Review of Challenges in Heat Exchanger Network Developments for Electrified Industrial Energy Systems

The shift towards electrified industrial energy systems is pivotal for meeting global decarbonization objectives, especially since process heat is a significant contributor to greenhouse gas emissions in the industrial sector. This review examines the changing role of heat exchanger networks (HENs) within electrified process industries, where electricity-driven technologies, including electric heaters, steam boilers, heat pumps, mechanical vapour recompression, and Organic Rankine Cycles, increasingly supplant traditional fossil-fuel-based utilities. The analysis identifies key challenges associated with multi-utility integration, multi-pinch configurations, and low-grade heat utilisation, influencing HEN design, retrofitting, and optimisation efforts. A comparative evaluation of various methodological frameworks, such as mathematical programming, insights-based methods, and hybrid approaches, is presented, highlighting their relevance to electrified systems' specific constraints and opportunities. Case studies from chemicals, food processing, and cement sectors demonstrate the practicality and advantages of employing electrified HENs, particularly concerning energy efficiency, emissions reduction, and enhanced operational flexibility. The review concludes that effective strategies for HENs are essential in industrial electrification, facilitating increased efficiency, diminished emissions, and improved economic feasibility, especially when integrated with renewable energy sources and sophisticated control systems. Future initiatives must focus on harmonising technical advances with system-level resilience and economic sustainability considerations.