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Advanced Research on Heat Exchangers Networks and Heat Recovery

A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "J: Thermal Management".

Deadline for manuscript submissions: 20 June 2025 | Viewed by 9557

Special Issue Editors


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Guest Editor
Faculty of Mechanical Engineering and Naval Architecture, University of Zagreb, Zagreb, Croatia
Interests: heat exchanger networks; heat transfers; energy saving; heat recovery; process integration
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
National-Local Joint Engineering Laboratory of Harbour Oil & Gas Storage and Transportation Technology, Zhejiang Ocean University, Zhoushan 316022, China
Interests: process integration; oil and gas; energy systems analysis; supply chain management; pipeline engineering
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Guest Editor
School of Engineering Academic, The University of Waikato, Hamilton, New Zealand
Interests: energy; process integration; heat pumps; digital twins; heat and mass transfer
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Energy is the one of the most important resources for modern society. The use of energy defines the paradigm of economic development around the globe, and energy efficiency is the one of the key issues for both economic efficiency and environmental impact. Heat exchanger networks in different industries can recover the process heat energy, avoiding additional fuel consumption in furnaces and electricity consumption for cooling cycles. Heat exchanger network synthesis, retrofit, and optimization are long-term developing goals that face new challenges today. Industrial energy transition to renewable energies and the low carbon agenda lead to the formulation of new objectives for heat exchanger networks and heat recovery. Both theoretical aspects and technoeconomic criteria affect future industrial energy systems, where heat recovery plays a key role. This Special Issue is aimed at new advancements and developments in heat exchanger networks, including but not limited to network synthesis and optimization, thermodynamic and thermal design, operation and maintenance, networks for industry electrification, digital twins of heat recovery systems, hydrogen-containing recovery systems, and the integration of renewable energies to heat recovery networks.

Dr. Stanislav Boldyryev
Dr. Bohong Wang
Dr. Timothy Gordon Walmsley
Guest Editors

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Keywords

  • heat exchanger networks
  • design and retrofit of recovery systems
  • network modeling and optimization
  • energy saving
  • operation, maintenance, prediction

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Published Papers (8 papers)

