1 P.Y. Liew et al.

Renewable andand
/ Renewable Sustainable Energy
Sustainable Reviews∎ ∎(∎∎∎∎)
Reviews
Energy (∎∎∎∎)∎∎∎–∎∎∎
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Contents lists available at ScienceDirect

Renewable and Sustainable Energy Reviews

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

Total Site Heat Integration planning and design for industrial,

urban and renewable systems
Peng Yen Liew a,b, Wai Lip Theo c, Sharifah Rafidah Wan Alwi a,c,n, Jeng Shiun Lim a,c,
Zainuddin Abdul Manan a,c, Jiří Jaromír Klemeš d, Petar Sabev Varbanov d
a
Process Systems Engineering Centre (PROSPECT), Research Institute of Sustainable Environment (RISE), Universiti Teknologi Malaysia,
81310 UTM Johor Bahru, Johor, Malaysia
b
Department of Environmental Engineering and Green Technology, Malaysia – Japan International Institute of Technology (MJIIT), Universiti Teknologi
Malaysia, 54100 Kuala Lumpur, Malaysia
c
Faculty of Chemical and Energy Engineering, Universiti Teknologi Malaysia, 81310 UTM Johor Bahru, Johor, Malaysia
d
Faculty of Information Technology and Bionics, Pázmány Péter Catholic University, Práter u. 50/a, 1083 Budapest, Hungary

a r t i cle in f o a b s t r a c t

There has been growing interest in developing Locally Integrated Energy Sectors (LIES) as a Process
Keywords: (Heat) Integration approach for synergising the industrial thermal energy systems that include renew-
Total Site Heat Integration able energy resources with urban (i.e. civic, residential, business and service complexes). The aim is to
Locally Integrated Energy Sectors enhance the regional energy efficiency and minimise greenhouse gas (including carbon) emissions.
Industrial However, a comprehensive planning and design framework is crucial at the onset of its development,
Urban and renewable energy systems which is accounting for supply and demand sides, but there have been limited works directed to this
Process Integration scope to date. For the development of such framework, this paper reviews the energy consumption
targeting methodologies via Total Site Heat Integration for estimating and designing the capacity of the
utility have been reviewed in this work, inclusive of both insight-based Pinch Analysis and mathematical
modelling approaches. As a final outcome of the review, suggestions are provided for investigating key
factors for integration of industrial, residential, commercial, institutional and service energy systems,
maximising the integration and reuse of waste and low potential heat, including renewables to boost
sustainability aspects. The review of methodologies for energy system integration is followed by iden-
tification of research directions that deserve future attention, refinement and development.
& 2016 Elsevier Ltd. All rights reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Overview of Total Site/utility system configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1. Renewable energy supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1. Solar thermal energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2. Geothermal energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.3. Biomass energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.4. Wind energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2. Heat demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3. Heat energy storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Total Site Heat Integration for industrial complexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1. Heat Recovery Pinch Analysis and targeting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2. Mathematical modelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.1. Process-oriented Total Site Process Integration models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.2. Utility system-oriented Total Site Heat Integration models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

n
Corresponding author.
E-mail address: shasha@cheme.utm.my (S.R. Wan Alwi).

http://dx.doi.org/10.1016/j.rser.2016.05.086
1364-0321/& 2016 Elsevier Ltd. All rights reserved.

Please
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as: as:
Liew
Liew
PY,PY,
et et
al. al.
Total
Total
SiteSite
HeatHeat
Integration
Integration
planning
planning
andand
design
design
for for
industrial,
industrial,
urban
urban
andand
renewable
renewable
systems.
systems.
Renewable
Renewable andand
Sustainable
Sustainable Energy
Energy
Reviews
Reviews (2016),
(2016), http://dx.doi.org/10.1016/j.rser.2016.05.086i
http://dx.doi.org/10.1016/j.rser.2016.05.086i
2 P.Y. Liew et al.Renewable andand
/ Renewable Sustainable Energy
Sustainable Reviews∎ ∎(∎∎∎∎)
Reviews
Energy (∎∎∎∎)∎∎∎–∎∎∎
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3.3. Hybrid Pinch and mathematical modelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4. Total Site Heat Integration for Locally Integrated Energy Sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1. Factors for integrating industrial clusters, urban with renewable energy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1.1. Economic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1.2. System reliability or stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1.3. Environmental impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2. Methodology development for integrating industrial, urban and renewable energy systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2.1. Research gaps and future research directions for industrial TSHI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2.2. Research gaps and future research directions in TSHI for industry, urban and renewable energy systems . . . . . . . . . . . . . . . . . 18
6. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1. Introduction
Process Integration (PI) as one of the methodologies for energy
saving and pollution reduction, has been studied extensively for
resource conservation for more than forty years [1]. PI has been
initially developed for aiding decision makers on the possible heat
savings by reusing waste heat. It has been further extended with an
important implementation in the mitigation of GHG emissions, and in
solutions for environmental and sustainability issues [2]. Heat Inte-
gration is the earliest PI methodology, which has been introduced for
minimising industrial energy consumption during the energy crisis in
1970s [3]. The concept has been widely used in processing and power
generation industries. In performing PI, Mathematical Programming
and Pinch Analysis are among the most popular approaches used [4].
Heat Pinch Analysis comprises systematic thermodynamically
based approach for exploring and optimising energy recovery oppor-
tunities between heat sources and heat sinks, which is able to reduce
the external hot and cold utility usage. Besides Heat Pinch Analysis,
the Pinch concept has been extended to hybrid power systems [5],
which involves integrating renewable energy into a commercial
power system aimed at reducing the non-renewable energy sources.
The Pinch Analysis concept has also been applied in the context of
other resources, including for decentralised electricity generation [6],
CO2 emission [7], carbon emissions constrained energy planning [8],
carbon emission planning [9], cogeneration and waste [10], mass [11],
water [12], gas [13], production planning [14], supply chain [15] and
property [16].
Klemeš et al. [1] reviewed the forty years development of Heat
Integration through Pinch Analysis and mathematical programming
until 2012. In another paper, Klemeš et al. [4] summarised the recent
developments of Process Integration. As an insight-based tool, Pinch
Analysis provides the advantage for users to visualise the saving
potentials and modifications required in a process, which is favourable
for engineers and decision makers. Mathematical Programming
approaches have also been widely used in the field of Process Inte-
gration, due to its capability of solving multi-objectives problems. In
recent years, research on Total Site Heat Integration (TSHI) involving
inter-process heat recovery that include low-grade waste heat and
integration of renewable energy sources has received substantial
attention, along the line of both the insight-based as well as the
mathematical programming approaches. This can be seen by the
growing number of research publications, research teams involved,
and industrial implementations associated with TSHI.
This paper reviews the state-of-the-art on the targeting metho-
dology for inter-process heat recovery using Heat Pinch Analysis and
mathematical programming approaches in the field of Process Inte-
gration. This paper provides an overview of the current TSHI meth-
odologies for integrating urban and renewable energy to LIES. It then
discusses the challenges for integrating industrial, urban and renew-
able energy system from the sustainability point of view. The potential
for the future research directions for heat generation and distribution
planning as well as the associated design tools and methodologies are
highlighted.
2. Overview of Total Site/utility system configuration
Single process Heat Integration using Pinch Analysis [17] has
been extended to examine the energy recovery potential between
industrial processes by Dhole et al. [18] and further developed by
Klemeš et al. [19], known as Total Site Heat Integration (TSHI). Site
Utility System (e.g. steam, hot oil and hot water) serves as the heat
transfer medium for recovering energy between processes. Heat
excess from a process can be transferred to a utility system for the
purpose of generating steam or heating hot oil or heating water.
The utility stream generated in this way can be further used by
another process to satisfy the energy demand.
Fig. 1 illustrates the relationship between processes, con-
densate, and steam at different pressures [20]. The site steam
system in this example has three different levels, which are High
Pressure Steam (HPS), Medium Pressure Steam (MPS) and Low
Pressure Steam (LPS). A process with excess heat source generates
steam for steam header. The generated steam is then used for
satisfying the heat sinks at other processes. If the process heat
sources are not able to satisfy the process heat sink, boiler steam
generation is considered for fulfilling the site total energy demand.
The boiler steam generation has typically higher quality (steam
temperature and pressure) than the required quality by the pro-
cess. Steam turbine can be used to reduce the pressure of the
steam and simultaneously generate electricity for operating other
electrical equipment on site. The steam turbine can be either be a
condensing steam turbine, or a back-pressure steam turbine, and
there can be intermediate extraction points. Steam can be
extracted from the turbine at different pressure levels. Steam
consumed by process heat sinks is returned to the de-aerator as
condensate. The condensate is treated in the de-aerator and exits
as boiler feed water for fuel boiler and process boilers. The
remaining cooling demands/excess energy are cooled by the
Cooling Water (CW) system in the site utility system.
TSHI was first introduced for the purpose of maximising thermal
energy saving via the integration of industrial processes. The concept
has been further extended to include renewable energy sources as
well as to consider other sources and consumers as site processes –
e.g. leisure and commercial buildings. This conceptual extension is
known as Locally Integrated Energy Sector (LIES) [21]. The structure of
LIES is as shown in Fig. 2. Kwak et al. [22] analysed four types of low
grade heat utilisation technologies for a TS system. The work con-
cluded that Organic Rankine Cycle is a promising technology during
winter time, while boiler feed water heating is found to be the best
solution within the study during summer, for recovering low grade
heat in process industry. The energy availability and the storage

Please
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citecite
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article
as: as:
Liew
Liew
PY,PY,
et et
al. al.
Total
Total
SiteSite
HeatHeat
Integration
Integration
planning
planning
andand
design
design
for for
industrial,
industrial,
urban
urban
andand
renewable
renewable
systems.
systems.
Renewable
Renewable andand
Sustainable
Sustainable Energy
Energy
Reviews
Reviews (2016),
(2016), http://dx.doi.org/10.1016/j.rser.2016.05.086i
http://dx.doi.org/10.1016/j.rser.2016.05.086i
3 P.Y.P.Y.
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Cooling Chiller
Boiler 1 Boiler 2
Tower
VHPS
Electricity

Condensate
HPS

MPS
BFW

LPS

CW

ChW

Process A Process B Process C Process D

BFW
Condensate
Condensate
System Electricity

Fig. 1. Total Site utility system [2].

