Applied Thermal Engineering 89 (2015) 1001e1005

Contents lists available at ScienceDirect

Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

Applied thermal engineering solutions through process integration,

modelling and optimisation

a b s t r a c t

Keywords: This special issue of Applied Thermal Engineering contains thirteen selected contributions that were
Process integration originally presented in the 17th Conference Process Integration, Modelling and Optimisation for Energy
Modelling Saving and Pollution Reduction e PRES 2014. The PRES conference offers a unique and prestigious stage
Optimisation
for applied thermal engineering innovations achieved through ingenious process integration and holistic
Engineering solutions
design approaches. The long collaboration between the PRES conference and the Applied Thermal En-
Applied thermal engineering
gineering Journal is epitomised by this selection of high quality articles covering a wide variety of topics
ranging from complex thermal network analysis and optimisation, to operations and control of thermal
processes, innovative thermal equipment design through efcient computational tools, and nally to
mathematical models for thermal systems.
2015 Elsevier Ltd. All rights reserved.

1. Introduction especially close working friendships. Out of 551 abstracts, prepared

Applied Thermal Engineering is in the centre of the develop-
ments in the quest for highly energy efcient, sustainable, and
cost effective process systems. Process Integration and Intensica-
tion concepts have been pivotal in product and process design
and optimisation. The conference series of Process Integration,
Modelling and Optimisation for Energy Saving and Pollution
Reduction e PRES [1] has established itself as a worldwide stage
where innovative solutions incorporating existing but also intro-
ducing new tools are being presented, discussed, and critically
assessed. The delegates of PRES'14 brought forward through
numerous distinguished contributions a unique blend of chal-
lenging scientic and industrial problems and proposed solutions
that made a signicant impact in a variety of subjects relevant to
applied thermal engineering.
PRES series commenced within the CHISA shell in 1998, in
Prague, Czech Republic. Since then, PRES conferences have also
been organised in Hungary, various places in Italy, Canada, and
Greece. In the year 2015, for the rst time, PRES conference will
be held in Asia at Kuching, Sarawak, Malaysia.
PRES'14 was held in Prague, Czech Republic, in late August 2014
and provided an excellent opportunity for the dissemination of
novel ideas in applied thermal engineering, ingenious design pro-
cedures, Heat Integration and computer aided solutions to indus-
trial challenges and experimental results. The organisers of the
PRES conferences in 2014 joining forces with CHISA are proud to
continuously attract many professional scientists/researchers
from various countries and continents providing a genial platform
for the fast and efcient spreading of novel ideas, processes, and
by 2133 authors from 57 countries, the PRES 2014 Scientic Com-
mittee selected 216 oral presentations, 33 keynote, and 4 plenary
lectures common for PRES and CHISA, and 233 posters. From pre-
sented papers 25 have been invited to this SI and after a thorough
reviewing 13 papers have been accepted for this Special issue.
PRES conferences offer a comprehensive publication strategy of
best papers. This Special Issue (SI) has been already the 15th SI of
Applied Thermal Engineering, dedicated to selected contributions
from PRES conferences starting from PRES'99 in 2000 [2]. It has
been followed by SI of PRES 2000 [3], PRES'01 [4], PRES 2002 [5],
PRES'03 [6], PRES 2004 [7], PRES'05 [8], PRES 2006 [9], PRES'07
[10], PRES 2008 [11], PRES'09 [12], PRES 2010 [13], PRES'11 [14],
PRES 2012 [15], PRES 2013 [16]. In addition to Applied Thermal En-
gineering, other well-known journals have been collaborating with
PRES and related conferences: Energy e PRES 2010 [17], PRES 2012
[18] and PRES 2013 [19], Journal of Cleaner Production e PRES'11
[20], Cleaner Technologies and Environmental Policy e PRES 2010
[21], PRES'11 [22], PRES 2012 [23], and PRES 2013 [24], Theoretical
Foundations of Chemical Engineering [25], Heat Transfer Engineer-
ing e PRES 2008 [26], Resources, Conservation and Recycling e
PRES 2008 [27] and Waste Management e PRES'99 [28].
2. Selected contributions and the main thematic groups
The Special Issue articles have been thoroughly evaluated and
then selected, applying the high standards for quality assurance
during the peer review process. They are briey presented grouped
thematically to provide the readers with a structured guide to the
individual research efforts and achievements. The presentation

