A successful transition to low-carbon electrification necessitates a thorough understanding of the interplay between heat and work in industrial processes. While existing methods have been developed to facilitate heat integration, their applicability remains largely confined to limited systems. However, industries are likely to transition to electrified processes only if such pathways are also cost-effective, highlighting the need for economically viable integration strategies. As industries progressively shift towards electrified and hybrid configurations, the simultaneous integration of heat and work becomes increasingly intricate. Despite its importance, limited studies have explored the co-optimization of heat and work integration, underscoring the urgent need for standardized frameworks and regulatory guidelines that can inform the design and operation of electrified industrial processes.
To address this gap, a systematic procedure for work-integrated heat exchanger network synthesis is proposed. This approach enables the determination of minimum operating costs in addition to minimum utility targets—both thermal and work-related—prior to the design phase. The methodology introduces novel concepts, including the parameterized Grand Composite Curve and differential temperature interval analysis, to establish optimal targets in advance of the design process. Furthermore, the modified Pinch Design Method is employed to synthesize an optimal heat exchanger network that effectively integrates both heat and work. The effectiveness of the proposed framework is demonstrated through its application to vapor recompression column designs and natural gas liquefaction processes, both of which exhibit significantly reduced operating costs in comparison to conventional configurations.
The methodologies developed in this study offer a generalized framework that can be tailored to a wide range of industrial applications. By enhancing process efficiency, minimizing operational costs, and reducing energy consumption, these methodologies contribute to the broader goal of industrial sustainability. It is anticipated that the proposed framework will serve as a valuable tool in the ongoing transition toward low-carbon, energy-efficient industrial systems.