Fig. 2. Locally Integrated Energy Sector (LIES) [21].

systems are the key elements for integrating urban and renewable
energy into an industrial energy system.
2.1. Renewable energy supply
Total Site Heat Integration is introduced for waste heat recovery
between industrial processes. For utilisation of renewable energy
resources, their availability and potential for extraction (to be supplied
for fulfilling the industrial and urban heat energy demands) become
concern for the system [23]. Among the array of renewable energy
resources, such as, solar, geothermal, biomass and wind, are capable of
generating thermal energy.
2.1.1. Solar thermal energy
Thermal energy can be extracted from solar irradiation directly. For
industrial use, where temperatures above 100–150 °C are usually
needed, solar thermal energy extraction can be achieved via con-
centrating solar power (CSP) plants [24], whereby the solar radiation is
typically concentrated to heat up a particular working fluid as heat
sink for heat source generation. A typical CSP facility comprises of two
parts, namely solar focusing device and solar receiver, whereby the
former serves to focus the solar irradiance towards the receiver, and
the latter enables the transfer of concentrated solar heat energy to the
heat transfer fluid (to be carried to the heat storage system or supplied
to the heat demands). The design and configuration of a CSP plant can
be classified based on the focus type and receiver mode.
The availability of solar energy for thermal energy extraction
varies in response to the geographically-dependent solar intensity
variation throughout the daily timeframe, and is found to be
relatively more abundant at midday (of a typical day) compared to
early morning and late afternoon [25]. This observation is attrib-
uted to the highest position of sun at the midday time range,

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as: as:
Liew
Liew
PY,PY,
et et
al. al.
Total
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SiteSite
Heat
Heat
Integration
Integration
planning
planning
andand
design
design
for for
industrial,
industrial,
urban
urban
andand
renewable
renewable
systems.
systems.
Renewable
Renewable andand
Sustainable
Sustainable Energy
Energy
Reviews
Reviews (2016),
(2016),http://dx.doi.org/10.1016/j.rser.2016.05.086i
http://dx.doi.org/10.1016/j.rser.2016.05.086i
4 P.Y.P.Y.
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leading to shortened path for solar radiation through the atmo-
sphere and subsequently minimising the loss of solar energy via
absorption as well as scattering [26]. For equatorial continents,
solar energy availability is independent of seasonal effect, but
highly influenced by the factors limiting the solar radiation
penetration to Earth surface, such as cloud coverage [27] and
weather pattern [28].
2.1.2. Geothermal energy
Geothermal energy is a form of heat generated and embedded in
the Earth's inner core [29]. It is often manifested in the form of geo-
thermal fluid (i.e. water in vapour, liquid, and mixed vapour-liquid
phases) at certain geographical depression, magmatic system, hot dry
rock (HDR) system, geopressured-geothermal system, and low-
enthalpy systems [30]. Geothermal energy is highly reliable without
resource supply intermittency [31], but its availability is geographically
limited to some regions around the Pacific Ocean with high volcanic
activities and vulnerability to earthquake occurrence, known as the
‘ring of fire’ (i.e. comprising of the United States, Canada, Italy, Japan,
Philippines, New Zealand, etc.) [32], as well as North Africa [33] and
some parts of America and Europe.
2.1.3. Biomass energy
Biomass could be another sustainable source of renewable thermal
energy, if properly managed. In general, the range of biomass
resources encompasses the agricultural and forestry residues, wood,
energy crops, biological residues, and municipal waste [34]. Certain
industries have large amounts of biomass as by-product, which could
be used as renewable thermal energy source for the plant, e.g. bagasse
from sugar cane processing plant [35] and empty fruit bunch (EFB)
from oil palm processing plant [36]. Currently, thermal energy could
be derived from biomass resource via thermo-chemical conversion
(i.e. combustion, pyrolysis and gasification) of the biomass residues as
well as biofuels (derived from biomass via biochemical conversion)
[34]. Some common primary biomass resources are constituted by
energy crops cultivated in agricultural lands, agricultural and forestry
residues, dedicated agricultural biomasses, food and organic wastes,
cattle manure, and municipal sewerage wastes [37], whereas the
biomass fuels comprise of biogas, biodiesel, bio-ethanol, and vegetable
oils [38].
2.1.4. Wind energy
Wind energy is generally harvested by wind turbines, which
convert the rotating kinetic energy to electrical energy [39]. There is
also research on converting the kinetic energy from wind energy to
thermal energy or heat through a heat generator [40]. This generator
are typically utilising the concept of friction between solid materials,
agitation of fluid or electromagnetic induction. A heat generation
using materials’ friction concept requires frequent maintenance, while
temperature of the heat generated from fluid agitation system is
restricted by the fluid characteristic. Therefore, electromagnetic sys-
tem has the highest potential to be used for converting kinetic energy
to thermal energy [40]. However, the wind thermal energy production
is not widely known compared to wind power generation.
2.2. Heat demand
Energy consumption by the urban and industrial sectors features
long-term (seasonal) and short-term (daily) variations. Long-term
variation could be caused by changes in the surrounding, such as
physical properties and outdoor properties [41], while short-term
variation may be caused by process disturbances.
Daily and seasonal heat load variations exist in the domestic, com-
mercial, institutional, and industrial sectors at different extents
depending on the types of activities involved [42]. In general, the
seasonal thermal load variation is attributed to the outdoor tem-
perature change over an annual timeframe especially for regions with
seasonal climatic variations [43]. The typical seasonal heat load profile
in a district heating system is as illustrated in Fig. 3, with low thermal
load requirement in summer season and high heat load requirement
in winter season. In the latter climatic scenario, the temperature dif-
ference between the outdoor ambient and building interior shall be
greater, therefore leading to higher thermal load in general.
For non-industrial applications, it has been observed that
domestic and commercial sectors involve consistent and periodic
daily heat load variation across a typical week, while the govern-
ment sector (i.e. public administrative buildings) have greater heat
load requirement during weekday period as compared to the
weekend period [42], as illustrated in Fig. 4–6. The observed
phenomenon is due to the periodic and homogeneous activity
patterns that span consistently throughout the week in domestic
and commercial sectors, since the daily lifestyle, consumption
pattern, and business activities would not undergo drastic changes
in weekday and weekend periods. However, in public institutional
sector, low activity level shall be expected during weekend period
since it coincides with the public holiday period.

Please
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citecite
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article
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as: as:
Liew
Liew
PY,PY,
et et
al. al.
Total
Total
SiteSite
Heat
Heat
Integration
Integration
planning
planning
andand
design
design
for for
industrial,
industrial,
urban
urban
andand
renewable
renewable
systems.
systems.
Renewable
Renewable andand
Sustainable
Sustainable Energy
Energy
Reviews
Reviews (2016),
(2016),http://dx.doi.org/10.1016/j.rser.2016.05.086i
http://dx.doi.org/10.1016/j.rser.2016.05.086i
5 P.Y.P.Y.
LiewLiew
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et /al.Renewable
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andand
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Fig. 3. Seasonal variation of heat load profile for a district heating system [43].

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citecite
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as: as:
Liew
Liew
PY,PY,
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Total
Total
SiteSite
Heat
Heat
Integration
Integration
planning
planning
andand
design
design
for for
industrial,
industrial,
urban
urban
andand
renewable
renewable
systems.
systems.
Renewable
Renewable andand
Sustainable
Sustainable Energy
Energy
Reviews
Reviews (2016),
(2016),http://dx.doi.org/10.1016/j.rser.2016.05.086i
http://dx.doi.org/10.1016/j.rser.2016.05.086i
6 P.Y.P.Y.
LiewLiew
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et /al.Renewable
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Fig. 4. Domestic heat load seasonal variation [42].

Fig. 5. Commercial sector heat load seasonal variation [42].

2.3. Heat energy storage
The variations on the supply and demand sides of energy sys-
tems (either due to renewable energy availability or batch process)
requires energy storage in order to smooth the energy transfer
between time variations and to store excess energy for utilisation
during energy deficit period. In the specific area of heat recovery
and utilisation heat storage is important. There are three major
types of heat energy storage system available in the market, which
are sensible energy storage [44], latent heat storage using Phase
Change Materials (PCM) [45] and thermo-chemical storage [46].
The energy density of the heat storage medium is one of the
main concerns in the storage technology selection. Energy density
is defined as the amount of energy stored in a constant volume or
mass of storage medium. In a fixed volume of material, high
energy density material is able to store more energy compared to
low energy density material. High energy density would lead to
space reduction for the storage system. Fig. 7 shows the energy
density comparison for different types of energy storage system
[47]. It is obvious that the energy density for thermo-chemical
storage is generally higher than physical energy storage systems.
Energy storage via heat of reaction is comparatively less spacious
among the storage methods [48]. In energy losses, physical heat
storage gradually loses its energy by heat conduction and radia-
tion. Thermo-chemical storage stored energy as reactants/pro-
ducts with small losses [49].
The technical performances and cost for different types storage
technology [50] are shown in Table 1. The thermo-chemical sto-
rage has high efficiency, low storage volume, low cost as compared
to PCM and sensible heat storage in theory. The sensible heat
storage is currently available commercially, while the PCM storage
is available for certain temperature and material. However,
thermo-chemical energy storage technologies are still in material
investigation and laboratory-scale experimental stage [51].
3. Total Site Heat Integration for industrial complexes
Heat Integration for individual processes has been a well-
established concept in industry. There are several books available
in the market, which compile the important concepts, methodol-
ogies and literature for Heat Integration primarily focused on
individual processes (e,g.: Kemp [52]). This section focuses on the
review of the existing methodologies for Total Site Heat Integra-
tion (TSHI) or Inter-Process Heat Integration through direct and
indirect heat transfer mechanisms.

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Fig. 6. Institutional sector heat load seasonal variation [42].

Fig. 7. Energy density comparison for different type of energy storage system [47].

TSHI analysis has been applied in different types of industrial Table 1

Thermal energy storage technology comparison [50].
processes for enhancing site energy efficiency, e.g., heavy chemical

complexes [53], industrial cluster [54], petro-chemical plant [55], Technology variants Sensible Ther- Phase Change Thermo-chemical
steel plants [56], large dairy factories [57] and bromine plant [58]. mal Storage Materials (PCM) Energy Storage

Chew et al. [59] studied the issues and challenges involving the Technical performance Typical current international values and ranges
industrial implementation of TSHI concept. The issues discussed in Energy Input/Output Solar, waste heat, variable renewable energy sources
that work are operations, design, regulatory and economic issues, (PV, wind), electricity/heat
Storage capacity 10–50 50–150 120–25
as well as reliability, availability and maintenance. Atkins et al. [60] (kWh/t) 0
reported the challenges of the integration of non-continuous Thermal power (MW) 0.001–10 0.001–1 0.01–1
processes (dairy processing industry in particular) using TSHI Cost (€/kWh)
Efficiency (%) 0.1–10
50–90 10–50
75–90 8–100
75–100
methodologies.
Typical capacity (MWe) 25 0.5 100

The methodology for exploring TS energy recovery opportu- Installed capacity 9–10 (all «1 18 (estimate)
nities can be divided into three types, which are Pinch Analysis (GWe) types)

Storage period scale d/mon–mon h/mon h/d

graphical and algebraic methodology, Mathematical Programming
approach and Hybrid Pinch and Mathematical Model methodol- Cost (USD 2008) Typical current international values and ranges
Investment cost ($/kW) 3,400–4,500 6,000–15,000 1,000–3,000
ogy. The review in this section comprises of all the three types of

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methodologies. This section focuses on the integration of pro- O&M cost–fixed & 120 250 20–60
variable ($/kW/y)
cesses located above the ambient temperature. Cooling require- Total production cost, 80–110 120–300 25–75
ment for processes below the ambient temperature is assumed to $/MWh

Economic lifetime(y) 20
be supplied by refrigeration systems.