http://dx.doi.org/10.1016/j.applthermaleng.2015.07.060
1359-4311/ 2015 Elsevier Ltd. All rights reserved.
1002 P. Seferlis et al. / Applied Thermal Engineering 89 (2015) 1001e1005
starts with articles on network issues, proceeding then to operation
and control, equipment design, and computational aspects.
2.1. Complex thermal networks design and optimisation
Design and optimisation of thermal networks pose signicant
challenges due to the high complexity and substantial inherited
interaction among the various constituent subsystems. This is a
direct result from higher degree of integration that is deemed
necessary to enable additional energy savings and emissions reduc-
tion. There is a great need for new tools that can unveil the major
underlying phenomena and provide insights into the main trends
and bottlenecks of such networks. Four contributions cover the
area of process tools for thermal network design and optimisation
offering superstructure optimisation [29], tools for the strategic
introduction of renewables in community energy networks [30],
total site heat integration [31], and heat exchanger network retrot
through a novel visualisation decision support tool [32].
Optimisation of pump networks for cooling water utilities in a
plant is the subject of Sun et al. [29]. A two steps approach is
selected consisted of a step that identies the optimal in terms of
the total annualised costs cooling water heat exchanger network
based on thermodynamic considerations. Secondly, an additional
step calculates optimally the necessary hydraulic head that is
required by the network pumps to compensate for the pressure
drop. The resulted network combines cooling water heat ex-
changers connected in both parallel and in series congurations.
Despite the higher cooling water return temperature to the cooling
tower and a larger pressure drop, signicant reduction in the total
utilised water quantity is achieved. A 23% reduction in the annual-
ised costs is possible than the conventional network conguration
with a 63% reduction in the used cooling water.
Kostevsek et al. [30] employed the concept of Locally Integrated
Energy Sectors (LIES) introduced by Perry et al. [33] for the estab-
lishment of renewables energy sources (RES) based networks. The
main aim is to support the transformation of any energy conversion
network towards a sustainable local energy system. Municipal en-
ergy systems are excellent candidates for the integration of LIES
concepts to accomplish greater energy efciency as stated by Var-
banov and Kleme
s [34]. LIES integrates various sectors such as in-
dustry, households, transport, agriculture, service and public
sectors together in terms of energy usages. The incorporation of
an efcient RES utilisation network during the planning phase of
such installation has been demonstrated with a case study. The hi-
erarchical design procedure achieves higher efciency and sup-
ports the sustainability and viability of municipal energy systems.
A systematic Total Site heat integration methodology that aims
to reduce the capital cost of heat transfer units at Total Sites is pre-
sented in Chew et al. [31]. The methodology employs a set of heu-
ristic rules that enable the identication and prioritisation of the
strategic process modications that have the greatest impact on
the Total Site performance. More specically, the most critical tem-
perature intervals for the overall heat integration improvement
have been effectively selected whereas the keep hot stream hot
(KHSH) and keep cold stream cold (KCSC) principles have been
applied to modify the Total Site prole (TSP) favourably. A meticu-
lously implemented design procedure exploits individual process
knowledge to result in a holistic improvement of Total Site Heat
Integration.
Heat exchanger network (HEN) retrot has been established as
an important and efcient task in process design with multiple
alternative approaches proposed. Yong et al. [32] propose an
enhanced visualisation and decision-making tool for HEN retrot.
The tool is based on an extended type of Grid Diagram properly vis-
ualising the HEN arrangements that incorporates a shifted
temperature scale and enables the direct consideration of the ef-
fects key parameters such as heat capacity owrates, stream tem-
peratures and temperature differences have on the HEN. It is
capable of accounting for both thermodynamic constraints and
target loads enabling a competent screening of feasible retrot op-
tions. Furthermore, insights regarding possible trends and oper-