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Research

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27 pages, 8761 KiB  
Article
Environmental and Economic Benefits of Waste Heat Recovery as a Symbiotic Scenario in Sweden
by María Dolores Mainar-Toledo, Irene González García, Hector Leiva, Jack Fraser, Danna Persson and Thomas Parker
Energies 2025, 18(7), 1636; https://doi.org/10.3390/en18071636 - 25 Mar 2025
Viewed by 436
Abstract
This study pioneers a combined Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) evaluation of an industrial symbiosis (IS) case involving waste heat recovery from a pulp and paper mill to a tomato greenhouse in Sweden. Unlike previous studies that assess environmental [...] Read more.
This study pioneers a combined Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) evaluation of an industrial symbiosis (IS) case involving waste heat recovery from a pulp and paper mill to a tomato greenhouse in Sweden. Unlike previous studies that assess environmental or economic aspects separately, this research provides a holistic assessment quantifying both environmental burdens and economic feasibility. A comparative analysis framework is applied, evaluating a symbiotic real case of waste heat recovery versus conventional greenhouse tomato production in the Netherlands and subsequent import to Sweden. LCA examines greenhouse gas emissions, eutrophication, toxicity, land use, and resource depletion, while LCC assesses total ownership costs, including Capital and Operational Expenditures. The findings demonstrate that the IS scenario significantly reduces greenhouse gas emissions and operational costs while enhancing energy efficiency. This work fills a gap in IS literature, offering a replicable framework for sustainable greenhouse operations. The results highlight the potential of IS to improve resource efficiency, promote circular economy strategies, and foster sustainable practices in the agri-food sector. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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34 pages, 11575 KiB  
Article
Energy-Saving Design Strategies for Industrial Heritage in Northeast China Under the Concept of Ultra-Low Energy Consumption
by Shiqi Yang, Hui Ma, Na Li, Sheng Xu and Fei Guo
Energies 2025, 18(5), 1289; https://doi.org/10.3390/en18051289 - 6 Mar 2025
Viewed by 496
Abstract
Countries around the world have developed standards for ultra-low energy consumption building design and future plans. Unfortunately, these standards lack specific requirements for industrial heritage. As an important carrier of urban context, history, and the transmission of residents’ memories, industrial heritage cannot be [...] Read more.
Countries around the world have developed standards for ultra-low energy consumption building design and future plans. Unfortunately, these standards lack specific requirements for industrial heritage. As an important carrier of urban context, history, and the transmission of residents’ memories, industrial heritage cannot be overlooked in urban development. This study uses DesignBuilder energy simulation software to model industrial heritage (taking the Changchun Tractor Factory as an example) and compares the energy consumption before and after renovation strategies. The results show that in the Case 4 plan, after implementing the renovation strategy, heating energy consumption can be reduced by about 11,648 (kWh/m2) over the heating season, the total primary energy was reduced by about 4 million (kgce/tce), and total energy consumption decreases by approximately 95%. This demonstrates the effectiveness of the industrial heritage reuse design strategy proposed in this paper. It provides a new direction for reuse design under ultra-low energy consumption requirements in related case studies. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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21 pages, 27629 KiB  
Article
Multi-Objective Optimization Design for Cold-Region Office Buildings Balancing Outdoor Thermal Comfort and Building Energy Consumption
by Fei Guo, Shiyu Miao, Sheng Xu, Mingxuan Luo, Jing Dong and Hongchi Zhang
Energies 2025, 18(1), 62; https://doi.org/10.3390/en18010062 - 27 Dec 2024
Viewed by 977
Abstract
Performance parameters and generative design applications have redefined the human–machine collaborative relationship, challenging traditional architectural design paradigms and guiding the architectural design process toward a performance-based design transformation. This study proposes a multi-objective optimization (MOO) design approach based on performance simulation, utilizing the [...] Read more.
Performance parameters and generative design applications have redefined the human–machine collaborative relationship, challenging traditional architectural design paradigms and guiding the architectural design process toward a performance-based design transformation. This study proposes a multi-objective optimization (MOO) design approach based on performance simulation, utilizing the Grasshopper-EvoMass multi-objective optimization platform. The Non-dominated Sorting Genetic Algorithm II (NSGA-II) is applied to coordinate two performance metrics—outdoor thermal comfort and building energy loads—for the multi-objective optimization of architectural design. The results indicate that (1) a performance-based multi-objective optimization design workflow is established. Compared to the baseline design, the optimized building form shows a significant improvement in performance. The Pareto optimal solutions, under 2022 meteorological conditions, demonstrate an annual energy efficiency improvement of 16.55%, and the outdoor thermal neutrality ratio increases by 1.11%. These results suggest that the optimization approach effectively balances building energy loads and outdoor thermal comfort. (2) A total of 1500 building form solutions were generated, from which 16 optimal solutions were selected through the Pareto front method. The resulting Pareto optimal building layouts provide multiple feasible form configurations for the early-stage design phase. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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20 pages, 3435 KiB  
Article
Optimal Dispatching Strategy for Textile-Based Virtual Power Plants Participating in GridLoad Interactions Driven by Energy Price
by Tingyi Chai, Chang Liu, Yichuan Xu, Mengru Ding, Muyao Li, Hanyu Yang and Xun Dou
Energies 2024, 17(20), 5142; https://doi.org/10.3390/en17205142 - 16 Oct 2024
Viewed by 924
Abstract
The electricity consumption of the textile industry accounts for 2.12% of the total electricity consumption in society, making it one of the high-energy-consuming industries in China. The textile industry requires the use of a large amount of industrial steam at various temperatures during [...] Read more.
