Total Site Integration

JiJaromrKlemea,SimonJohnPerryb,PetarVarbanova,ZsfiaFodora
a

EC Marie Curie Chair (EXC), CPI2 FIT, University of Pannonia, H - 8200, Hungary,
klemes@cpi.uni-pannon.hu
b
Centre for Process Integration, CEAS, The University of Manchester, M60 1QD, UK

Introduction
In recent years there has been considerable progress in developing procedures for
energy systems targeting and design, to satisfy the heat and power requirements of
industrial processes. This area of process design is known as Heat and Power
Integration (Raissi, 1994). Two types of approaches have been mainly used: Pinch
Analysis and Mathematical Programming.
Total Sites are usually served by central utility systems, which in a way also link the
served processes (Figure 1). A site utility system consumes fuel in central boilers
(steam generators) and supplies the necessary steam to the process consumers.

POWER

Fuel 1

COND
HIGH PRESS
MED. PRESS
LOW

Fuel 2

PROCESS 1

PROCESS 2

PRESS

PROCESS 3
COOLING WATER

Figure 1. Industrial Site

It has steam and gas turbines also taking part in the energy conversions. The
individual processes receive steam and electrical power from the utility system, and
sometimes use fuel directly via local furnaces. In some cases, direct-drive machines

are used for satisfying shaft-power requirements. Examples of these are direct-drive
steam turbines and direct-drive gas turbines.
Depending on the overall site power demand and the amount of co-generation, there
is either power import to or export from the site. Demands for heating, cooling and
electricity in processes can be met by locally captured renewable energy sources
such as wind, solar cells as well as by some excess heat and power available from
local industry. Locally installed boilers, consuming traditional fossil fuels, biomass, or
waste, can also help in meeting these requirements, when the demand is high or
other sources are unavailable.
There are three different cases to which Total Site integration can be applied:
grassroots design, retrofit of an existing site, site expansion.

Total site targets for heat recovery

Heat recovery can be performed at two levels within a single process or between
processes. The latter is often referred to as site-wide heat recovery or Total Site heat
recovery. Total Site heat recovery is performed by identifying the heat sources and
heat sinks on the site. They stem from the individual site processes. There are two
main options for applying this identification:
Take all heat sources and sinks from the processes, regardless of the
opportunities for intra-process heat recovery.
Take only the net heat sources and net heat sinks from the individual
processes, accounting for intra-process heat recovery.
In this material the second option is used.
The procedure for targeting intra-process heat recovery uses the Pinch Analysis
approach (Linnhoff and Flower, 1978; Linnhoff and Hindmarsh, 1983). By plotting
composite enthalpy changes versus the temperature, in order to produce the grand
composite curve (GCC) as shown in Figure 2 (Linnhoff et al., 1982), several energy
integration aspects are considered:
(i) Heat recovery among the streams inside the process

(ii) The profile above the process pinch represents a net heat sink, whereas the
profile below the process pinch represents a net heat source (Dhole and
Linnhoff, 1993).
(iii) Minimum requirements for external heating and cooling. GCC also gives the
opportunity to produce targets for multiple utility levels.

T*

HP
MP

Tmin

LP

CW

H
Figure 2. Grand Composite Curve

Moving from the single process level to that of the Total Site, the residual heat
sources and heat sinks are identified from the GCC of each process (Figure 3).

T*

T*

T*

H
Mirror the heat
sources

Remove the pocket

Figure 3. Identification of net heat sources and sinks from a GCC

The site heat source profile is then constructed by combining the heat source
information from all the available processes into a single profile which is analogous to
the hot composite curve for a single process. In a similar way, the site heat sink
profile is formed by combining the heat sink information from all available processes,
and is analogous to the cold composite curve. Together, the total site profiles give a
simultaneous view of surplus heat, and heat deficit, for all the processes on the site
(Figure 4).
300
250

T [oC]

200

Sources

Sinks

150
100
50
0

Enthalpy [MW]
Figure 4. Total Site Profiles

VHP
HP

QREC
HP

MP
MP

MP

LP

LP

LP
PINCH

CW

CW
H

Figure 5. Total Site Composites

The amount of heat recovery that can take place on the total site through the steam
mains can be derived from the Total Site Composite Curves - Figure 5 (Kleme et al.,
1997). By shifting the Sink Composite Curve parallel to the enthalpy axis towards the

Source Composite Curve, their overlap represents the amount of heat recovery that
can be obtained through the steam mains.
The limit to the heat recovery is reached when the two site composite curves touch
and cannot be shifted further. The Total Site Pinch divides the problem into net heat
sink (above) and net heat source (below). The remaining site sink profile heat
demand is met by the supply of steam from a central boiler. Below the site pinch the
excess heat is removed by cooling (water) or produces very low pressure steam. The
area enclosed by the Site Composite Curves is proportional to the cogeneration
potential of the site utility system.

Integration of renewables
Renewable resources are usually available on smaller scale, distributed over a given
area. Their availability (with the exception of biomass) is usually well below 100 %.
The resource availability varies significantly with time and location, caused mainly by
the changing weather and geographic conditions. The energy demands (heating,
cooling and power) of the considered sites also can vary significantly with time of the
day and period of the year (Figure 6). The variations of renewable supplies and the
demands are partly predictable and some are not changing in very short time
intervals e.g. day and night for solar energy. However some availability as the wind
generated energy can be less predictable.
Power (kWe)
3
2

12

15

18

21

Figure 6. Variability of demands

24

Time (h)

Therefore, optimising the design of energy conversion systems using renewable

resources is more complex than when using just fossil fuels. By combining the supply
and demand streams of the individual users, such systems may serve industrial
plants as well as residential customers and the service sector (hotel complexes,
hospitals). They could typically utilise various energy carriers and the task is to
account for the variability on both the demand and supply sides.
The outlined challenges lead to the formulation of a Total Site extension concept
the Locally Integrated Energy Sector (Figure 7) (Perry et al., 2008), which besides
industrial energy users also includes residential customers and commercial buildings.

Figure 7. Locally Integrated Energy Sector

References
Raissi K., 1994, Total Site Integration. PhD Thesis, UMIST, UK.
DholeV. R., Linnhoff B., 1993. Total site targets for fuel, co-generation, emissions,
and cooling. Computers and Chemical Engineering, 17 (Supplement) S101-S109.
Kleme J., Dhole V.R., Raissi K., Perry S.J. and Puigjaner L., 1997. Targeting and
Design Methodology for Reduction of Fuel, Power and CO2 on Total Sites,
Applied Thermal Engineering 17 (8/10), 993-1003.

Linnhoff B., Flower J.R., 1978. Synthesis of Heat Exchanger Networks: I. systematic
generation of energy optimal networks, AIChE Journal 24 (4), 633642.
Linnhoff B., Hindmarsh E., 1983. The Pinch Design Method for Heat Exchanger
Networks, Chemical Engineering Science 38 (5), 745-763.
Linnhoff B., Townsend D. W., Boland D., Hewitt G. F., Thomas B. E. A., Guy A.R.,
and Marsland R. H., 1982. A user guide on process integration for the efficient
use of energy. IChemE, UK. (last reprint 1994)).
Perry S., Kleme J., Bulatov I., Integrating Waste and Renewable Energy to Reduce
the Carbon Footprint of Locally Integrated Energy Sectors, Energy, Vol. 33, no.
10, pp. 1489-1497, 2008.