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3.1. Heat Recovery Pinch Analysis and targeting
A simple plot of overlapping Grand Composite Curves for two
processes [19] is the first methodology used for exploring inter-
process energy recovery opportunities. The concept introduced is
considering direct heat transfer between process streams regard-
less the distance of the processes. The Heat Integration between
area of integrity is then proposed by Ahmad et al. [61]. Indirect
heat transfer is brought into the concept for recovering energy at
different areas or processes, with maximising the use of direct
heat transfers. The methodology uses matrix representation for
determining all possible integration between areas of integrity.
This method is then extended for considering minimum heat
recovery cost (capital and operating) between different processes
[62].
In the same time period, Dhole et al. [18] proposed a new
methodology for TSHI based on the common used graphical Pinch
Analysis tools in single-process Heat Integration. The Grand
Composite Curves for individual processes (Step 1, Fig. 8) are used
to construct Source Sink Composite Curves [19], which is later
known as Total Site Profiles – TSP (Step 2, Fig. 8) in the later
publications. These curves represent the energy availability at
different temperature level for all processes involved in the sys-
tem. In order to maximise the energy recovery within process
using direct heat transfer, all heat pockets are removed before the
GCC is used for constructing TSP. However, research done to
exploit the heat pockets [63] has shown that the heat pocket can
be useful in TS analysis under certain circumstances.
The Site Utility Composite Curves (SUCC) are used for targeting
the utility generation and consumption potentials based on energy
availability at different temperature ranges as shown in TSP (Step
3, Fig. 8). There are two parts of SUCC: Utility Generation and
Consumption Curve. The minimum heating and cooling require-
ment for the TS is determined by pinching the Utility Generation
Curve with the Utility Consumption Curve (Step 4, Fig. 8). The Site
Utility Grand Composite Curve (SUGCC) is plotted based on the
SCC for estimating the power generation potential through co-
generation in the TS steam system (Step 5, Fig. 8) [64]. These
primary methodologies have been applied to industrial complexes
[19], which have shown that the TS concept is capable of up to 30%
energy savings, 10% capital cost savings and about 30% emission
reduction. As a result, these methodologies become the main-
stream research direction for TSHI methodology afterwards.
In order to handle industrial- and community-size problems,
the use of graphical methodology without programmed software
can be complicated. Software for TS energy targeting is widely
available in the market, however, these software packages are very
costly. Liew et al. [65] introduced the analogous numerical cascade
methodology for targeting the energy requirement of TSHI. The
methodologies are designed for integrating multiple continuous
processes based on TSHI concept. Liew et al. [66] analysed the
effects of process operational changes and shutdown towards the
TS utility consumption using a novel numerical tool, Total Site
Sensitivity Table (TSST), for site utility system planning and design.
Batch Heat Integration is also a potential application of Total Site
concept. Chaturvedi et al. [67] proposed a methodology for max-
imising energy recovery of multiple batch processes by incorpor-
ating indirect heat medium or centralised utility system, which is
similar to TSHI concept application.

STEP 1: Individual Process Energy Targeting STEP 2: TS Energy Targeting

(Grand Composite Curve) (Total Site Profile)
T (°C)

T (°C)

T (°C)

Heat Source Curve

Process A Process B
ΔH (kW) ΔH (kW)
T (°C)

T (°C)

Heat Sink Curve

Heat
Pocket ΔH (kW)
Process C Process D
ΔH (kW) ΔH (kW)

STEP 2: TS Energy Targeting STEP 4: TS Energy Targeting STEP 5: Cogeneration

(Total Site Profile, Site Utility Composite Curves) (Site Utility Composite Curves) Targeting (Site Utility GCC)
T (°C)

T (°C)
T (°C)

VHPS Boiler
Load VHPS
HPS HPS HPS
Utility/Steam
Generation Curve
MPS MPS MPS
Cooling
tower load Area α Cogeneration
Utility/Steam ChW Potential

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Consumption Curver Load

LPS LPS
LPS

CW CW CW

ChW ChW ChW

ΔH (kW) ΔH (kW) ΔH (kW)

Fig. 8. Pinch Analysis targeting steps for TSHI [64].

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The TS-targeting methodologies had originally been developed graphical TS Pinch targeting methodologies in Matsuda et al. [53] for
assuming a global minimum temperature difference (ΔTmin). analysing the current condition of the utility system and determining
However, this assumption may lead to inaccurate targeting results
due to the imprecise value of ΔTmin between streams especially if
different processes are integrated. Varbanov et al. [68] revised
these methodologies and implemented a different individual
ΔTmin to recover the heat between processes (ΔTmin,pp) as well as
between a process and utility (ΔTmin,up). Fodor et al. [69] further
enhanced the methodology for incorporating the stream specific
ΔTmin, whereby individual ΔTmin is accounted in this methodology
for all different stream pairs. However, the stream specific ΔTmin is
difficult to be applied in a real case study.
Liew et al. [70] included the boiler feed water preheating, steam
superheating and condensate recovery in the cascade TS targeting
methodology. Sun et al. [71] proposed a graphical methodology for
the similar propose. There are some small differences between these
methodologies. The latter performed the utility generation targeting
for the Heat Source Profile, and the energy consumption for water
sensible heat is added as part of the load for Heat Sink Profile. The
former performed the utility generation and consumption targeting
for the Heat Source Profile and Heat Sink Profile individually, then the
water sensible heat is excluded from the targeted utility generation
curve. From the mathematical point of view, the two proposed
methodologies yield the same hot and cold utility requirements for
the TS system.
Efforts have been done to enhance the energy targeting results
towards the actual situation. The distance between processes is one of
the main issues, which has been neglected most of the time. Wang
et al. [72] examined effects of the distance between processes towards
the energy demands for inter-process Heat Integration using mathe-
matical programming methodology. In parallel, Liew et al. [73] con-
sidered the pressure drops and heat losses in the TSHI using algebraic
cascade analysis. Wang et al. [74] considered the trade-off between
heat recovery opportunity and distance related costs for ensuring the
cost-effectiveness of a TSHI project. TSHI considering minimum heat
transfer area for capital cost minimisation is proposed by Boldyryev
et al. [58]. Chew et al. [75] extended the TS targeting methodology for
incorporating the horizontal pressure drop in the steam network.
These developments produces the more realistic and practical tar-
geting results for an industrial process plant.
The current TSHI targeting methodologies are mainly focussing on
the steam system. Walmsley et al. [76] discussed the design of low
temperature heat recovery loop or hot water loop in inter-process
Heat Integration. Hot water loop in this study involves the determi-
nation of the starting and ending temperature for the sensible heating
and cooling in the loop, as well as the storage temperature. Hot oil
loop is a very common high temperature heat transfer medium in
industrial complexes. Ataei et al. [77] introduced the hot oil loop
design methodology for industrial processes. The work started with
examining the performance of the hot oil generator and the energy
transfer efficiency, and continued with the design or retrofit of hot oil
system.
A few studies have been done to discover heat recovery or retrofit
opportunities based on the existing heat exchanger network. Feng
et al. [78] introduced a guideline for defining the system boundary
and proposing retrofit strategies for TS process retrofitting in petro-
chemical plant. Plus-Minus Principle is a common process modifica-
tion guiding tool in Pinch Analysis and updated to handle TS situation
by Raissi [64]. This principle is important for guiding cost benefit
process modification in TS level. Chew et al. [79] explored the effects
of process modification for achieving better energy recovery oppor-
tunities in TSHI. Chew et al. [80] prioritised the process modification
options for modifying the shape of TSP to reduce the TS capital cost of
heat transfer units. R-curve concept is implemented together with the

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the maximum theoretical energy saving potential of the system, In particular, Zhang et al. [94] developed an LP-based mathema-
Energy saving options for the system are suggested based on the tical modelling framework for optimising the integration of hydrogen
results from R-curve and TSHI. Nemet et al. [81] introduced the Ret- network and utility system with the refinery processing. In this model,
rofit Tracing Grid Diagram to represent all streams and heat exchan- refinery process stream flow, hydrogen flow, steam flow, and power
gers according to temperature scale. This new tool could help in
visualising the current state of the Heat Exchanger Network.
Miah et al. [82] introduced a Heat Integration retrofit frame-
work that considers direct and indirect heat recovery from zonal
level to TS level. This framework accounted the practicality issues
in process retrofit, which are stream availability, geographical
location, and product quality. Liew et al. [55] included the Plus-
Minus Principle in a retrofit framework for ensuring individual
process and utility system retrofit packages can bring direct
energy savings in TS level. The framework also categorised a few
common TS retrofit strategies for kick-starting the retrofit analysis.
Song et al. [83] introduced a new inter-processes heat recovery
methodology for achieving the maximum heat recovery without
or with minimum changes in existing heat exchanger network.
Čuček et al. [84] reported a novel data acquisition methodology for
TSHI considering different operational conditions.
Total Site Heat Integration has been studied with industrial cases
for proofing the effectiveness of the methodologies. Industrial case
studies in major publications are summarised in Table 2.

3.2. Mathematical modelling

In this section, the mathematical models reviewed are gen-

erally categorised into two broad classes, i.e. (1) process and utility
system optimisation, and (2) utility system optimisation, whereby
the former shall require process stream operational conditions
whilst the latter needs the utility demand data.

3.2.1. Process-oriented Total Site Process Integration models

Pinch-based techniques for TSHI have been discussed in the
previous part of the review. Mathematical Programming meth-
odologies are important in this field for considering various issues
in a single model. Shang et al. [87] extended the transhipment
model [88] to represent a Total Site utility system model for steam
level optimisation. The model consists of three energy cascades,
which represent heat sources, heat sinks and steam levels. The
most beneficial steam levels condition is selected through the
optimisation model. Fig. 9 illustrates the transhipment model
developed for representing the heat flow between process heat
sources and sinks via steam headers.
Similarly, Papoulias et al. [89] introduced an integrated mixed
integer linear programming (MILP) model for optimising the total
processing site. This model comprises MILP models accounting for
chemical processes and utility system, as well as linear programming
(LP) transhipment model for heat recovery network design. For even
better process integration, heat integration between heat exchange
network (HEN) and steam distribution network (SDN) was enabled by
the integrated SDN-HEN model introduced by Chen et al. [90]. Being
the combination of SDN model and HEN model [91], this SDN-HEN
model aims to minimise the total annualised cost of optimised total
processing site. The economic benefits and overall processing site
energy efficiency improvement through TSHI between HEN and SDN
were demonstrated by Chen et al. [92] using specific chemical plant-
based case studies. There are also models developed for integrating
the utility system and major processes in specific industries. Goh et al.
[93] modelled the Automated Targeting Methodology (ATM) by NLP
model for simultaneous design of HEN and planning of utility system
to minimise the total operating cost of the utility system.

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Table 2
Highlights of industrial case studies on Total Site Heat Integration using Pinch Analysis.

Industry Descriptions Highlights

Refinery Lindsey Oil Refinery comprises 26 process units [19]. Total potential energy saving opportunities up to 12.4%
Hellenic Aspropyrgos Refinery produces about 6 million tons of petroleum products [19]. Total potential energy saving opportunities up to 28%
Leuna Hydrocracking Plant [19]. Energy savings reached up to 6 MW; Electric power
surplus of 2.2 MW
An Aromatic hydrocarbon plant with hydrocracking, aromatic hydrocarbon extraction, and Hot utility saving potentials up to 44.5 MW (61.1%)
isomerisation unit [78].
An aniline plant with four process units, which includes nitrobenzene unit, aniline unit, Total energy saving potential up to 2.6 MW (76.2%)
natural gas unit and waste acid treatment [78].

