Total Site Methodology as a Tool for Planning and Strategic Decisions

A Total Site (TS) is defined as a set of processes (industrial plants, residential, business and agriculture units) linked through the central utility system. The utility system incorporates a number of operating units such as boilers, steam turbines, gas turbines and letdown stations. Many sites are using the TS system representation. Heat Integration at TS level has been well developed and successfully implemented. However, sites typically develop with time and even minor changes/extensions can affect TS heat recovery significantly. It is beneficial to plan their strategic development in advance, to increase or at least not to decrease the rate of heat recovery when integration of additional processes takes place. Even when this has not been done at the initial stage, the TS methodology can still be used as a tool for the strategic planning decision making. This work illustrates how the TS methodology can contribute to the strategic development and the extension planning of already existing TS. The aim is to reveal the potentials for Heat Integration, when new units or processes are considered for the inclusion in the TS. Moreover, some operating parameters (e.g. temperature or capacity) of the unit can be proposed to achieve the best possible heat recovery. The degrees of freedom for TS changes can be on two levels: (i) only adding an operating unit to the current utility system (the Total Site Profiles remain the same) or (ii) changing of the TS by including more processes (the Total Site Profiles are changed). The first group of changes includes the integration of heat engines to produce electricity utilising heat at higher temperature and returning it to the system at lower temperature, which is still acceptable for the heat recovery and simultaneously for the electricity production. The second group of changes is more complex. For evaluating these changes a plus/minus principle is developed allowing the most beneficial integration of new units to the TS. Combinations of both types of changes are also considered.