The electricity consumption of the textile industry accounts for 2.12% of the total electricity consumption in society, making it one of the high-energy-consuming industries in China. The textile industry requires the use of a large amount of industrial steam at various temperatures during production processes, making its dispatch and operation more complex compared to conventional electricity–heat integrated energy systems. As an important demand-side management platform connecting the grid with distributed resources, a virtual power plant can aggregate textile industry users through an operator, regulating their energy consumption behavior and enhancing demand-side management efficiency. To effectively address the challenges in load regulation for textile industry users, this paper proposes a coordinated optimization dispatching method for electricity–steam virtual-based power plants focused on textile industrial parks. On one hand, targeting the impact of different energy prices on the energy usage behavior of textile industry users, an optimization dispatching model is established where the upper level consists of virtual power plant operators setting energy prices, and the lower level involves multiple textile industry users adjusting their purchase and sale strategies and changing their own energy usage behaviors accordingly. On the other hand, taking into account the energy consumption characteristics of steam, it is possible to optimize the production and storage behaviors of textile industry users during off-peak electricity periods in the power market. Through this electricity–steam optimization dispatching model, the virtual power plant operator’s revenue is maximized while the operating costs for textile industry users are minimized. Case study analyses demonstrate that this strategy can effectively enhance the overall economic benefits of the virtual power plant. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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18 pages, 4334 KiB  
Article
Advancing Industrial Process Electrification and Heat Pump Integration with New Exergy Pinch Analysis Targeting Techniques
by Timothy Gordon Walmsley, Benjamin James Lincoln, Roger Padullés and Donald John Cleland
Energies 2024, 17(12), 2838; https://doi.org/10.3390/en17122838 - 8 Jun 2024
Cited by 1 | Viewed by 1587
Abstract
The process integration and electrification concept has significant potential to support the industrial transition to low- and net-zero-carbon process heating. This increasingly essential concept requires an expanded set of process analysis tools to fully comprehend the interplay of heat recovery and process electrification [...] Read more.
The process integration and electrification concept has significant potential to support the industrial transition to low- and net-zero-carbon process heating. This increasingly essential concept requires an expanded set of process analysis tools to fully comprehend the interplay of heat recovery and process electrification (e.g., heat pumping). In this paper, new Exergy Pinch Analysis tools and methods are proposed that can set lower bound work targets by acutely balancing process heat recovery and heat pumping. As part of the analysis, net energy and exergy load curves enable visualization of energy and exergy surpluses and deficits. As extensions to the grand composite curve in conventional Pinch Analysis, these curves enable examination of different pocket-cutting strategies, revealing their distinct impacts on heat, exergy, and work targets. Demonstrated via case studies on a spray dryer and an evaporator, the exergy analysis targets net shaft-work correctly. In the evaporator case study, the analysis points to the heat recovery pockets playing an essential role in reducing the work target by 25.7%. The findings offer substantial potential for improved industrial energy management, providing a robust framework for engineers to enhance industrial process and energy sustainability. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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35 pages, 979 KiB  
Article
Simultaneous Optimization of Work and Heat Exchange Networks
by Nidret Ibrić, Chao Fu and Truls Gundersen
Energies 2024, 17(7), 1753; https://doi.org/10.3390/en17071753 - 6 Apr 2024
Cited by 2 | Viewed by 1228
Abstract
This paper introduces a simultaneous optimization approach to synthesizing work and heat exchange networks (WHENs). The proposed work and heat integration (WHI) superstructure enables different thermodynamic paths of pressure and temperature-changing streams. The superstructure is connected to a heat exchanger network (HEN) superstructure, [...] Read more.
This paper introduces a simultaneous optimization approach to synthesizing work and heat exchange networks (WHENs). The proposed work and heat integration (WHI) superstructure enables different thermodynamic paths of pressure and temperature-changing streams. The superstructure is connected to a heat exchanger network (HEN) superstructure, enabling the heat integration of hot and cold streams identified within the WHI superstructure. A two-step solution strategy is proposed, consisting of initialization and design steps. In the first step, a thermodynamic path model based on the WHI superstructure is combined with a model for simultaneous optimization and heat integration. This nonlinear programming (NLP) model aims to minimize operating expenditures and provide an initial solution for the second optimization step. In addition, hot and cold streams are identified, enabling additional model reduction. In the second step of the proposed solution approach, a thermodynamic path model is combined with the modified HEN model to minimize the network’s total annualized cost (TAC). The proposed mixed integer nonlinear programming (MINLP) model is validated by several examples, exploring the impact of the equipment costing and annualization factor on the optimal network design. The results from these case studies clearly indicate that the new synthesis approach proposed in this paper produces solutions that are consistently similar to or better than the designs presented in the literature using other methodologies. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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31 pages, 11680 KiB  
Article
Improving the Economic Efficiency of Heat Pump Integration into Distillation Columns of Process Plants Applying Different Pressures of Evaporators and Condensers
by Stanislav Boldyryev, Mariia Ilchenko and Goran Krajačić
Energies 2024, 17(4), 951; https://doi.org/10.3390/en17040951 - 18 Feb 2024
Cited by 2 | Viewed by 1778
Abstract
The electrification of process industries is one of the main challenges when building a low-carbon society since they consume huge amounts of fossil fuels, generating different emissions. Heat pumps are some of the key players in the industrial sector of the carbon-neutral market. [...] Read more.
The electrification of process industries is one of the main challenges when building a low-carbon society since they consume huge amounts of fossil fuels, generating different emissions. Heat pumps are some of the key players in the industrial sector of the carbon-neutral market. This study proposes an approach to improve the economic feasibility of heat pumps within process plants. Initial energy targeting with grand composite curves was used and supplemented with the detailed design of an evaporator and a compressor for different condensation and evaporation pressures. The trade-off between the capital cost of the heat pump and the electricity cost was investigated, and optimal configurations were selected. This case study investigates the gas fractioning unit of a polymer plant, where three heat pumps are integrated into distillation columns. The results demonstrate that the heat recovery is 174 MW and requires an additional 37.9 MW of electricity to reduce the hot utility by 212 MW. The selection of the evaporation and condensation pressures of heat pumps allows 21.5 M EUR/y to be saved for 7 years of plant operation. The emission-saving potential is estimated at 1.89 ktCO2/y. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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Review