A petrochemical plant in Malaysia with 11 process units and cogeneration system [55]. Hot utility savings up to 29.7 MW (28%); Cooling utility
saving potential up to 2.1 MW (23%)
Paper and Pulp A tissue paper mill with pulp preparation lines, waste paper line and two paper machines Energy savings potentials up to 7.15 MW (24.5%)
[19].
Dairy A large dairy factory with multiple milk powder plants, Anhydrous Milk Fat (AMF), cream An average heat recovery up to 5.88 MW.
products, cheese and casein production lines [60]. This industrial problem involves non-
continuous processes.
Steel A large steel production plant with four process lines integrate with an adjacent thermal Annual energy savings up to 24.4 106 GJ
power plant, which receives by-product of steel plant and produce heat and electricity for
the steel plant [56].
Industrial Cluster A chemical industrial cluster comprises six plants, which includes surfactants, polyolefin, Hot utility saving up to 129 MW (42%)
amines and others. These chemical plants operate by five different companies [85].
Kashima Industrial Area in Japan has been studied in the paper. This heavy chemical Annual energy savings up to 9 105 GJ
industrial area consists of 31 processing sites, including petrochemical complexes, refi-
neries and power plant [53].
Map Ta Phut Industrial area, Thailand covers 15 chemical plants, including refineries, Energy saving potential up to 29%
chemical, gas separation and utility company [86].
Temperature (°C)

HP
Heat Source Cascade

Heat Sink Cascade

MP

LP

Enthalpy (kW)

Fig. 9. Total Site heat energy flows representation between processes and steam headers in a transhipment model [87].

flow were simultaneously optimised for achieving holistic total site optimisation design. For better long-term operational and mainten-
process integration in refinery plant. Li et al. [95] attempted to opti- ance scheduling of production plants and utility system in a chemical
mally couple the utility plant with chemical and refinery processes in production complex, Cheung et al. [96] proposed a multi-period MILP
petrochemical industry via multi-period MILP mathematical model site model with consideration of impacts of inventory capacity,
formulation. Steam, fuel gas, and electric power consumption bal-
ances were considered for petrochemical plant material and energy
integrations with temporal utility demand variation. Various opera-
tional scenarios were simulated to produce a comprehensive total-site

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electricity contract fee, as well as supply and demand of intermediate

materials.
In another mathematical modelling study, Moita et al. [97] inte-
grated the cogeneration system with salt recrystallisation process
using dynamic modelling approach with consideration of multiple
operational scenarios as well as sensitivity analysis of atmospheric
condition variation on the performance of process integration.
Meanwhile, Zhang et al. [98] designed an improved multi-period MILP
model for the more efficient integration of utility plant with proces-
sing facilities in a refinery complex. Seasonal variation in the energy
demands of process units attributed to throughput fluctuations as
well as operational mode changes was considered in reformulation of
process unit energy consumption balances, while MILP model was

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incorporated for more accurate optimisation of utility plant. Another
multi-period MILP model was also developed by Micheletto et al. [99]
for utility system integration in oil refinery plant. This model was
designed not only to minimise the utility cost, but also to enable
identification of energy dissipations from steam generation plant as
well as inefficient unit operations in the oil refinery operation.
Alternatively, Stijepovic et al. [100] suggested a systematic TS
methodology considering waste heat quality and energy reuse
possibilities, as well as distance across different individual pro-
cessing plants. An optimisation model is then used to determine
the optimum inter-processes energy recovery system. Zhang et al.
[101] also formulated a coupling MINLP mathematical framework
for integration of process plants and utility systems. The optimi-
sation framework constitutes individual process plant Heat Inte-
gration, optimisation of utility system, and total site steam inte-
gration. Nemet et al. [102] considered the economics in their
proposed mathematical programming model for designing cost
effective Heat Exchanger Network for the Total Site utility system.
The heat exchange amongst process, steam generation and utili-
sation are considered simultaneously in the programming. Nemet
et al. [103] extended the model for considering the predicted
utility prices, which enhance the accuracy of the trade-off between
lifetime operating and capital cost for synthesising TS utility
network. Nemet et al. [104] further work introduced the MINLP
model with additional safety consideration during TS HEN synth-
esis. A risk factor is assigned to the potential heat transfer matches
for trading-off between safety and economic benefit of a heat
recovery option. Farhat et al. [105] worked on another MILP model,
which incorporates TSHI and exergy analysis in a single model for
energy and exergy conservation in a multi-process plant. The
analysis simultaneously considered the heat transfer and energy
conversion system for higher energy and exergy recovery in the
processing sites.
In addition, Zhang et al. [106] proposed a multi-period MINLP
model for integrating the mass and energy balances between func-
tional unit operations and utility plants in total refinery site, con-
sidering the optimal production planning, targeting of minimum
energy requirement (MER), optimal operational schedule of utility
plants, and total site mass balances for utility system. Zhao et al. [107]
found that decomposing the standard MINLP model into separate
MILP and NLP models for individual optimisation of refinery pro-
duction system and utility system actually improved solution quality
and algorithm efficiency. Indirect inter-plant Heat Integration using
intermediate hot water circles, which would help to increase the
overall efficiency of TSHI for plants far away from each other, was also
optimised by mathematical modelling approach. In the latest work,

Table 3
Summary of mathematical models for process-oriented Total Site Heat Integration.

Optimisation Algorithm Key Feature/s or Strength/s Reference

Linear Programming (LP) Simultaneous optimisation of process stream flow, hydrogen flow, steam flow, and power flow for Zhang et al. [94]
holistic Total Site Process Integration in refinery plant

Mixed-integer Linear Programming MILP model for optimisation of process plant and utility system; LP model for optimisation of Heat Papoulias et al. [89]
(MILP) Exchange Network.
Simultaneous optimisation of Heat Exchanger Network and energy conversion system for minimising Farhat et al. [105]
the energy and exergy consumption in the site.

Mixed-integer Non-linear Programming
(MINLP)
Enabled better Heat Integration between steam distribution network (SDN) and HEN; Combined LP- Chen et al. [90]
based SDN and MINLP-based HEN model; Aimed to minimise the total annual cost of total processing
site
Improved economics and energy efficiency through TSHI between SDN and HEN for chemical plant- Chen et al. [92]
based total processing site
Simultaneous process-to-process and process-to-intermediate utility system Heat Integrations, with Nemet et al. [102]
financial consideration; Investigated sequential and simultaneous approaches, whereby the latter
resulted in more economical design
Considered predicted utility prices; Enabled more accurate trade-off between capital and operational Nemet et al. [103]
expenditures for total site utility network synthesis
Considered pumping power, pipeline investment, and heat loss in optimising total site hot water Chang et al. [108]
circuit

Coupling MINLP
Non-linear Programming (NLP)
MILP and Non-linear Programming (NLP)
Multi-period MILP
Multi-period MILP Multi-period MINLP
Considered safety factor for heat recovery options Nemet et al. [104]
Comprised of individual plant Heat Integration, optimisation of utility system, and total site steam
integration
Optimisation on HEN and utility system for minimising total utility cost; Included the operating cost
of trigeneration system
Decomposition of standard MINLP problem into MILP and NLP sub-problems; Improved solution
quality and solver efficiency
Inclusion of boiler hardware model (BHM) and turbine hardware model (THM); Consideration of
multiple scenarios
Petrochemical plant process and Heat Integrations under uncertainties due to temporal fluctuations
in utility demand
Assisted long-term operational and maintenance scheduling of production units and utility system in
chemical production complex; Considered impacts of inventory capacity, electricity contract fee, as
well as supply and demand of intermediate materials
MILP formulation increased accuracy of optimisation analysis; Considered temporal changes in
energy demand, process throughput, and operational mode

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y cost of oil refinery plant; Enabled identification of mechanisms for energy loss as well as inefficient Zhang et al. [101]
equipment
Simultaneous optimisation of production planning, energy requirement, utility plant operational Goh et al. [93]
schedule, and utility system process balances for refinery plant
Zhao et al. [107]

Shang et al. [109]

Li et al. [95]

Cheung et al. [96]

Zhang et al. [98]

Micheletto et al. [99]

Zhang et al. [106]

Multi-period/Dynamic Programming Considered multiple operational scenarios; Moita et al. [97]
Investigated the impact of atmospheric condition changes on the performance of process
integration

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Chang et al. [108] had developed MINLP model for indirect TSHI model was developed to result in optimal site utility system design for
through hot water loop with minimum total annual cost, considering Mitsubishi Yokkaichi chemical plant [121].
key factors such as pipeline investment, pumping cost, and heat loss.
Detailed comparison of mathematical models for coupled process and
utility system TSHI is as summarised in Table 3.

3.2.2. Utility system-oriented Total Site Heat Integration models

Extensive research has been done for optimising the utility
system between processes, aimed at enhancing the inter-process
energy recovery efficiency. These models typically have not con-
sidered process-level energy targeting. Steam headers model with
pressure let-down station or steam turbine models are very
important in such optimisation framework.
For facilitating more a comprehensive component-wise opti-
misation of steam network system design, Petroulas et al. [110]
proposed an optimisation framework comprising of two (2) sub-
problems. The first sub-problem utilised dynamic modelling to
optimise the number of steam headers and their pressure levels
for minimising the power dissipation, while the latter was for-
mulated as a LP model for driver selection at minimal utility
requirement [110]. The shortcomings of this model include the
exclusion of gas turbine model as well as irrational design deci-
sions from LP formulation. As a countermeasure, Papoulias et al.
[111] designed an MILP model to perform structural and para-
metric optimisation for synthesising utility network serving
invariant steam, mechanical power, and electricity loads, with
consideration of gas turbine in utility system design. In order to
cater for more realistic plant operational scenarios, Papoulias et al.
[112] extended the previous work into multi-period MILP model to
optimise the synthesis of flexible utility system capable of fulfilling
these process loads with temporal variations at minimal invest-
ment requirement. In this model, the cost objective function was
modelled as a piecewise linear function. The model was further
improved by Iyer et al. [113] considering operational cost as well as
changeover cost for shut-down or start-up operations in cost
function. Apart from that, the MILP problem was simplified via
coupling with shortest path algorithm. In the subsequent work of
Iyer et al. [114], the complexity of the MILP model was resolved
with introduction of bi-level decomposition algorithm to reduce
the number of binary variables involved. Besides, a new approach
was introduced by Kim et al. [115] to decompose the multi-period
planning problem of utility system into NLP sub-problem catering
for optimisation of utility system configuration and dynamic pro-
gramming sub-problem for minimising the operational expendi-
ture and switching cost. This actually led to more reliable and
accurate optimal solution within shorter computational period.
On another part of this field, Kalitventzeff [116] proposed a mixed-
integer non-linear programming (MINLP) model for utility system
management. Similarly, Papalexandri et al. [117] had introduced a
multi-period MINLP model for steam generation network optimisa-
tion with accounting of process uncertainties via data reconciliation
technique. However, the models above had neglected the substantial
seasonal fluctuations in the energy prices (due to variations in energy
supply and demand) as well as monthly operational schedule varia-
tions. For resolving this shortcoming, Cai et al. [118] had developed a
fuzzy-random interval programming (FRIP) model for enabling flex-
ible operational planning of regional energy management system
(EMS) under various uncertainties. Hui et al. [119] had considered the
temporal variations in the boiler and turbine operations, power
export, and gas fuel consumption in their developed multi-period
mixed integer programming (MIP)-based utility system model. The LP
site model had been applied to enhance the economics and overall
efficiency of utility system owned by Kashima-Kita Electric Power
Corporation (KKEPC) [120], while multi-period/multi-scenario site