ating limits to heat recovery can be easily derived after a new
HEN path is specied.
2.2. Process operation and control via advanced techniques
The increased degree of process integration and intensication
makes the process operation an even more challenging tasks. To
this end, simulation tools for operation training, control system
design methods, and the consideration of operability and controlla-
bility properties in the design stage are essential for the achieve-
ment of high valued products and subsequently highly protable
and sustainable process systems. Two contributions investigate
the introduction of advanced control techniques in heat exchanger
units [35], and the incorporation of operability and process vari-
ability in the selection of the optimal working medium in solar
organic Rankine cycles [36].
An advanced control strategy for a heat exchanger that employs
a neural network predictive control framework combined with a
fuzzy controller is presented in Vasi
ckaninova  and Bako
sova [35].
The controlled variable is the outlet temperature of the process
stream, whereas the main manipulated is the auxiliary stream
owrate. The neural network is trained through a set of simulated
data from a nonlinear model with the interval parametric uncer-
tainty. A fuzzy controller is introduced that utilises a second manip-
ulated variable; namely the process stream owrate. In this way,
fast system dynamics are controlled by the secondary manipulated
variable whereas the slower dynamics are controlled by the main
control loop. The proposed combined control scheme exhibits su-
perior dynamic performance than conventional control
congurations.
The contribution by Mavrou et al. [36] addresses the selection of
working uid mixtures in view of operating variability in solar
Organic Ranking Cycles (ORC). A systematic sensitivity analysis pro-
cedure explicitly considers the impacts of working uid and ORC
design/operating decisions on the ability of the ORC to alleviate
the effects of deviations from the nominal operating conditions.
The proposed method calculates the effects of variability resulting
from the simultaneous consideration of multiple system design
and operating parameters on multiple ORC performance indicators
taking into account the system nonlinearities and constraints. Each
ORC system with a different mixture as the working medium is
then assessed and rank ordered based on thermodynamic and
operability performance indicators. The merits of the method are
demonstrated for several working uid mixture candidates
through the identication of the mixtures with minimum sensi-
tivity in operating variability and maximum overall ORC perfor-
mance. The authors concluded that without a systematic
consideration of operation variability signicant performance los-
ses may be inherited in the process by the mixture selection.
2.3. High performance novel thermal equipment design
Thermal equipment design can really make a great difference in
the overall improvement of energy efciency. High heat transfer
rates, enhanced mixing, suitable ow properties, and reduced pres-
sure drop are some of the key directions in which advances are ex-
pected through ingenious and creative thermal equipment design.
Obviously, computer aided process engineering methods and tech-
niques offer the tool-kit for a speedy and effective design
 P. Seferlis et al. / Applied Thermal Engineering 89 (2015) 1001e1005
procedure. Four contributions investigate the enhancements that
new equipment developments bring in red heaters [37], heat ex-
changers [38] printed circuit heat exchangers [39], uidised-bed
evaporation [40], and multi-stream spiral-wound heat exchangers
[42].
Fired heaters are commonly used processes in reneries. The
American Petroleum Institute (API) Standard 560 is a frequently
used procedure for the design of such equipment. The work of Jegla
et al. [37] adopts a novel methodology to analyse heat transfer in a
red heater. The methodology employs a Computational Fluid Dy-
namics (CFD) model with main focus on the balanced application of
adequate models for turbulence, combustion chemistry and radia-
tion. In addition to the three dimensional CFD model, two dimen-
sional simulations of radiative heat transfer are developed to
provide insight into the effects tube deformations have on circum-
ferential tube heat ux non-uniformity. It is specically concluded
that standard one dimensional design calculations of red heaters
signicantly underestimate real heat ux variability especially in
the longitudinal direction.
