Applied Thermal Engineering 61 (2013) 17e25

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Applied Thermal Engineering

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

Industrial implementation issues of Total Site Heat Integration

Kew Hong Chew a, Ji
r Jaromr Kleme
s b, Sharifah Radah Wan Alwi a, *,
Zainuddin Abdul Manan a
a

Process Systems Engineering Centre (PROSPECT), Faculty of Chemical Engineering, Universiti Teknologi Malaysia, 81310 UTM Johor Baru, Johor, Malaysia
}
Centre for Process Integration and Intensication e CPI2, Research Institute of Chemical and Process Engineering e MUKKI,
Faculty of Information
_
Technology, University of Pannonia, Egyetem u. 10, H-8200 Veszprem,
Hungary
b

h i g h l i g h t s

g r a p h i c a l a b s t r a c t

< Current TSHI methodology has been

used for solving models with certain
simplications.
< Several issues that can inuence
practical implementation of TSHI
are identied.
< Impacts of these issues on safety,
environment and economics are
evaluated.
< The ndings form a basis for an
improved and practical implementation of TSHI.

a r t i c l e i n f o

a b s t r a c t

Article history:
Received 26 December 2012
Accepted 8 March 2013
Available online 21 March 2013

Heat Integration has been a well-established energy conservation strategy in the industry. Total Site Heat
Integration (TSHI) has received growing interest since its inception in the 90s. The methodology has been
used with certain simplications to solve TSHI problems. This paper investigates the main issues that can
inuence the practical implementation of TSHI in the industry. The main aim is to provide an assessment
and possible guidance for future development and extension of the TSHI methodology from the industrial perspective. Several key issues have been identied as being of vital importance for the industries: design, operation, reliability/availability/maintenance, regulatory/policy and economics. Design
issues to consider include plant layout, pressure drop, etc. For operation, issues such as startup and
shutdown need to be considered. Reliability, availability and maintenance (RAM) are important as they
directly affect the production. Relevant government policy and incentives are also important when
considering the options for TSHI. Finally, a TSHI system needs to be economically viable. This paper
highlights the key issues to be considered for a successful implementation of TSHI. The impacts of these
issues on TS integration are summarised in a matrix, which forms a basis for an improved and closer-toreal-life implementation of the TSHI methodology.
2013 Elsevier Ltd. All rights reserved.

Keywords:
Total Site Heat Integration
Key issues
Industrial implementation
Minimum energy targets
Design

1. Introduction
Rising fuel cost, depletion of fossil fuel reserves and threat of
global warming have encouraged industries to maximise heat recovery via Heat Integration as one of the effective strategies to

* Corresponding author. Tel.: 60 (0)7 5535533; fax: 60 (0)7 5536165.

E-mail address: shasha@cheme.utm.my (S.R. Wan Alwi).
1359-4311/$ e see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.applthermaleng.2013.03.014

conserve energy. Alongside this development, Total Site Heat

Integration (TSHI) has received growing interest since its inception
in the 90s [1]. Several successful project implementations involving
large petro-chemical sites have been reported by world-leading
companies such as CHIYODA Japan by Matsuda et al. [2], BP UK
and US, and by MOL Hungary. A large-scale TSHI implementation
on the steel industry has also been reported by Matsuda et al. [3].
Some other works presented e.g. by Hackl et al. [4] on TSHI have
explored how companies within a large industrial cluster can

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K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