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Maia et al. [122] applied simulated annealing (SA) model to opti- was investigated as well [133]. The concept was further improved to
mise the utility system configuration subjected to different seasonal Top-Level Analysis by Varbanov et al. [134], which is a robust opti-
input utility and output power demands, while modular approach for misation for providing energy saving strategies and proposing
industrial utility system synthesis was introduced by Falcetta et al.
[123] with consideration of configurational, parametric, and topolo-
gical optimisations. Marechal et al. [124] had formulated a multi-
period MILP utility system model with different sub-systems char-
acterised by various utility requirements and representative time
frames (in an annual period) to represent time-varying operating
conditions of utility system due to variations in chemical plant pro-
duction level, equipment operation schedule, market conditions, and
energy prices. The sub-system definition was conducted with genetic
algorithm (GA) technique. The multi-period MILP model is able to
optimise operational problems, including different operational sce-
narios, site conditions, process utility demands and current site per-
formance. This proposed methodology also handles the utility system
design for grassroots and retrofit problem.
Non-linear programming (NLP) model was later introduced to
synthesise optimal configuration of utility system with high level of
integration with chemical processes based on the temperature inter-
val (TI) concept and Rankine cycle superstructure [125]. This model
somehow did not consider the optimisation of steam turbine con-
figuration and excluded electrical motor from mechanical driver
option, and therefore was not sufficient to meet the actual industrial
design requirements. This had prompted Bruno et al. [126] to develop
a more comprehensive MINLP model with non-linear rigorous per-
formance equations, utility system configurational optimisation, as
well as determination of optimal operational conditions.
Transhipment model has been another main mathematical
modelling-based approach for utility system optimisation. The
development of such model commenced when Cerda et al. [127]
applied LP-based transportation model to optimally allocate utility
resources to heat exchange network (HEN). This LP transhipment
model was extended by Swaney [128] with incorporation of heat
engines, heat pumps, heat rejection sources, and power utilities.
However, this model class neglected the impacts of load-dependent
efficiency and capacity limitation of turbines. In order to include these
constraints in utility system optimisation, a lot of researches on utility
system hardware or equipment modelling, e.g. turbines and boilers,
have been conducted hand-in-hand with the utility system optimi-
sation research. Mavromatis et al. [129] proposed a THM for esti-
mating the turbine power generation based on Willian's line concept
for targeting the shaft-work and steam level selection to maximise
cogeneration opportunities. The model incorporated various turbine
efficiencies at different turbine size, load and operating condition.
Shang [130] contributed to development of gas turbine and boiler
models. Later, Shang et al. [109] incorporated THM and boiler hard-
ware model (BHM) in their newly developed MILP model for steam
level optimisation of total site utility system. For simultaneous con-
sideration of interaction between turbine and steam level, as well as
minimisation of steam flowrate, a MINLP model was introduced by
Beangstrom et al. [131] for synthesis of steam generation system with
hot liquid reuse.
For better modelling result, the steam and gas turbine models
were improved by Varbanov et al. [132] using a correlation between
the power output and the difference between inlet and outlet
saturation temperatures. Moreover, a successive MILP (SMILP) fra-
mework was developed in this work to overcome the partial optim-
ality trap of MINLP formulation in utility system optimisation [132].
Sun et al. [133] introduced a new steam turbine model, which con-
siders complex multi-stage turbines for designing, optimising and
retrofitting site utility system. The influence of structural and opera-
tional parameters of steam turbine on its performance and efficiency

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modifications in site utility system. The SMILP model introduced in sideration of economic, environmental, and exergetic aspects
[132], comprising steam turbine, gas turbine, and boiler models, has using multi-objective MILP (MOMILP) model, with flexibility for
been utilised for obtaining marginal price curves for utility system
steam headers, aiding in the targeting the potential profitability of
process heat recovery projects. As an improvement, Shamsi et al. [135]
introduced the exergy costing methodology as design constraints in
their transhipment and MINLP models for utility system optimisation
for minimising the TS energy cost due to exergy decomposition.
The cogeneration potential for Total Site utility system, which
has gained very much attention for recovery energy from pro-
cesses, is another crucial part of utility system optimisation. The
Site Utility Grand Composite Curve (SUGCC) is one of the pioneer
targeting tools for utility system's cogeneration potential estima-
tion using graphical methodology [136]. A new thermodynamic
model was proposed by Sorin et al. [137] based on the Rankine
cycle concept. The modified SUGCC proposed is able to target fuel
consumption, cooling demand and shaft-work. The targeted result
is represented in the special segment of the modified SUGCC.
However, the work proposed is based on the ideal shaft work of a
cogeneration system. Medina-Flores et al. [138] introduced a new
model based on the Turbine Hardware Model (THM) for targeting
the power exhaust of a single- and multi-extraction back pressure
steam turbine. The algorithm represented the turbine perfor-
mance with a single weighted average efficiency. Khoshgoftar
Manesh et al. [139] proposed an algorithm for estimating accurate
cogeneration potentials and total annualised cost. The paper also
extended the SUGCC methodology for simultaneous representa-
tion of total annualised cost and total annualised sale of product in
the tools. Apart from that, Mohan et al. [140] developed an alge-
braic cogeneration potential targeting approach based on the
concept of extractable power [141]. Bandyopadhyay et al. [142]
proposed a simplified cogeneration estimation methodology based
on Salisbury [143]. They represented the cogeneration potential in
an enthalpy-flow rate diagram. Kapil et al. [144] presented another
estimation algorithm, which is developed based on isentropic
expansion. An Iterative Bottom-to-Top Model (IBTM) [145] is
presented for targeting the cogeneration potential in site utility
system, which estimates the appropriate degree of superheat for
steam generators and boiler house. A new targeting methodology
for estimating the cogeneration opportunities has been proposed
for mathematical programming methodology [146].
There were also research works devoted to incorporate sus-
tainability, efficiency and reliability to the modelling approach for
utility system optimisation. In particular, the MINLP multi-
objective model proposed by Martinez et al. [147] optimised the
utility system at minimum operational expenditure and life cycle
environmental impacts. Francisco et al. [148] extended the multi-
period MILP model of Iyer et al. [113] with incorporation of
objective function to minimise the fuel combustion-induced pol-
lutant emission. In a more recent work, Luo et al. [149] formulated
a non-linear mathematical model for optimising utility system
comprising of multiple extractions steam turbines, wherein the
complex turbine system was decomposed into an array of simple
turbines operating in series. A more complicated multi-period
steam power system (SPS) model was implemented using particle
swarm optimisation (PSO) approach with simultaneous con-
sideration of equipment depreciation, changeover costs, and
environmental costs in geographical context of China [150]. Luo
et al. [151] devised the multi-period MILP model for optimisation
of multiple interlinked steam power plants (SPP) with concurrent
minimisation of environmental cost and environmental impact,
while that of Luo et al. [152] catered for the reliability aspect by
considering the utility equipment failures. Later, Luo et al. [153]
optimised the utility system design with simultaneous con-

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cogeneration technology selection. In similar fashion, the MILP posed to efficiently handle the non-convex feasible operational
model proposed by Sun et al. [154] was intended to synthesise region of cogeneration unit [165]. The introduction of real coded
optimal steam and power system design with minimum penalty genetic algorithm (RCGA) with enhanced mulenbein mutation,
and compensation costs attributed to equipment failures as well as
fluctuations in steam and power demands. Another reliability-
based utility system optimisation research conducted by Liu et al.
[155] incorporated probabilistic approach to simulate the uncer-
tainties associated with boiler system failure as well as steam and
power demand fluctuations.
Besides synthesis of steam network system, there were also
researches directed to formulating models for retrofitting existing
steam utility plants. Chen et al. [156] developed a MINLP model for
retrofitting steam power plants in steel mill for Heat Integration of
synthesis gas stream resulted from the coke processing unit
operation (i.e. for steam generation). The MINLP total site steam
system model was also applied for retrofitting SDN in petroleum
refinery [157]. This work was further extended by Chen et al. [158]
with incorporation of industrial symbiosis concept, by applying
MINLP model for process integration of steam utility systems
operated by different plants in an industrial sector via appropriate
retrofitting designs.
A major branch of such equation-oriented (EO) approach for
integrated steam and cooling utility system has been found to be
Sequential Quadratic Programming (SQP). SQP development was
pioneered by Morton et al. [159], resulting in a set of fundamental
equations for realistic simulation of process balances and perfor-
mances for combined heat and power (CHP) system. This approach
was extended by Rodriguez-Toral et al. [160] to optimise the
design of combined cycle cogeneration plant (CCCP) with minimal
investment requirement. However, the improved version had
greater complexity and was more computationally intensive, and
had to be solved using the flexible modelling system (FMS). In
addition, Rodriguez-Toral et al. [161] further improved SQP-based
model above with inclusion of thermodynamic equations to more
precisely describe the physical states of water/steam and air pro-
cess streams involved, and applied the improved SQP model for
utility system optimisation.
However, in the SQP models above, the CHP plant utility system
was optimised without holistic consideration of cooling water
network, and therefore may not yield the global optimal design. As
a countermeasure, Ndlovu et al. [162] formulated a NLP model for
integrated utility system of steam power plant comprising of
individual Rankine cycle and cooling tower models. With non-
linear formulations of mass and energy balances as well as ther-
modynamic performances, this new model combined the two (2)
sub-models above by minimising the heat dissipated from the
cooling tower to the atmosphere per unit power generation.
Enhanced integration of boiler and cooling tower models was
achieved in the improved version introduced by Ndlovu et al.
[163], with objective function of maximising the profit from utility
system operation.
Besides the main Process Integration mathematical models
above, there have also been numerous analogous mathematical
modelling studies focusing on the combined heat and power
economic dispatch (CHPED) problem. In this field, the objective is
to minimise the total fuel cost required for combined heat and
power (CHP) utility operation with fulfilment of power and ther-
mal energy demands. These models shall be reviewed as follows.
Lagrangian relaxation with surrogate subgradient multiplier
updates was introduced by Sashirekha et al. [164] as simple and
flexible solution for cogeneration facility design optimisation.
Benders decomposition approach, on the other hand, was pro-

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allowed the valve point effects and transmission losses to also be extended by Majozi et al. [181] to sustain the boiler efficiency. In
considered in the CHPED problem solving [166]. this study, it was discovered that optimisation could be achieved
Beigvand et al. [167] attempted to optimise the power gen-
eration and dispatch scheduling using different meta-heuristic
approaches i.e. gravitational search algorithm (GSA), genetic
algorithm (GA), harmony search (HS), classic particle swarm
optimisation (CPSO), economic dispatch harmony search (EDHS)
and time varying acceleration coefficients particle swarm optimi-
sation (TVAC-PSO). In this work, GSA was found to be the best
solving algorithm resulting in the minimal operational cost of USD
9,913. In another study, Jena et al. [168] found that differential
evolution with Gaussian mutation (DEGM) performed better than
differential evolution (DE) scheme for achieving global optimality
and enhancing search efficiency. In addition, Basu [169] applied
non-dominated sorting genetic algorithm - II (NSGA-II) for solving
CHPED with fuel constraints.
More recently, non-linear fractional programming approach
was applied to optimise the thermal dispatch system with simul-
taneous minimisation of total fuel cost and emissions [170]. Grey
wolf optimisation, which is simpler and involves fewer para-
meters, was applied for dynamic economic dispatch, static eco-
nomic dispatch and environmental-economic dispatch with better
solution quality and consistency [171]. Power dispatch optimisa-
tion was conducted by Bilil et al. [172] for energy system inte-
grated with renewable energy resources. A LIES comprising of
district heating and cooling units (DHCs) and wind power gen-
eration was optimised by Zheng et al. [173] using multi-objective
optimisation algorithm. Cuckoo search algorithm was another
effective approach for CHPED optimisation with shorter compu-
tational time [174], and its performance could be further enhanced
with incorporation of penalty function [175]. On the other hand,
crisscross optimisation algorithm was proposed for optimisation of
large power system [176].
The Process Integration-based mathematical models reviewed
in this section are summarised in Table 4. The advanced mathe-
matical models had resulted in satisfactory retrofitted design with
significant cost savings (based on the industrial case studies), and
the optimisation outcomes are summarised in Table 5.

