Novel Methodology for Cogeneration Targeting with Optimum Steam Level Placement

This study aims to develop a novel method to synthesise site-wide heat recovery, distribution, cogeneration systems with optimum operating conditions of the steam mains. Previous approaches have simplified the problem to the extent that many important practical issues have been neglected and restricted the scope of the options included. The proposed methodology uses a combination of total site analysis and mathematical programming for a holistic approach to the steam system, which accounts for interactions between site utility system and processes. The optimisation problem involves the selection of more realistic operating conditions of the steam mains (superheating and pressure). The model will also account for water preheating, and superheating and desuperheating for process steam generation and use. Deaerators and let-down stations are also included in the analysis. The application of this methodology to a case study yielded a 7.6 % reduction in total energy requirement, compared to conventional utility system design method. The proposed approach addresses severe shortcomings in previous research on this topic and provides a foundation for future work to explore the next generation of sustainable utility systems.