cooperate with each other. A recent study [5] proposed the integration of processes below ambient temperature. However, due to
the condentiality issues, only a limited number of implementations have been released for publication. TSHI is a tool used to set
targets for heat recovery on a Total Site. The Total Site Proles (TSP)
is constructed from the Grand Composite Curves (GCC) of individual processes [1]. Heat recovery can either be direct between processes or indirect via an intermediate medium such as steam. Direct
heat transfer is not always acceptable due to distances between
processes and operational issue. Indirect heat recovery offers
operational exibility but there is a penalty due to reduced temperature driving forces. With indirect heat recovery, the number of
utility temperature levels set the utility targets. More utility levels
result in higher heat recovery however the heat recovered has to be
weighed against the required capital cost [6]. The utility targets
obtained can be used as the basis for the Central Utilities System
(CUS) in a grassroots design or to identify energy saving opportunities in a retrot project. Those heating and cooling duties that are
excluded from TSHI for e.g. due to process reasons, are serviced by
local utilities at individual processes.
The TS methodology, like many engineering approaches, has
been solving models with certain simplications. Only stream
temperatures and average heat capacities have been taken into
account while other issues have yet to be considered in detail. In
real life, these simplications may steer the TSHI project towards
sub-optimal and even non-realistic solutions that can be difcult to
rectify at the later stage of the project implementation. The drivers
for TSHI projects are energy saving and reduced emissions. The
investment required has its associated risks e whether the capital
cost sanctioned will deliver the project and if the expected savings
can be achieved. An adequate TSHI design denition will reduce the
uncertainty in cost estimate, potential for cost overrun due to
design change and improve condence in the expected saving.
Therefore issues other than temperature and heat capacities that
have impact on the TSHI solution should be considered as far as
possible, during the early stages of the process development. This
work aims to investigate the main issues that can support the
practical implementation of TSHI in real-life projects. The main
target is to provide a direction for future extension of TSHI methodology from the industrial perspective.
2. Issues to be considered for Total Site Heat Integration
To arrive at an optimal design, Heat Integration (HI) opportunities are evaluated in the context of wider issues in addition to
stream temperatures and heat capacities. These issues often cannot
be easily quantied like temperatures and heat capacities, but
nevertheless their impacts on TSHI solution in terms of safety,
operability, economics and environment cannot be ignored. It has
always been a question during which phase should these issues be
considered. When too many of these factors are considered upfront,
it could make the TSHI problem too complicated to study and
evaluate. On the other hand, leaving out these issues, at best, may
result in less than cost-effective, and at worst, infeasible design for
implementation. Several key issues have been identied as
important for the industries: design, operations, reliability, availability and maintenance (RAM), regulatory/policy and economic
issues.
2.1. Design
Beyond the heat capacity and temperature, various design issues
can strongly inuence the individual plant design. Interactions
between processes add further complexities to the TSHI analysis.
The main issues to be considered are as follows:

(a) Layout e An issue important for grassroots design and even

more so for retrot. In a plant, the equipment is laid out with
due considerations to factors such as construction, process,
operations and maintenance requirements, safety, etc. [7].
Mathematical programming based methodology [8] has been
used to address the impact of layout in TSHI optimisation. The
inuence of layout is represented as piping costs and weighted
proportional to the distance between the plants. Where a heat
exchanger is located has important implications on the cost.
The pipe lengths, ttings such as pipe bends, valves add to the
line pressure losses. For liquid streams, the elevation of the
equipment, in addition to the distance, is also important as
energy is needed to overcome the static head due to a rise in
elevation.
For retrot, space constraints for new equipment or piping
modication are always a challenge to overcome. HI methodology for retrot has received some attention as majority of
industrial cases are retrot cases. Zhu et al. [9] demonstrated the
viability of using heat transfer enhancement (HTE) against the
traditional additional heat transfer area in HEN retrot. Placentino [10] proposed recently an integrated approach, using
driving force plot and exergy destruction factor, to identify the
optimal HEN retrot and relaxation strategies at an aromatics
plant. In comparison, there is less work on TSHI retrot. Feng
et al. [11] works on the retrot of a petrochemical complex
showed that signicant energy saving is achievable with minimum HEN structure changes. Atkins et al. [12] introduced the
use of heat recovery loop to improve heat recovery in a large
dairy factory which has non-continuous processes.
Energy saving from heat recovery has to be justied against
additional piping, insulation and pumping (for liquids) or
compressor (for gases) cost as discussed by Kleme
s and Varbanov [8], both for capital and operating expenses.
(b) Contamination risk e This is normally identied by HAZOP
however it will be preferable to capture any potential for
contamination from the hot stream to the cold stream, or vice
versa, due to potential leakages in early stage of design. In some
cases, this does not create a serious problem if the leak is
detected early enough. For example, a process uid leak into
the condensate return line in a steam heater can be handled by
dumping the condensate once the contamination is detected
without causing serious damage to the boiler. However, in
some cases contamination may not be acceptable, for e.g.
contamination of food grade product has serious health and
safety implications.
(c) Pressure e The operating pressures of the streams affect the
pressure rating of the equipment, and consequently, the cost of
the heat exchanger as pointed out by Hall et al. [13] already in
1990. When streams of different pressure levels are matched,
the lower pressure side has either to be designed at the same
pressure level as the higher pressure side or provided with an
overpressure protection. Higher pressure rating equipment is
more costly and overpressure protection system can have signicant cost and maintenance implications. The heat
exchanger has to be rated to the design pressures of the system
it is residing in, both hot and cold sides. This may have cost
implications especially with high pressure system where cost
of pipes and valves can be considerable.
(d) Fluid characteristics e The characteristics of the uids
inuence stream matching and selection of suitable utilities.
Fluids such as waxy crude oil which has high pour point
(temperature at which the uid stop to ow) may dictate
matches to avoid or even forbid, limit the type of cold utilities
to be used and minimum temperature of approach in order to
maintain a effective heat transfer coefcient. Viscosity is

