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Pressure drop is an important consideration in Total Site Heat Integration (TSHI).This is due to the typically large distances between the different plants and the flow across plant elevations and equipment, including heat exchangers. Failure to consider pressure drop during utility targeting and heat exchanger network (HEN) synthesis may, at best, lead to optimistic energy targets, and at worst, an inoperable system if the pumps or compressors cannot overcome the actual pressure drop. Most studies have addressed the pressure drop factor in terms of pumping cost, forbidden matches or allowable pressure drop constraints in the optimisation of HEN. This study looks at the implication of pressure drop in the context of a Total Site. The graphical Pinch-based TSHI methodology is extended to consider the pressure drop factor during the minimum energy requirement (MER) targeting stage. The improved methodology provides a more realistic estimation of the MER targets and valuable insights for the implementation of the TSHI design. In the case study, when pressure drop in the steam distribution networks is considered, the heating and cooling duties increase by 14.5% and 4.5%. OPEN ACCESSEnergies 2015, 8 1115

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Upstream oil production using dual string completion, i.e., two tubing inside a well casing, is common due to its cost advantage. High pressure gas is employed to lift the oil to the surface when there is insufficient reservoir energy to overcome the liquids static head in the tubing. However, gas lifting for this type of completion can be complicated. This is due to the operating condition where total gas is injected into the common annulus and then allowed to be distributed among the two strings without any surface control. High uncertainties often result from the methods used to determine the split factor—the ratio between the gas lift rate to one string over the total gas injected. A hybrid model which combined three platforms: the Visual Basics for Application programme, PROSPER (a nodal analysis tool) and Excel spreadsheet, is proposed for the estimation of the split factor. The model takes into consideration two important parameters, i.e., the lift gas pressure gradient along the annulus and the multiphase pressure drop inside the tubing to estimate the gas lift rate to the individual string and subsequently the split factor. The proposed model is able to predict the split factor to within 2% to 7% accuracy from the field measured data. Accurate knowledge of the amount of gas injected into each string leads to a more efficient use of lift gas, improving the energy efficiency of the oil productions facilities and contributing toward the sustainability of fossil fuel.