Advances in process integration and heat exchanger network design: Toward intelligent, sustainable, and low-carbon industrial systems

The role of process integration in improving industrial energy efficiency, is increasingly important, especially in response to fossil fuel depletion and environmental concerns. This paper provides comprehensive review that focusses on examining the heat and resource recovery process through Process Integration. The review comprehensively examines systematic process integration methodologies, including heat integration through heat exchanger network (HEN) design, water pinch analysis (mass integration), and integrated industrial decarbonization strategies. It synthesizes recent advances in energy, water, and resource integration to enhance process efficiency, minimize environmental impacts, and promote sustainable industrial systems. Additionally, the study highlights how modern tools such as process optimization techniques, artificial intelligence, machine learning, and advanced materials further improve efficiency and innovation in process industries. Industrial applications are emphasized, showing that process integration helps industries reduce CO 2 emissions, improve sustainability, and maintain profitability in complex economic conditions.