. Increasing energy demand will lead to an increase in fuel consumption and CO2 emissions. Improving the thermal efficiency of conventional power systems is one way to reduce fuel consumption and carbon emissions. The previous study has developed a new methodology called Trigeneration System Cascade Analysis (TriGenSCA) to optimise the sizing of power, heating, and cooling in a trigeneration system for a Total Site system. However, the method only considered a single period on heating and cooling demands. In industrial applications, there are also batches, apart from continuous plants. The multi-period is added in the analysis to meet the time constraints in batch plants. This paper proposes the development of an optimal trigeneration system based on the Pinch Analysis (PA) methodology by minimizing cooling, heating, and power requirements, taking into account energy variations in the total site energy system. The procedure involves seven steps, which include data extraction, identification of time slices, Problem Table Algorithm, Multiple Utility Problem Table Algorithm, Total Site Problem Table Algorithm, TriGenSCA, and Trigeneration Storage Cascade Table (TriGenSCT). An illustrative case study is constructed by considering the trigeneration Pressurized Water Reactor Nuclear Power Plant (PWR NPP) and four industrial plants in a Total Site system. Based on the case study, the base fuel of the trigeneration PWR NPP requires 14 t of Uranium-235 to an average demand load of 93 GWh/d. The results of trigeneration PWR NPP with and without the integration of the Total Site system is compared and proven that trigeneration PWR NPP with integration is a suitable technology that can save up to 0.2% of the equivalent annual cost and 1.4% of energy compared to trigeneration PWR NPP without integration. [ABSTRACT FROM AUTHOR]

To date, research on heat pumps (HP) has mainly focused on vapour compression heat pumps (VCHP), transcritical heat pumps (TCHP), absorption heat pumps, and their heat integration with processes. Few studies have considered the Joule cycle heat pump (JCHP), which raises several questions. What are the characteristics and specifics of these different heat pumps? How are they different when they integrate with the processes? For different processes, which heat pump is more appropriate? To address these questions, the performance and integration of different types of heat pumps with various processes have been studied through Pinch Methodology. The results show that different heat pumps have their own optimal application range. The new JCHP is suitable for processes in which the temperature changes of source and sink are both massive. The VCHP is more suitable for the source and sink temperatures, which are near-constant. The TCHP is more suitable for sources with small temperature changes and sinks with large temperature changes. This study develops an approach that provides guidance for the selection of heat pumps by applying Process Integration to various combinations of heat pump types and processes. It is shown that the correct choice of heat pump type for each application is of utmost importance, as the Coefficient of Performance can be improved by up to an order of magnitude. By recovering and upgrading process waste heat, heat pumps can save 15–78% of the hot utility depending on the specific process. [ABSTRACT FROM AUTHOR]

Research and development on integrated energy systems such as cogeneration and trigeneration to improve the efficiency of thermal energy as well as fuel utilisation have been a key focus of attention by researchers. Total Site Utility Integration is an established methodology for the synergy and integration of utility recovery among multiple processes. However, Total Site Cooling, Heating and Power (TSCHP) integration methods involving trigeneration systems for industrial plants have been much less emphasised. This paper proposes a novel methodology for developing an insight-based numerical Pinch Analysis technique to simultaneously target the minimum cooling, heating and power requirements for a total site energy system. It enables the design of an integrated centralised trigeneration system involving several industrial sites generating the same utilities. The new method is called the Trigeneration System Cascade Analysis (TriGenSCA). The procedure for TriGenSCA involves data extraction, constructions of a Problem Table Algorithm (PTA), Multiple Utility Problem Table Algorithm (MU PTA), Total Site Problem Table Algorithm (TS PTA) and estimation of energy sources by a trigeneration system followed by construction of TriGenSCA, Trigeneration Storage Cascade Table (TriGenSCT) and construction of a Total Site Utility Distribution (TSUD) Table. The TriGenSCA tool is vital for users to determine the optimal size of utilities for generating power, heating and cooling in a trigeneration power plant. Based on the case study, the base fuel source for power, heating and cooling is nuclear energy with a demand load of 72 GWh/d supplied by 10.8 t of Uranium-235. Comparison between conventional PWR producing power, heating and cooling seperately, and trigeneration PWR system with and without integration have been made. The results prove that PWR as a trigeneration system is the most cost-effective, enabling 28% and 17% energy savings as compared to conventional PWR producing power, heating and cooling separately. [ABSTRACT FROM AUTHOR]