K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

related to temperature and this can increase the pumping cost

considerably. In some cases, cost saving from heat recovery has
to be checked against the increase in pumping cost of a colder
and more viscous liquid.
(e) Undesired phase change e The potential for phase change due to
an increase in temperature has to be considered. For example,
when considering heat recovery from ue gas, the potential for
undesired vaporisation of the cold stream, for example during
low ow or no ow, has to be carefully evaluated as it will lead
to a considerable pressure increase and may result in tube
failure. Bypass arrangement for typically large size ue gas
ducting is expensive. Moreover, if the bypass valves are not leak
tight, credit cannot be taken for isolation, a trip of the high
temperature source, e.g. the furnace is still necessary. The
benet of heat recovery from ue gas has to be weighed against
the cost of production loss.
(f) Limitation on utility levels e The optimal levels of utilities are
selected based on consideration of all process, heat recovery
and operational requirements. For example, in the selection of
low pressure steam level, the pressure loss in the distribution
piping system and line pressure necessary for condensate recovery need to be considered. This would normally limit the
low pressure steam pressure to around 3.5 barg or a steam
temperature of around 150  C.
(g) Material of construction e The required materials for heat exchangers, piping and vessels are very much related to the
operating temperature and pressure. If TSHI suggests changes
in related parameters, this can have signicant inuence on the
investment cost. For this reason when TSHI leads to a change in
temperature and pressure or in some cases a change in stream
composition also, the impact on investment cost should be
taken into consideration.
(h) Opportunities for cogeneration e Cogeneration can satisfy the
heat and power demand and at the same time improve site
energy efciency (with its associated reduction in carbon
footprint) as heat is recovered from the waste heat. The
viability of cogeneration should always be explored. Cogeneration is capital cost intensive and requires attention to start-up
issues during design [14]. Cogeneration efciency can be estimated by the R-curve concept [15]. It generally increases with
decreasing power to heat ratio. Many methods exist to estimate
cogeneration potential at a TS, from the simple exergy model
[16] to the more recent iterative bottom-to-top model [17].
Khoshgoftar Manesh et al. [18] extended the methodology to
include the estimation of total annualised cost of cogeneration.
(i) Utilisation of low grade heat e Low grade heat is frequently
dissipated to environment resulting in energy wastage.
However, increasingly more emphasis has been placed on
recovery of this form of energy. Low grade heat source has
been used to supply heating in district heating scheme in cities
around Europe. For e.g. in Vienna, low grade heat from power
stations nearby is used for the citys district heating schemes
[19]. Use of heat pumps to produce MP steam from condensate
low grade heat has also been practiced in a petrochemical
renery e see e.g. by Matsuda et al. [20]. When low grade heat
is identied by TSHI, it can be utilised by either modifying the
existing site/processes to exploit low grade heat, or outside the
existing site.
It may appear that issues (a)e(g) are related to individual process design, but what is true for single process is also applicable to
TS. In addition, when these issues are considered in the TS context,
they provide preferable suggestions to the design parameters of
individual processes. Two examples are given in Section 4 to
illustrate the impact on TSHI when the issues are considered.