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43 pages, 11377 KiB  
Review
Thermoelectric Generators Applied as a Power Source in CubeSats: State of the Art
by Gabriel Brugues Soares, Jorge Javier Gimenez Ledesma, Eder Andrade da Silva and Oswaldo Hideo Ando Junior
Energies 2025, 18(1), 173; https://doi.org/10.3390/en18010173 - 3 Jan 2025
Viewed by 1040
Abstract
This systematic review outlines the application of thermoelectric generators (TEGs) as energy sources in CubeSats. While CubeSats currently rely on solar cells with efficiencies between 16.8% and 32.2%, their performance diminishes with increased distance from the Sun. TEGs, although used in radioisotope thermoelectric [...] Read more.
This systematic review outlines the application of thermoelectric generators (TEGs) as energy sources in CubeSats. While CubeSats currently rely on solar cells with efficiencies between 16.8% and 32.2%, their performance diminishes with increased distance from the Sun. TEGs, although used in radioisotope thermoelectric generators (RTGs) for satellites, remain underutilized in CubeSats. A literature review revealed 33 relevant articles, with 21.2% employing simulation software to evaluate thermal behavior. Among 34 patents, only one mentioned micro-TEGs, with most focusing on structural improvements. Patent activity peaked between 2016 and 2020, emphasizing structural and thermal optimization, but no patents addressed TEGs as energy sources for CubeSats, highlighting a significant research gap. TEGs present a viable solution for harnessing residual heat in CubeSats. Full article
(This article belongs to the Special Issue Advanced Research on Heat Exchangers Networks and Heat Recovery)
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