Optimisation model for integration of cooling and heating systems in large industrial plants

Large industrial plants have often hundreds of heating and cooling heat exchangers. A common situation is that cooling demands of the processes are satisfied without any deeper analysis of the overall impact of the cooling systems on the plant’s economy or the environment. If cooling water is available it is used as much as needed and then pumped back to the river, some degrees warmer. An optimisation model was developed for integration of cooling and heating systems to tackle the problem. An industrial cooling system is a complex energy system comprising different options of producing cooling, distribution pipelines for cold media and cooling storages. Integration of power generation and heating systems to the cooling systems was included in the model. An illustrative example is presented in the paper. 10 process streams with cooling demand and 10 streams with heating demand were chosen, situated at different locations at the plant site. The optimal matches between the streams were found together with the sizes of the heat exchangers and the demands of hot and cold utilities. The costs of pipelines and the pumping costs of the streams are included in the model. The model can be used in the design of greenfield and retrofit investments and in versatile what-if analyses of the plant design or operation.