19

2.2. Operations
Operability is a crucial aspect of Heat Integration. Though this is
well recognised, it remains an area of research on how to effectively
address operability issue in the TSHI.
(a) Different operating scenarios e HI has to be exible enough to
allow for the different operating scenarios, e.g. different feed
stock compositions, anticipated. The capacities of the heat recovery equipment and utility systems have to cater for the
worst case scenarios. The impacts of the variations of individual units have to be considered for Total Site and not just the
units alone.
(b) Startup and shutdown e HI has to cater for startup and shutdown of a process or several processes. A contribution on how
to deal with these issues in TSHI has been developed e see e.g.
work presented by Liew et al. [21]. Startup heaters and coolers
have to be provided in parallel to the heat exchangers to allow
for startup and shutdown of processes. The cost of these exchangers has to be added to economic considerations. The
utilities required for startup and shutdown have also to be
included in the balance.
(c) Variation in operating conditions e Long term variations in
operating conditions are such as those due to fouling heat
exchanger (HE) surfaces or exhausted catalysts. A reactor using
catalyst may operate at different conditions with a fresh catalyst
compared to when the catalyst is near to exhaustion. In fouling
services such as renery crude preheating, stream temperature
will vary as the heat exchanger performance declines due to
fouling. These heat exchangers have to be routinely cleaned to
remove the fouling. The cleaning cycle depends on the operating conditions (temperature, pressure, ow speed), uid
characteristics, the HE type and construction. These factors can
be inuenced by TSHI and for this reason the impacts should be
considered when suggestions for modications are made. Short
term uctuations due to process upset are not crucial as the
control system when properly designed can cope with it and
return the process to normal operations quick enough.
(d) Turndown requirements e Some processes may at times operate
at turndown conditions, for e.g. due to reduced demand for its
products. To cater for the varying ow rates, parallel units, e.g.
2  50% or 3  33.3% conguration for heat exchangers may be
used to cater for the design ow ranges. This especially so with
viscous uids in order to maintain the minimum velocity
needed for effective heat transfer and at times to reduce fouling
potential.
(e) Controllability e The impact of heat integration on process
controllability has to be considered. For example, typical renery crude preheating involved an equal 50% stream split. A
simple way of control is to use manual valves and symmetrical
piping for ow splitting as shown in Fig. 1(a). A more sophisticated way is to use ow cascaded with temperature control
loops, see Fig. 1(b). The downside of the sophisticated method
is the increased pressure losses across the control valves. The
sophisticated control loops along with its hardware have
considerable cost implications. If risk of production loss is high,
decision may be taken to exclude a stream from HI even though
TSHI has identied the opportunity. For e.g. in a distillation
column where the product purity is very sensitive to the column bottom temperature, a heating medium is preferred over
a hot process stream for the reboiler. If a process stream is used
instead, there is a chance for column upset as any upset in the
process stream would affect the column operations. Process
upsets translate directly to production losses as it takes time for
the production to recover from upsets to normal.

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K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

appropriate provision of overpressure protection, etc. Plugging due

to fouling of heat transfer surfaces can be minimised by selecting a
suitable operating regime that minimise fouling and suitable
stream match. The maintenance requirement depends very much
on the type of uids and operating conditions. Fouling services
require more maintenance. Provisions have to be made to resume
production during equipment maintenance. This can be done by,
for example, provisions of two units with bypass conguration, so
that operations can continue at reduced capacity when 1 unit is
taken out of service.
Aguilar et al. [25] have proposed a method, based on mathematical programming, whereby the availability and reliability issues are considered simultaneously with the design and
operational parameters of the utility systems. Smith et al. [26]
developed a methodology that allows the incorporation of reliability issues in the optimization of the utilities system. The penalty
of downtime cost is considered simultaneously with operating
costs in order to dene the best operating strategy and optimal total
cost.
2.4. Regulatory/policy

Fig. 1. Simple versus complicated spilt ow control.