3.3. Hybrid Pinch and mathematical modelling

Pinch Analysis methodology and Mathematical Programming

models have their own privileges in solving Heat Integration
problem. There are several methodologies that have been pro-
posed for inter-process Heat Integration, which combined Pinch
Analysis methodology and Mathematical Programming models.
The combined Pinch Analysis and Mathematical Programming
workflow proposed is a three-step approach, which considers
retrofit within process as well as inter-process energy recovery
system. Pinch Analysis is used for analysing the site-wide waste
heat availability, while MINLP model is built based on tranship-
ment model for retrofit options selection.
Shang et al. [179] proposed a five-stage combined approach for
optimising TS utility system. Pinch-based TSHI methodology [19]
is used for targeting the energy integration opportunity. A multi-
period MILP model is then constructed for optimising utility sys-
tem with steam turbine system, gas turbine network, steam reheat
cycle, and boiler systems. In addition, Coetzee et al. [180] had
developed a methodology that applied graphical approach for
steam flow rate targeting and LP mathematical model for opti-
mising the steam network layout, besides proposing another MILP
model for simultaneously implementing steam flowrate targeting
as well as steam network layout optimisation. This hybrid meth-
odology intended for steam flowrate minimisation was then

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without degrading the boiler efficiency via preheating of boiler Varbanov and Klemeš [190] used the analogy of batch pro-
feed water (BFW) using superheated steam or dedicated pre- cesses Heat Integration: In late 1980s, Obeng et al. [187] applied
heater facility. Further improvement on this method was later the conventional Pinch Analysis targeting methodology for
achieved by Price et al. [182] to reformulate the HEN layout with
incorporation of turbines operating at various steam pressure
levels. Incorporation of turbine background processes in the HEN
design via this improvised methodology had enabled reutilisation
of exhaust gas from high-pressure turbines for BFW preheating,
improving the overall process efficiency.
Realising that retrofitting of steam system network would
induce significant pressure drop and therefore power consump-
tion, Price et al. [183] included the critical path algorithm in the
previous hybrid method for minimising the pressure drop of steam
system network at the minimum steam flowrate (being optimised
using the previously introduced formulations). Luo et al. [184]
brought in the novelty by introducing improved version of hybrid
methodology that would enable the heat integration of process
surplus heat (PSH) and regenerative Rankine cycle (RRC). This
hybrid methodology somehow restricted the integration of RRC
after process-to-process Heat Integration for deferment of possible
design complications. In another hybrid methodology introduced
by Prashant et al. [185], MILP model had been incorporated to
optimise the steam pressure and number of steam levels for ful-
filling total site utility requirement after extracting data of design
targets from SUGCC and shaft-work targeting model. The hybrid
approach was further extended by Rad et al. [186] with incor-
poration of multi-objective optimisation model which was solved
by genetic algorithm (GA) to optimise the objective functions
associated with availability, reliability, and economic aspect.
Chang et al. [187] introduced a two-step targeting methodology
for targeting the inter-plant Heat Integration using the concept of
heat recovery loop. Graphical approach is used for targeting the
minimum energy requirement of the system, while a MINLP model
is used for minimising the total annual cost considering additional
heat exchangers, pumps and pipelines for long distance due to the
system architecture in heat recovery loop concept. Bungener et al.
[188] introduced a methodology for handling multi-period pro-
blem in TSHI, which includes an algorithm for period selection in
data preparation step. The methodology is proven to simplify an
annual data to 20 typical periods, which fits to the production
profiles. The existing TS Pinch targeting methodology is then used
to determine the supply and demand in the utility system for the
periods identified.

4. Total Site Heat Integration for Locally Integrated Energy

Sectors

The industrial TS system is extended to include renewable

energy supply, as well as energy demand of service and residential
buildings. Such integrated system was known as Locally Integrated
Energy Sectors (LIES) in Perry et al. [21]. Several efforts have been
done for extending the TS Pinch targeting methodology to cope
with the new TS concept with incorporation of the variable energy
availability issues in LIES. This section reviews the developments
of the energy integration design and planning tools for integrating
industrial clusters with urban facilities and renewable energy
resources.
The concept is extended for targeting TS system with variable
energy supply and demand in Varbanov et al. [189]. In this work,
they have defined the Total Site Heat Cascade (Fig. 10) as the tool
for evaluating the heat recovery targets for time varying demand
and supply of energy.

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3

Table 4
Summary of mathematical models for utility system-oriented Total Site Heat Integration.

Optimisation Algorithm Description Reference

Dynamic Programming and Linear Pro- Dynamic programming optimises the header selection to minimise the exergy loss; LP model Petroulas et al. [110]
gramming (LP) optimises the driver allocation design to minimise the steam and electric power requirements

Simulated Annealing (SA) Accounted for the seasonal variations in input utility and output power demands Maia et al. [122]
Modular Approach Enabled simultaneous configurational, parametric, and economic optimisation of utility system Falcetta et al. [123]
Linear Programming (LP) Improved the overall efficiency and economic performance of power plant utility system with Hirata et al. [120]
tolerance of relaxed accuracy and precision requirements

Mixed Integer Linear Programming (MILP)
Extended to include heat engines, heat pumps, heat rejection sources, and power utilities Swaney [128]
Concurrent configurational and parametric optimisation of utility system; Linearisation of model Papoulias et al. [111]
via introduction of piecewise linear cost function; Inclusion of gas turbine in utility system design
Incorporated turbine hardware model (THM) and boiler hardware model (BHM) for more rea- Shang et al. [109]
listic optimisation analysis
Optimised the steam and power system with minimum compensation and penalty costs asso- Sun et al. [154]
ciated with equipment breakdown and utility demand uncertainties
Optimised boiler system design with stochastic programming approach, i.e. Markov probabilistic Liu et al. [155]
approach for equipment failure and normal distribution for steam demand uncertainty

Successive MILP (SMILP)
Non-linear Programming (NLP)
Improved steam and gas turbine models; Achieved global optimality of optimisation solution Varbanov et al. [132]
Simplified analysis approach using Top-Level Analysis, with scrutiny on the utility demand data Varbanov et al. [134]
from centralised utility facility (CUF)
Based on temperature interval (TI) concept, and formulated from Rankine cycle superstructure; Colmenares et al. [125]
Achieved high level of integration with chemical processes

Devised for optimisation of utility system with multiple extractions steam turbines Luo et al. [149]
Optimised the steam power plant utility system by coupling individual boiler and cooling tower Ndlovu et al. [162]
models via minimisation of heat loss from cooling tower per unit power generation
Enabled integrated optimisation of boiler and cooling tower systems, with maximisation of profit Ndlovu et al. [163]
derived from utility system operation

Mixed Integer Non-linear Programming Enabled control strategy formulation for utility system management via sensitivity analysis Kalitventzeff [116]

(MINLP) More realistic industrial utility system design requirement with consideration of steam turbine Bruno et al. [126]
configurational optimisation as well as inclusion of electrical motor in mechanical driver option
Incorporated hot liquid reuse in the synthesis of optimal steam generation system with con- Beangstrom et al. [131]
sideration of interaction between turbine and steam level

Combined with transshipment model; Intended to minimise the cost associated with exergy loss Shamsi et al. [177]

Retrofitted the power plant of steel mill; Chen et al. [156]

Enabled Heat Integration of synthesis gas from coke processing plant
Enabled efficient retrofit of power plant in petroleum refinery site Chen et al. [157]
Conceptualised the benefits of industrial symbiosis by inter-plant steam integration Chen et al. [158]
Fuzzy-random Interval Programming Enabled flexible operational planning of regional energy management system considering sea- Cai et al. [118]
(FRIP) sonal variations in the energy prices as well as monthly disturbances in operational schedule

Sequential Quadratic Programming
Realistic simulation of process balances and thermodynamic performances of steam and power Morton et al. [159]
system
Extended to consider the optimisation of combined cycle cogeneration plant (CCCP) with greater Rodriguez-Toral et al. [160]
complex computational framework
Incorporated more detailed thermodynamic descriptions of physical states of water/ air process Rodriguez-Toral et al. [161]
streams

Multi-objective MILP (MOMILP)
Multi-objective MINLP (MOMINLP)
Multi-objective Steam Power System (SPS)
Allowed selection of environmentally friendly cogeneration technologies; Luo et al. [153]
Optimisation of utility system with concurrent consideration of economic, environmental and
exergy aspects
Considered simultaneous minimisation of operational cost and life cycle environmental impacts Martinez et al. [147]
Particle swarm optimisation (PSO) approach of steam generation system design with simulta- Dai et al. [150]
neous consideration of equipment depreciation, changeover cost, and environmental cost

Multi-period LP Flexible utility system optimisation for chemical plant under multiple scenarios Hirata et al. [121]
Multi-period MILP Flexible to fulfil the requirements of process utilities (i.e. steam, deaerated water, cooling water,
and electricity) with consideration of temporal fluctuations in their demands, with the objective
of minimising the financial investment requirement
Inclusion of operational expenditure and changeover cost in cost function; Simplified by coupling
with shortest path algorithm
Incorporated bi-level decomposition algorithm for reduction of binary variables involved;
Applicable for design problems involving more unit operations in the utility plant
Considered uncertainties induced by variations in boiler and turbine operations, gas fuel con-
sumption, and power demand with respect to time

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4

presentation of utility plant operational condition changes with genetic algorithm Papoulias et al. [112]
(GA)-derived subsystems characterised by different utility requirements and representative
periods
Iyer et al. [113]

Iyer et al. [114]

Hui et al. [119]

Marechal et al. [124]

Considered reliability issue due to utility system equipment failure Luo et al. [152]
Multi-period MINLP Consideration of process uncertainties in steam generation network optimisation via data Papalexandri et al. [117]
reconciliation technique

Multi-period NLP and Dynamic NLP and dynamic programming for separate optimisation of utility system configuration, as well Kim et al. [115]
Programming as operational cost and switching cost; Improvement of solution quality and computational time
requirement

Multi-period MOMILP Incorporated the objective of minimising the pollutant emission attributed to fuel combustion Francisco et al. [148]
Concurrently minimised the environmental cost and environmental impacts for optimisation of Luo et al. [151]
multiple interconnected power plants

