Energy recovery and optimal process design

Global uncertainties related to climate change and resource security, particularly in energy, water, and food, have compelled industries and policymakers to pursue sustainable solutions for industrial systems. This review explores advancements in energy cost and pollution reduction through process optimization and waste heat recovery (WHR). The objective is to optimize industrial operations by minimizing environmental pollution while maximizing energy savings. Critical to climate change mitigation are alternative technologies subjected to regulatory and technical obligations. Comprehensive techno-economic analysis techniques during the design stage are crucial to determine optimal configurations that consider environmental and economic dimensions. Additionally, retrofitting analyses during the operation stage can enhance profitability and environmental performance through process reconfiguration or technology substitution. This review covers the accomplishments in developing environmentally conscious frameworks and optimization techniques, including waste heat recovery options, life cycle assessments, and process system engineering. Recent advancements in WHR technologies, such as the integration of low-grade heat power generation and the development of more efficient Organic Rankine Cycle systems, highlight the potential for significant energy savings and emission reductions. The role of policy and regulatory frameworks in promoting sustainable industrial practices is emphasized, along with the need for continuous research and development in this field. By integrating advanced WHR technologies and renewable energy sources, industries can achieve substantial reductions in their carbon footprint. Economic and environmental assessments, including life cycle assessments and techno-economic analyses, are essential for evaluating the long-term benefits of these technologies. The review also underscores the importance of educating and training the next generation of engineers and scientists in sustainable practices. This review aims to inform the industrial sector about existing process optimization and WHR tools, bridge the gap between decision-makers and available models, and identify potential research areas in industrial sustainability. By adopting a comprehensive approach that addresses both technical and non-technical challenges, industries can significantly reduce energy costs and environmental impact, contributing to a more sustainable future.