(f) Operational hazards e Any hazards arising from the Heat Integration have to be identied via a hazard and operability study,
HAZOP. Necessary mitigation and control measures have to be
put in place as required where these have safety implications.
Inherent safety design takes away reliance on instrumentation
or operators action to arrest an unsafe situation hence is superior over any operational measures.
Consideration of operational issues is essential to arrive at a
realistic target that can be used as the basis for CUS in a grassroots
design or to identify energy saving opportunities in a retrot
project. The basis for design has to be as good as practicable to avoid
design changes (which can be costly and can cause project delay)
during the implementation stage.

2.3. Reliability, availability and maintenance (RAM)

Reliability, availability and maintenance (RAM) should be
considered during the early stages and not as an afterthought [6]. A
properly related planning of maintenance scheduling can lead to
better energy utilisation and reduced production losses see e.g. by
Cheung and Hui [22]. This is demonstrated in an industrial case
study by Hirata et al. [23]. TSHI has to ensure that the added
equipment and the overall system are of acceptable RAM requirements. Except for fouling services, heat exchangers when
properly design and selected have relatively less RAM issues
compared to rotating equipment such as a turbine or compressor.
The failure modes of heat exchangers are such as leak, rupture and
plugging, due to corrosion and material degradation [24]. The potential for leaks and rupture can be minimised by suitable selection
of material of construction, correct equipment pressure rating,

When evaluating the options for TSHI, it is also important to

consider relevant government policies and incentives. The policies
and incentives on energy efciency vary from country to country.
The European Union (EU) in particular has a complex set of directives. There are more than 400 acts related to the Energy
Legislation, among them, policies specic to the industries such as
the regulations on equipment efciency (e.g. Directive 92/42/EEC
on boiler efciency requirement [27]), regulations on energy
management (e.g. Directive 2010/31/EU on building energy performance [28]), negotiated agreement between government and
industries [29]. Incentives such as in the forms of energy and carbon taxes, subsidies, loans, the greenhouse gas emission cap-andtrade (ETS) scheme, etc. are given to encourage energy saving
projects. There are also policies to promote energy saving such as
energy saving tools (for e.g. energy audit and benchmarking),
partnership programme between government and industries [30].
In Japan, where TSHI has been implemented in a large industrial
area [2] and a steel plant [3], there are regulations for energy
management as well as negotiated agreement for industries to set
energy-saving goals. The economic incentives are in the form of tax
exemptions/deduction, preferential loans and subsidies as well as
greenhouse gas (GHG) trading scheme. Industries can partner with
government to identify energy efciency opportunities [30].
In Malaysia, the energy policy promotes energy security and
efcient energy usage, and aims to minimise the negative impacts
of energy production. The government encourages the industries to
improve energy efciency through provision of scal incentives in
terms of accelerated capital allowances (related equipment to be
written off within a period of one year) and exemption of tax and
duty on equipment purchased for energy saving projects [31]. The
Energy Efciency and Conservation Guidelines encourage industries to adopt practices to improve energy usage for commonly
used equipment such as motors, fans, pumps, etc. The Industrial
Energy Audit Guidelines provide useful procedure for the systematic survey of energy usage in an installation [32].
For potential economic benets for cogeneration can be very
dependent on the local government policies and incentives. In the
EU, the feasibility to sell electricity to the grid, and the potential to
transfer electricity and heat between companies located in an industrial site offer further economic advantages. However, in some
countries, any additional electricity generated has to be consumed
in-house since there is no provision for selling back the excess
electricity generated.

K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

2.5. Economic issues

A TSHI system has to be economically viable. It is essential to
evaluate the cost and benets of the proposed TSHI options. In
addition, for industrial implementation, the main concerns are cost
escalation and schedule delay due to design changes. Therefore
sufciently accurate cost estimate and adequate design denition
are essential for project decision. Life cycle cost should be considered, i.e. from the initial conceptual stage to the decommissioning
of the equipment at the end of the installation life.
(a) Capital expenditure, Capex e This is the installed cost of the
system. The installed cost is all the cost involved to have the
TSHI system installed on site ready for operations. It includes
engineering, equipment, piping, valves, control valves, instruments, control system, insulation, overpressure protection
system, site preparation, installation, etc. Design issues that
have Capex implications have to be factored into the cost
equations. In the same way operational and RAM issues that
have Capex implications have to be added in.
(b) Operating expenditure, Opex e This includes the energy, maintenance, downtime and other cost related to the operating of
the equipment such as chemicals etc. Additional Opex arises
from the consideration of operational and RAM issues have to
be added in. Energy cost should be evaluated for the potential
uctuation in energy prices in the future. It has been shown
that the use of projected utility prices over the project life span
yields signicantly affect the optimal solution for the HEN [33],
the same can be said of TSHI. Maintenance cost should include
cost necessary to maintain the equipment at its desired operation through the life.
(c) Decommissioning e Cost has to be allocated for safe disposal of
the equipment at the end of the life span. This may inuence
the selection of the type of equipment.