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integrating batch processes using Time Average Model (TAM) and examined the appropriate condition for making the integration of
Time Slice Model (TSM). The methodology was then extended in district heating and industrial complexes feasible._.
Kemp et al. [188], which introduced a time-dependent energy
cascade analysis. The paper also presented the detailed thermo-
dynamic capability of hot and cold streams in heat exchanging
between batch processes. The work was continued in Kemp et al.
[189], which applied the cascade analysis for heat exchanger net-
work design. The TSM was then used for handling TSHI with
variable energy availability issue, which included the integration
of batch processes, renewable energy supply and urban energy
consumption as proposed by Perry et al. [20].
The energy requirement targeting methodology is conducted
according to Time Slices (TSLs) identified. Energy surpluses in
earlier time intervals are stored in TES for the usage at later time
intervals. Total Site Heat Cascade was proposed in the same pub-
lication for representing the energy flows between processes,
steam headers and TES (Fig. 10). The cascade is drawn based on
temperature for specific types of utility and time intervals. The
figure shows the possible options for energy cascading. Some of
the flows in Fig. 10 would be eliminated after the quantitative
energy analysis is being done.
Nemet et al. [190] proposed a mathematical optimisation frame-
work for determining the TSLs of a TS system with variable supply and
demand problem. In this framework, the candidates of TSLs for vari-
able energy sources and demands are identified separately. The TSLs
determined for sources and demands are merged to be combined
TSLs. The model is able to minimise the inaccuracy of the energy
availability approximation. The integration of solar thermal energy
supply with TS system was presented in this work. Walmsley et al.
[191] examined the use of energy storage system for integrating solar
thermal energy with industrial batch processes. The paper suggested
the targeting and designing algorithm for TS energy recovery network
with constant temperature storage (CTS) and variable temperature
storage (VTS). VTS control was suggested to be more promising in
energy conservations.
Liew et al. [192] proposed a systematic cascade analysis algo-
rithm, Total Site Heat Storage Cascade (TS-HSC), for TS energy
targeting incorporating short-term energy availability variations.
Liew et al. [193] extended the algorithm, Seasonal TS-HSC, con-
sidering seasonal or periodic energy variations. This series of
methodology considers possibility of energy recovery between TES
system at different energy levels. Thermo-chemical energy storage
system was assumed to be used in the TS system in these papers.
The charging and discharging efficiencies were taken into con-
sideration in the study. Baniassadi et al. [194] used R-curve to
evaluate the effects of the integration of renewable energy
towards the TS utility system. The paper also introduced an effi-
ciency improvement factor for representing the contribution of
the integration of renewable energy in combined heat and power
system. Kostevšek et al. [195] introduced a framework for
enhancing the renewable energy utilisation in municipal energy
network through the implementation of LIES concept.
District heating is one of the most popular approaches for
integrating multi-processes industry with urban system for uti-
lising the industrial waste heat for hot water generation [196].
Kapil et al. [197] introduced a framework for evaluating the cost-
benefit of utilisation of industrial waste heat by integrating district
heating. Graphical TS targeting tool is extended for analysing the
thermodynamic feasibility of the integration and optimisation
models are used to determining the financial profitability margin
for this type of system. Morandin et al. [198] reported the feasi-
bility study for recovering industrial waste heat from Swedish
petrochemical cluster to be used for district heating. The work

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Hackl et al. [199] introduced a framework to target the energy advancement of new technology could drive the price down, due
system of an industrial complex for fuel switching from fossil fuels to widen acceptance of current technology. So the timing of
towards renewable energy feedstock using a series of Heat Inte- implementation could actually determine the feasibility of project.
gration tools. The methodology models or targets the existing
energy distribution situation in an industrial cluster and identifies
a suitable biorefinery concept to be integrated to the existing TS
system for enhancing the heat recovery and reducing the fossil
fuel consumption.
Oh et al. [200] proposed a multi-period methodology for designing
LIES system, together with techno-economic analysis. However, this
methodology was slightly different from the previous mentioned
methodologies in the sense that this work treated the local energy
system or non-industrial sector as a separate system from the
industrial processes. Energy recovery within industrial sites is first
optimised using heat storage system. The energy demand from local
energy system is then matched with the low grade heat excess from
industrial sites.
Integrating industrial, urban and renewable energy in LIES is still a
rather new concept. Researches are still focusing on developing tar-
geting and designing methodologies based on literature case study.
However, this concept has been examined using real case study by
several researchers, as listed in Table 6. Promising results are pro-
duced through the methodologies proposed in different researches.

5. Discussion

The research progress for Total Site Heat Integration on industrial

processes, as well as integrating urban and renewable energy systems
with industrial complexes has received in last few years a consider-
able attention. The scope of the methodology has been substantially
extended towards the solution of real-life problems.
The methods of Process Integration and Process Optimisation
have spread wide as can be seen from the overview by Friedler
[202] as well as the more methodological overviews [1] focused on
the historical development of Process Integration as a family of
methodologies. There are some directions that need additional
attention from the researchers in this field.

5.1. Factors for integrating industrial clusters, urban with renewable

energy

Sustainability aspects such as economic, system reliability, and

environmental impact need further examination to integrate the
renewable energy system into thermal energy system of industrial
clusters and urban.

5.1.1. Economic
For designing such integrated renewable energy system, the
key determinant is the economic feasibility of the project. The
economic feasibility of such renewable energy system is heavily
influenced by the fossil fuel prices, as high fossil fuel prices will
always motivate the company to implement a renewable energy
based thermal energy system to reduce the utility cost. Never-
theless, it would be quite a challenge to determine the future fossil
fuel cost, as the fuel cost is much dependent on the global political
outlook. In the case of biomass systems, there is an additional risk
factor on the volatility of regional biomass price, subject to the
demand of local community. To address this issue, the company is
advised to secure the biomass supply through long term contract
to lock in the price.
Within the system cost itself, the capital expenses of technol-
ogy cost are the key costing component for project feasibility. The

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Please cite this article as: Liew PY, et al. Total Site Heat Integration planning and design for industrial, urban and renewable systems.

Table 5
Summary of mathematical modelling optimisation outcomes.

Plant Description Model Optimisation outcomes Reference

Crude Oil South China; MILP model Product portfolio variation based on the temporal demand; Flexible Zhang and Hua [112]
Refinery equipment maintenance scheduling based on the temporal-varying load
demands
China; Refinery complex comprised of eight process units MINLP model Greater profit achieved with simultaneous total site material and energy Zhang et al. [119]
stream optimisation

United States; Refinery plant of 200,000 barrels per stream day MILP model 37.4% reduction of fuel cost, and 41% improvement of total annual profit Papoulias and Gross-
mann [125]

P.Y. Liew et al. / Renewable and Sustainable Energy Reviews ∎ (∎∎∎∎) ∎∎∎–∎∎∎
Sao Paulo, Brazil; RECAP refinery plant with boilers, vessels and MILP model For scenario of constant utility demand, 10% cost reduction achieved; For Micheletto et al. [113]
pump units scenarios involving temporal varying demands, an average of 3–5% cost
savings achieved

Chemical Plant United States; Methanol plant comprising of synthesis gas MINLP model 35% steam recovery achieved form recommended retrofit Bruno et al. [139]
production unit, crude methanol production unit and methanol
purification unit
Japan; Mizushima site with three boilers and five steam MILP model Optimal operational and maintenance schedules determined for boiler Hui and Natori [132]
turbines and turbine facilities; Found that integration of turbine with boiler was
only favourable above certain investment level
South Africa; Petrochemical plant with seven process streams MINLP model 28.6% reduction in total steam flowrate Beangstrom and Majozi
to be retrofitted [144]
Taiwan; Steel mill with two steam power plants, each con- MINLP model 67.5% reduction in the total annual cost Chen and Lin [170]
sisting of four steam headers
Taiwan; Steel mill (with two steam power plants) and oil MINLP model Achieved total annual cost savings up to USD 50 M/y Chen and Chen [172]
refinery plant (with three boilers)
China; Juijiang Petrochemical Complex comprising of fertiliser MILP model 46% reduction of total annual cost (as compared to base case) Li et al. [109]
factory, refinery and utility plant

Utility System Comprised of heat recovery steam generator, two steam boilers, MILP model 14% savings for total annual operational cost; Varbanov et al. [145]
six steam turbines and two direct drive steam turbines Improved efficiency of power and heat generation
Steam production facility comprising of two furnaces, steam MINLP model Preliminary utility system optimisation: 17.5% savings achieved; Multi- Papalexandri et al. [130]
headers, degassing section and turbopump section period optimisation: 17.35% savings in midweek operational cost, and
gained profit about 65.7% of the current cost from weekend operation
Utility network comprising of two boilers (up to 100 t/h) and MILP model Configuration involving turbines operating in parallel was found to be the Iyer and Grossmann
three turbines (up to 13 MW) most economical; 5% savings in the annual operational cost achieved [126]
Total site utility system involving four main steam levels and MINLP model coupled with Specific Energy cost saving up to 8% Shamsi et al. [149]
nine demanding facilities (1–40 MW) Exergy Costing (SEPCO) approach
Taiwan; Utility system consisting of boiler and back-pressure Steam distribution network (SDN) Five process streams integrated with optimal temperature range of 188.5– Chen and Lin [104]
steam turbines model 388.7 °C for low to high pressure steam headers; Minimal total annual
cost achieved at USD 16.07 M/y
United Kingdom; Utility system (base case) involving three MINLP model Total annual cost optimised to be about USD 82 -84 M/y (for three sce- Chen et al. [178]
boilers and eight steam turbines narios considered)
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To have a better representation of costing model, stochastic 5.1.3. Environmental impact

modelling may need to be incorporated to investigate the financial
feasibility of the project.
5.1.2. System reliability or stability
Preventive reliability, availability and maintenance (RAM) should
be the paramount focus of the plant [203]. There are three key
components in the utility systems to be addressed, i.e., supply of
renewable energy resources, generation of thermal energy and heat
demand. In terms of energy supply, one would need to consider the
intermittency of energy resources in the design stage [204]. On the
demand site, the designer would need to consider the variation in
process heat demand, especially for processes with a sudden peak
requirement in thermal energy. This issue can be addressed by
incorporating a hybrid energy system with non-intermittent energy
resources or energy storage.
In terms of reliability of utilities system, one would need to con-
sider the life cycle performance of the key unit operation such as
boiler and heat exchanger, instead of focusing on the up front capital
cost only, to minimise the impact of equipment breakdown on the
production system. Also, a proper optimised maintenance schedule on
centralised utility system will assist the company to minimise the
overall cost of maintenance and losses due to production failure. This
can be done by studying the impact of performance deterioration of
individual component to the entire system. For example, in the case of
heat exchanger, by understanding the impact of fouling to the heat
efficiency of heat exchanger, one can analyse the trade-off between
maintenance cost due to maintenance and additional utility cost due
to fouling. With this, the maintenance engineer would be able to
make an informed decision to schedule the maintenance period.
Lastly, the operational flexibility of utility system shall be improved
through continued introduction of reliability-related objective i.e.
minimising the compensation and penalty costs induced by utility
demand and operational uncertainties.
Fig. 10. Total Site Heat Cascade with TSLs [189].
Environmental impact is another key aspect to be considered
during the design stage. This impact could be assessed through
different tools for footprint analysis [205]. Renewable energy is
generally claimed as clean energy, but from the life-cycle per-
spective, different renewable energy resources will generate dif-
ferent life-cycle carbon footprint [206]. The utilisation of renew-
able energy sources should be properly planned, especially bio-
mass resources, which cause other environmental issues in the
transition period [15]. Combustion-dependent renewable energy
such as biomass and biogas will generate higher fugitive emis-
sions, as compared to combustion-independent renewable energy,
such as solar energy.
5.2. Methodology development for integrating industrial, urban and
renewable energy systems
The development of the integration of industrial clusters, urban
and renewable energy has been reviewed in the previous part of
the paper. The research gaps and future research directions on the
methodology development are provided in this sub-section.
5.2.1. Research gaps and future research directions for industrial
TSHI
There are two types of objective for performing Process Integration
analysis, which are grassroots and retrofit study. Grassroots project are
based on the design data of the processes, while retrofit study should
reflect the current operating conditions of the industrial processes.
The data input for retrofit study is the most important basis of
the work. A set representable data for the processes streams
should be selected for the study from the dynamic operational
data, which reflect the current operating behaviour corresponding
to process changes. In fact, there are a lot of literatures on data
reconciliation with complex calculations [207]. Simplified data
reconciliation tools should be researched for the use in Process
Integration study for enhancing the accuracy of the basis of
the study.
Power generation optimisation and maximisation from process
waste heat is one of the main focuses in TSHI targeting meth-
odologies. However, the power consumption from the processes
has not been properly discussed for matching with the power
generated. Efficient power consumptions guarantee the energy
recovered from the steam system is worth for the investment on
power generation facilities. Simultaneous TS Heat and Power
Integration could be one the potential future works in Process
Integration.
The graphical and numerical TS Pinch approach has been
developed by several groups of researcher around the world. The
plant layout issues [74] have been discussed in several publica-
tions recently. However, there is a need for further development,
which extends the consideration of the pressure drops [75] and
heat losses [73] due to the horizontal movements of the utility or
steam headers. Vertical movement of liquid utilities needs to be
incorporated in the TS targeting procedures. The energy

Table 6
Highlights of industrial case studies for Locally Integrated Energy Systems.