Enhanced inner surfaces in heat transfer equipment are
routinely used because they can produce improved tubeside heat
transfer coefcients without a limiting pressure drop. The 1EHT
surface is generally a hybrid surface that enforces the separation
of ow and induces an increased surface area. Kukulka et al. [38]
investigate experimentally the heat transfer phenomena in the
condensation and evaporation of R410A, R22 and R32 at a newly
developed enhanced surface Vipertex 1EHT tube. This enhanced
heat transfer tube produces enhanced performance of more than
100% when compared to a smooth tube for most evaporation or
condensation condition. Such an enhanced heat transfer surface
enables an increased performance through a combination of
several factors such as increased turbulence; boundary layer
disruption; secondary ow generation; increased heat transfer sur-
face area; and a high density of nucleation sites. Vipertex 1EHT
enhanced tubes recover more energy and provide an excellent op-
portunity for design advancements in many heat transfer
processes.
Printed circuit heat exchanger (PCHE) is recommended as an
intermediate heat exchanger in Very High Temperature Reactors
(VHTR). Manufactured by means of photochemical etching, main-
tains the internal structure and metal properties. Ma et al. [39]
investigate the manufacture of the airfoil PCHE plate by photo-
chemical etching. The resulted PCHE airfoil ns exhibit resem-
blance to a n-endwall llet. The thermal-hydraulic properties
of the PCHE are studied through the development of a CFD model
for a single uid and two uids. Simulated experiments reveal
that the n-endwall llet can increase the heat transfer and pres-
sure drop in the cases with the non-dimensional longitudinal
pitch being 1.63. The effect of n-endwall llet on thermal hy-
draulic performance decreases with the increase of transverse
pitch. An extensive sensitivity analysis unveils signicant features
in the complex heat exchanger geometry and sets the basis for
design.
Mizuno et al. [40] proposed a novel seawater desalination pro-
cess using a uidised-bed evaporator to prevent scale deposition
on the heat-transfer surface for the co-production of salt and
pure water. The operating principle of the uidised-bed evaporator
is based on the uid collision with heated uidised particles. A
shortcoming of the evaporation process is the occurrence of parti-
cle agglomeration that leads to deuidisation. Therefore, the
agglomeration behaviour is experimentally investigated. A balance
for the liquid bridge, solid bridge, and hydrodynamic forces is per-
formed in order to describe the agglomeration effects. Subse-
quently, a conceptual model is developed based on the
experimental investigation.
1003
Spiral-wound heat exchangers possess signicant advantages as
they offer compact equipment design, enable operation under high
pressure, achieve good thermal compensation performance, and
especially allow multi-stream heat transfer capability. Lu et al.
[41] investigate the impact changes in the geometry of multi-
stream spiral-wound heat exchangers have on the on ow and
heat transfer performance. The geometrical factors that have
been examined are the space bar thickness, the tube pitch in the
rst layer, the tube external diameter, the number of layers, and
the centre core diameter. The investigation is performed through
numerical simulations of a validated physical model accounting
for the mass, momentum and energy transfer and a suitable turbu-
lence model. The shell-side and tube-side Nusselt number and
pressure drop per unit length increase with a higher number of
layers, a larger centre core diameter, and a larger tube external
diameter. On the contrary, they decrease with the increase of space
bar thickness and tube pitch in the rst layer. Quantitatively esti-
mation of the effects of these ve geometrical parameters is
achieved by Taguchi type of experiments. Finally, a multivariate
model becomes available that expresses the behaviour of the
shell-side Nusselt number and friction coefcient with respect to
the main geometrical parameters of the heat exchanger equipment.
2.4. Models and computational techniques for improved design
solutions
Modelling has been the undisputed greatest aid in the evolution
of process design. Supported by high performance computation
techniques offers the ability to cover a vast design variable space
seeking the optimal design solution. Process models may vary in
resolution, complexity, and rigour but when developed properly
within a meaningful set of assumptions become the mean for an