21

(d) Design change e Cost of design change is signicant. It can increase up to several folds with each step of the life cycle, from
conceptual design, detailed design, construction to operation.
Therefore, there is big savings incentive to have an excellent
basic design during the conceptual stage to eliminate any
changes later [34].
(e) Uncertainties e Good cost data are not always available. For
energy, forecasted future cost is used and this always has its
associated uncertainties. The uncertainties in economic evaluated need to be addressed and sensitivity analysis carried out
(especially when future cost is involved).
(f) Policy and regulations e The economic assessment should also
consider and capitalise on the nancial incentives, any
favourable tax treatment, any penalty, subsidies and loans
made available for energy saving or energy efciency
improvement projects as these are equally applicable to Total
Site as with individual process.
A TSHI solution is optimal at the time of evaluation based on the
information available. Energy cost changes with time and often is
always on the increase. Therefore it will be prudent to revisit design
and economic analysis to explore opportunities for improving energy efciency. The cost model may be recalibrated with the actual
result after the implementation of the project.
3. Evaluation of the impacts on TSHI solutions
The main issues assessed for a successful implementation of
TSHI are summarised in a matrix presented in Fig. 2. This matrix
serves as a checklist as well as the basis for an improved, and closer
to real life TSHI methodology. The objective is to capture essential
issues in the proposed solutions for project decision e to implement or not. An expanded TSHI owchart to include consideration
of these issues is shown in Fig. 3.

Fig. 2. Matrix showing the main issues on Total Site Heat Integration solution.

22

K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

Temperature

Analysis /
Conceptual
Design

Heat
capacities

Contamination
risk

Varying
operating
conditions

Fluid
characteristics

Layout
Minimum
Energy
Target

Undesired
phase change

Turndown
Utility levels

Operating
Scenarios
Regulatory
/Policy

Controllability
Pressure

Detailed
Design

TSHI
options for
economic
evaluation

Startup &
shutdown
Usage of low
grade heat

Reliability,
Availability &
Maintenance
Cogeneration
potential
Operational
hazards

Fig. 3. Total Site Heat Integration owchart.

The potential impacts of these issues on economics, safety,

minimum energy target and environment are shown in Fig. 2 and
briey discussed below. All the issues listed can potentially affect
the economics either directly or indirectly. At the targeting stage,
layout can affect the decision whether to use direct or indirect heat
recovery, the utility supply pressure, etc. At the design stage, layout
has capital cost implication as discussed previously. Fluid characteristics may dictate the temperature limits for either the cold or
hot stream. This either increases the utilities requirement or
requires more heat transfer area and hence affect the economics. In
another example, if two streams of differing pressures are matched,
over-pressure protection arrangement has to be provided to protect
the lower pressure side. This will increase capital investment and
add to the maintenance cost. Also the pressure and temperature
rating of a heat exchanger affect the cost of heat exchanger per unit
area since heat exchangers rated for higher pressure and temperature are much more expensive than for those rated for lower
pressure and temperature. Provisions such as adequate space,
needs for operations, maintenance of equipment, etc., also affect
the economics.
Design and operational issues have safety and environmental
implications. Major process safety hazards are re, explosions and
toxic releases. In the context of TSHI, the aim would be to avoid the
arising of a new hazard as a result of the integration. For e.g.
introduction of a ammable stream to a safe area for the purpose of
heat recovery has serious safety and cost implications e the area
has to be reclassied as hazardous area and all electrical equipment
within the hazardous area have to be upgraded to suit the area
classication. In another example, when there is a potential for res
as a result of loss of containment, the equipment should be placed
at sufcient distance apart to mitigate escalation potential. It is

desirable that safety impacts to be captured as early as possible as

neglecting it in the early stage may result in design problem which
is difcult and expensive to x at a later stage [35]. Inherent safety
design takes away reliance on instrumentation or operators action
to arrest an unsafe situation. Such features are superior as such
operational hazards identied should be eliminated and/or mitigated by design instead of relying on operational procedures. The
environmental impacts in the context of TSHI would be to minimise
mainly any harmful gaseous emissions (GHG, SOx, NOx) to the
environment. These are for e.g. burning of extra fossil fuel or
increased occurrence of direct process releases due to process
upset.