Industry Descriptions Highlights

LIES A site utility (cogeneration) system integrates with a 13 MW solar power plant at Spain [194].Fuel saving up to 53 MW depending on the operating
condition.
A Swedish petrochemical cluster integrates with a neighbouring district heating system [198]. Potential fuel saving for heating up to 50%.
Solar thermal collector integrates with a dairy factory, which consists of four milk powder Potential hot utility reduction of 13.6 MW
plants and four other dairy processes [201].

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Integration of a biorefinery to a chemical processing cluster in Sweden [199]. Energy recovery up to 44.5 MW; Additional 343 MW of
recoverable heat excess.

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consumption in this movement should be accounted for the utility still not resolved, i.e. with absence of insights and logical justifi-
cost of a system. cations for the optimisation outputs. Therefore, hybrid model
The TS Pinch targeting techniques so far has not incorporated
the safety and sustainability or environmental indices in the
analysis. Inherent Safety were started to be considered in HEN
design methodology by Chan et al. [208] and extended to TS level
using mathematical modelling approach in Nemet et al. [104]. This
interdisciplinary study is able to enhance the reliability of the HEN
design in practice. In addition to safety aspect, sustainability and
other environmental factors [205] could be incorporated in the
analysis as the additional feature to the TS targeting tool for
engendering a more environmentally friendly total site utility
system design (as a way to fulfil corporate social responsibility).
Heat recovery targeting for hot water [76] and hot oil loop [77]
should be further explored for the optimal loop design with proper
arrangement of heating by process heat sources and cooling by
process heat sinks. The hot water loop serves as the heat transfer
medium for heat recovery at below 100 °C and above ambient
temperature, while the hot oil loop recovers very high tempera-
ture waste heat. Heat recovery in the loops is done through the
sensible heating and cooling of the heat transfer medium.
For utility system-based total site heat integration mathema-
tical models, it could be found that various model types (i.e. Linear
Programming, Mixed Integer Linear Programming, Mixed Integer
Non-Linear Programming, Non-Linear Programming, Sequential
Quadratic Programming, Simulated Annealing models, thermo-
dynamic models, and dynamic programming) had been explored.
These models were extended to include multiple objectives for
consideration of environmental sustainability and reliability
aspects. Moreover, multi-period versions of these models were
also introduced to investigate the impacts of temporal changes in
utility demands and utility system operational schedules.
For mathematical modelling approach for process-oriented
total site heat integration design, existing multi-period models
being developed were restricted to multi-period MILP and MINLP
categories, and not much multi-objective process-oriented models
had been reported in the literature. This reflected that the utility
system-based TSHI model development had been first intensively
worked out and therefore the research outcomes were more
established, with a huge number of key factors, frameworks, and
algorithms being verified and demonstrated for a wide variety of
industrial applications. The process-oriented TSHI model devel-
opment was extension of the former, and therefore there would be
a huge gap for development of multi-period models with multiple
objectives. Moreover, as compared to Power Pinch, the mathe-
matical modelling approach development for TSHI had been found
to be akin to the tip of an iceberg, in the sense that more math-
ematical algorithms i.e. particle swarm optimisation (PSO), artifi-
cial bee algorithm, ant colony algorithm, and other advanced
artificial intelligence algorithms were still overlooked. The incor-
poration of these alternative algorithms might help to achieve
global optimality of TS utility system design with lower
computational time.
It has been observed that some researchers attempted to lin-
earise the standard MINLP model into MILP version via substitu-
tion of conventional non-linear cost function with approximate
piecewise linear alternative. This would actually avoid the sub-
optimality trap induced by MINLP model. Besides, there was also
approach that decomposed the MINLP model into individual MILP
and NLP models to be optimised sequentially in an iterative
scheme for improving the quality of solution. Model simplification
was also accomplished through coupling with the shortest path
algorithm and bi-level decomposition approach. However, the
main weakness of the mathematical modelling approaches was

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approach shall be prioritised in the future work for more mean- heat storage system and non-industrial sectors are not being
ingful optimisation method development. considered in this work. The similar works on the integration of
The mathematical models could get frequently more compli- batch processes also could be extended for the integration of
cated with the requirement of realistic problem formulation is
another reason for the merit of hybrid model approach. If the
mathematical model were to be applied by itself, the design aspect
involving selection of utility system superstructure based on
demand variation/ operational condition fluctuation, with impacts
of varying loads on the unit efficiency, would significantly increase
the complexity and computational intensity of mathematical
model. Therefore, some researchers preferred to use hybrid model
approach, in which the energy targeting is done graphically using
Pinch Analysis for thermodynamic optimisation, while the other
factors are handled in mathematical modelling approach. This
approach kept the beauty of the Pinch Analysis to provide the
graphical insights, while remaining the strength of the mathe-
matical optimisation for handling various factors or constraints at
the same time. This Process Integration framework could be fur-
ther developed to be the future trend in this field of study.

5.2.2. Research gaps and future research directions in TSHI for

industry, urban and renewable energy systems
The integration of industrial complex with urban and renew-
able energy system is a relatively new area of research in Process
Integration using Pinch Analysis or Mathematical Models. It is
obvious that there is a huge gap in the targeting and design
methodologies for LIES system.
One of the future works in this area should focus on the data
preparation for handling the variability of the energy availability
for urban and renewable energy system. The integration of
renewable energy in process integration could be solved by
dynamic models with dynamic optimisation or multi-period
models assisted by a series of steady state model for all time
intervals within the period of interest [190]. The steady state
multi-period models for handling industrial processes are widely
available in literature. Therefore, there is a need for developing the
methodology for identifying the representable smaller time
intervals for the dedicated timeframe. Nemet et al. [190] devel-
oped a methodology for identifying the time slices for daily or
short timeframe, while Bungener et al. [188] reported an improved
methodology to select period within a yearly or longer timeframe.
More research could be done in this field for ensuring the accuracy
of the selection to cope different situations in plant. The Pinch
Analysis and mathematical modelling discussed in this review
paper is then able to be extended using the concept of multi-
period models across the scoped timeframe.
The Process Integration techniques development should
explore more in-deep insights on the limitation for renewable
energy, heat generation and collection technologies. The TS multi-
period Pinch targeting techniques [189] based on Time Slices
concept have been a very general methodology to incorporate
variable energy supply and demand problems. Site scale targeting
model for multi-period Process Integration was proposed by
Marechal et al. [209], while Shang et al. [87] introduced a trans-
hipment model to identify the optimum steam levels considering
multiple operating scenario of a site utility system. These multi-
period models could be extended to account for the urban and
renewable energy availability trends and further embed more
determination factors to the models. Chaturvedi et al. [67] intro-
duced a methodology for targeting the energy consumptions and
designing Heat Exchanger Network for batch processes. Similar to
Total Site Heat Integration, the proposed methodology is reco-
vering heat through direct and indirect heat transfer. However,

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[1] Klemeš JJ, Kravanja Z. Forty years of Heat Integration: Pinch Analysis (PA) and
urban and renewable energy system into industrial clusters energy
Mathematical Programming (MP). Curr Opin Chem Eng 2013;2:461–74.
system.

6. Conclusion

There is still a strong need for closely integrating the industrial,

urban, and renewable energy systems as an approach for improving
the regional energy efficiency and sustainability of energy sector. The
review underlined the impacts of intermittent availability patterns
and geographical constraints of renewable heat energy resources,
technical constraints of existing thermal storage technologies and
thermal conversion technologies, as well as temporal varying and
uncertain thermal load characteristics of urban and industrial systems
on the design of optimal TSHI network (with optimised heat transfer
mechanisms between the processes and utility systems). All these
uncertainties would have imposed design issues to TSHI analysis and
optimisation, yet overlooked by the conventional industrial TSHI
methodologies. Therefore, from the review, the paper identified the
need for continuous development on the new class of TSHI approa-
ches tailored made for industrial, urban and renewable energy system
integration, and reaffirmed the above statement via scrutinising on
the sustainability aspects of such development (i.e. economic, system
reliability and stability, and environmental significances). In identify-
ing the research gap, this paper recommended the development of a
simplified data reconciliation method for more appropriate usage of
highly uncertain supply and demand data, simultaneous total site heat
and Power Pinch Analysis, more comprehensive consideration of
thermal losses associated with actual process design aspects, inclusion
of more comprehensive artificial intelligence algorithms for mathe-
matical model improvement, more focus on hybrid mathematical
approach development, as well as coverage of hot oil and hot water
loops in the design of utility system for greater energy efficiency. For
TSHI for integrated industrial, urban and renewable energy systems or
LIES systems, there is the need to develop methods for selection of
representative time frame (for optimisation), consideration of non-
industrial sectors and industrial batch processes, and inclusion of
thermal storage system in the design framework.
Other important research directions related to the discussed area
can bring synergy in reducing environmental impact while saving
primary energy resources. Varbanov [210] emphasised that a key
resource closely related to energy is water, whose implications for
industry can be profound. Therefore, an important direction for future
work is to investigate the opportunities for site-wide industrial water
savings. The work by Jia et al. [211] provided a good step in this
direction. Process intensification, which typically addresses the
inherent process energy and resource demands, also has a critical role
to play in contributing towards system-wide resource and emission
minimisation. A good, recent example in this direction is the work by
Pleşu et al. on biodiesel process intensification [212].
Another important issue, stemming from the need to integrate
wider residential and commercial areas with industry, is the spa-
tial development. In this regard the P-graph framework has proven
as a very effective tool. Since its inception in 1992 by Friedler et al.
[213], it has also been successfully applied in combination with
targeting to the spatial development for biomass resource utili-
sation by Lam et al. [214]. More recently, a combination of the
spatial, process and temporal dimensions of the process network
optimisation have been successfully addressed by Tan et al. [215].

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