exhaustive investigation and evaluation of multiple process cong-
urations and operating conditions. Two contributions in this eld
discuss the modelling of turbulent free jets [42] and of waste supply
chains [43].
Turbulent free jets are of signicant importance for numerous
chemical engineering processes as they enhance heat and mass
transfer, intensify mixing, and enable entrainment and momentum
exchange. The development and optimisation of such processes are
usually supported by Computational Fluid Dynamics (CFD) simula-
tions, which allow the profound understanding of the underlying
ow phenomena. The selection of a proper turbulence model is
of paramount importance to generate meaningful results. The
work of Miltner et al. [42] offers a detailed analysis of the ow eld
of a straight and a slightly rotating turbulent free jet both experi-
mentally and through CFD simulations under various employed
turbulence models. Experimental analysis is performed by Laser-
Doppler-Anemometry to measure three-dimensional ow and tur-
bulence elds. CFD simulations are performed with a commercial
solver applying commonly used models for turbulence description.
The work concludes that unless the correct turbulence model is
employed in the CFD calculations the simulated results may fail
to predict the real ow conditions. Reynolds Stress Model has
been proved to provide results that best match the experimental
trends and features.
Uninterrupted supply of waste to plants dedicated in waste-to-
energy activities is identied as a unique most critical factor for
plant protability. Ferdan et al. [43] present a complex methodol-
ogy towards investment risk quantication in a waste-to-energy
(WTE) project. A novel approach is proposed, where waste avail-
ability is assessed considering the future competition in the waste
market. The approach encompasses the logistic-based optimisation
tool, NERUDA, which allocates processing capacities and proposes
waste ows between producers and processors within a targeted
1004 P. Seferlis et al. / Applied Thermal Engineering 89 (2015) 1001e1005
geographical region. A new term accounting for waste availability is
dened and incorporated in the project assessment. The practical
implications of such an approach are demonstrated through a
case where a stochastic simulation study with several uncertain pa-
rameters is concluded.
3. Conclusions
Thirteen selected articles have been included in this special
issue covering the scientic elds of complex thermal process
network design and optimisation, process operation and control
via advanced techniques, high performance novel thermal equip-
ment design, and models and computational techniques for
improved design solutions. The selection of these thirteen articles
demonstrates the diversity of methodologies, techniques, and
design procedures for the achievement of highly performing ther-
mal process systems. Any advance in the area of applied thermal
engineering requires deep understanding of the underlying phys-
ical and chemical phenomena. Such phenomena initiated at molec-
ular level interactions interrelate to the unit operation level with
interplay with the equipment congurations. The extension to
the plant-wide level enables the holistic consideration of the effects
of decisions. Eventually, integration at the enterprise level exem-
plies the potential benets towards energy efcient and sustain-
able engineering.
The editors would like to thank all the authors for the fruitful
collaboration and express their gratitude to the reviewers for the
hard work and the constructive comments that resulted in such
an excellent outcome. The reviewing is a key requirement for
peer-reviews publications and work of reviewers should be most
appreciated and also recorded by recently introduced r-index [44].
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Panos Seferlis
Department of Mechanical Engineering, Aristotle University of
Thessaloniki, Thessaloniki, Greece
Chemical Process and Energy Resources Institute, Centre for Research
and Technology e Hellas, Thermi-Thessaloniki, Greece
 P. Seferlis et al. / Applied Thermal Engineering 89 (2015) 1001e1005 1005

Petar Sabev Varbanov, Ji
r Jaromr Kleme
s* *

Corresponding author.
Centre for Process Integration and Intensication e CPI2, Research E-mail address: klemes@cpi.uni-pannon.hu (J.J. Kleme
s).
}
Institute of Chemical and Process Engineering e MUKKI, Faculty of
Information Technology, University of Pannonia, Veszpr em, Hungary 4 July 2015
Available online 12 August 2015