Fig. 4. Example of Total Site layout.

K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

Table 1
Steam distribution in a Total Site.
Process

CUSa
A
B
C
D
E
F

Distance from x
Horizontal
(m)

Vertical
(m)

0
200
500
1000
150
750
2250

0
500
500
500
700
700
1000

Location

Pressureb
(barg)

x
1
2
3
4
5
6

5.25
5.05
4.75
4.25
5.10
4.50
3.00

Location

Pressureb
(barg)

a
b
c
d
e
f

4.55
4.25
3.75
4.40
3.80
2.00

against the costs of a large pipe diameter and pumping cost

have to be considered. Fig. 4 shows a TS consisting of a CUS, six
processes and a low pressure (LP) steam distribution network.
Steam is required at a minimum pressure of 2.00 barg at the

CUS e Central Utilities System.

Pressure at various locations on the steam distribution network is estimated
assumed on a line pressure loss of 0.1 bar/100 m.
b

Issues that may limit or forbid certain stream matching are

likely to increase the cold and hot utilities above the minimum
energy requirement value which is based on thermodynamic
principles. Equipment layout and/or elevation that necessitate the
installation of pump or compressor along with the associated
piping, valves, insulation and control will add to the cost.
Regulations and policies have impact on the project economics
in terms of scal incentives and tax and duty exemption on
equipment. The limits on environment emission or discharge
would affect the technology and equipment selection and hence
economics as well.
It should be noted that these issues, to a certain extent, are also
valid for individual processes. However the inuences of many of
them are stronger when the processes are integrated e e.g. layout.
Non-normal operations such as startup, shutdown, and maintenance of individual processes affect the balance of the normal integrated TS.
A systematic approach is needed to take into account those issues raised to arrive at an optimal solution. An early identication
of the impacts is preferable. Heuristics may be developed to give
guidance as to when and where these issues need to be addressed,
from data extraction, to targeting, to result interpretation and
design. The TSHI methodology may be extended to incorporate
those issues that can be quantied. For issues that cannot be readily
quantied, a qualitative assessment can be made, for e.g. by the use
of a matrix with a weighting factor for these issues considering
their impacts on for e.g. economics, safety and environment. The
quantitative and qualitative methods together will enable a good
engineering decision on the optimum solution for industrial
implementation.
4. Illustrative examples
The impacts of the aforementioned issues on TSHI are illustrated
in two examples below.
(a) Layout e A Total Site typically involves long distances between
processes as such a reasonable line pressure drop, weighed
Table 2
Steam pressure required at the main header.
TSHI
Including

Excluding

A,
A,
A,
A,

e
F
C, F
C, E, F

B,
B,
B,
B,

C, D, E, F
C, D, E
D, E
D

Header
pressurea (barg)

Steam
temperatureb ( C)

5.25
3.50
3.45
2.85

177
154
154
146

a
Pressure required at header to supply steam at a minimum pressure of 2.00 barg
to the furthest consumer.
b
Corresponding saturated steam temperature at the header pressure.

23

Fig. 5. Impact of layout on LP steam generations.

24

K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

the processes are integrated, the header pressure required is

5.25 barg. Without the integration of process F (furthest from
the CUS), the pressure required at the header is at 3.50 barg. It
can be seen that pressure losses in the header and sub-header
depend on layout. The pressure losses have to be overcome by
higher steam supply pressure, the penalty of which is a
reduction in the quantity of steam generation from the processes as shown in Fig. 5(b) and (c). Without the consideration
of layout, LP steam is required at 2.00 barg, the corresponding
steam generation is at 12.1 MW. When the layout is considered
and all the six processes (A, B, C, D, E and F) are integrated, the
steam generation is reduced from 12.1 MW to 2.1 MW, see
Fig. 5(b). When process F (furthest from the CUS) is excluded
and line pressure losses are included, steam generation is
reduced from 9.5 MW to 6.8 MW, see Fig. 5(c).
If the layout is not considered, a lower LP steam temperature
may be used as approximation e.g. 120  C (corresponds to a pressure of 1 barg). This may result in overestimation of the amount of
LP steam that can be raised from the site source prole and
consequently underestimate the required external LP steam generation capacity.
(b) Shutdown e Most works on TSHI targeting are based on
continuous process this however does not give a complete
picture of the TSHI requirement. The capacity of the CUS has to
cater for all operating scenarios anticipated. Operational issues
such as shutdown and startup should be considered during the
targeting stage to give a more representative target for the CUS.
Fig. 6(a)e(c) gives the TSP of an aromatic hydrocarbon plant
consisting of three processes: hydrocracking unit (A), aromatic
hydrocarbon extraction unit (B) and isomerisation unit (C) [11].
Shutdown of processes affects the TSP in various degrees. In
this example, shutdown of process C alters the Site Source
Prole signicantly (refer to Fig. 6(b)) while shutdown of
process A (refer to Fig. 6(c)) only affects the Site Source Prole
slightly. The Site Sink Proles are independent of the shutdowns above 250  C implying that heating requirement above
this temperature is independent of the TSHI. Between 150  C
and 240  C, the amount of heating utilities required depends on
whether process C is in operations or not. A contribution on
how to deal with those issues in TSHI has been under development e see e.g. work presented by Liew et al. [21].

5. Conclusions

Fig. 6. Impact of shutdown on Total Site Proles.

users. Table 1 summarises the pressure at various locations at

the site. Pressure at x, located nearest to the CUS is 5.25 barg
and pressure at f furthest away is 2.00 barg. Table 2 gives the
steam header pressure required for the TSHI options. When all

Several key issues that have inuence on TSHI solution have

been identied. The impacts of these issues on TSHI have been
specically highlighted in two examples. The relevance of these
issues to the targeting and optimisation stages of the TSHI is
shown in Fig. 3. By considering these issues, design, operations,
RAM, regulatory and policy and economics, in the early stages a
closer-to- real-life TSHI solution can be derived for implementation. This approach provides more insights to TSHI design from the
industrial perspective. The development of the TSHI methodology
to incorporate those quantiable issues and those issues which
are to be qualitatively assessed is the subject of future work by the
authors. So far, the issues have been analysed for industrial units
type TSHI, however the methodology should be extended for TSHI
including services, businesses, residential and even agriculture
units e locally integrated energy sector (LIES) e introduced by
Perry et al. [36]. This is going to be the subject of future studies
on TSHI.

K.H. Chew et al. / Applied Thermal Engineering 61 (2013) 17e25

Acknowledgements
The authors gratefully acknowledge the nancial supports
from the Universiti Teknologi Malaysia (UTM) Research University
Grant under Vote No. Q.J130000.2544.03H44 and the EC FP7
project ENER/FP7/296003/EFENIS Efcient Energy Integrated
Solutions for Manufacturing Industries e EFENIS. The support from
the Hungarian project Trsadalmi Megjuls Operatv Program
TMOP e 4.2.2.A-11/1/KONV-2012-0072 e Design and optimisation of modernisation and efcient operation of energy supply and
utilisation systems using renewable energy sources and ICTs
signicantly contributed to the completion of this analysis.
Nomenclature
Capex
CUS
ETS
EU
GHG
HAZOP
HE
HI
HP
HT
HTE
LP
MP
Opex
RAM
TS
TSHI

Capital expenditure
Central Utilities System
Greenhouse gas emissions cap-and-trade schemes
European Union
Greenhouse gases
Hazards & operability study
Heat exchanger
Heat Integration
High pressure, barg
Heat transfer
Heat transfer enhancements
Low pressure, barg
Medium pressure, barg
Operating expenditure
Reliability, availability and maintenance
Total Site
Total Site Heat Integration

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