Steam system network synthesis with hot liquid reuse: II. Incorporating shaft work and optimum steam levels

•Comprehensive analysis of a system comprising HEN, boiler, and power block.•Holistic treatment of these units allows for an optimum design.•Novel MINLP model to synthesize HEN and design the power block.•Hot liquid reuse in HEN to yield minimum steam flowrate.•In a case study, the model produced a 28.6% reduction in steam flowrate. In this first of a series of two papers, the effects of varying steam levels on the total steam flowrate are analyzed mathematically for the traditional parallel configuration as well as for the case of hot liquid reuse. It is demonstrated that in the case of parallel heat exchangers utilizing only latent heat, a minimum total steam flowrate is obtained by optimally selecting steam levels, but that in the case of hot liquid reuse, introducing multiple steam levels increases the minimum total steam flowrate attainable under those conditions. The flowrate attained utilizing hot liquid reuse, however, remains lower than when only utilizing latent heat. It is concluded that the lowest steam flowrate is attained using hot liquid reuse and only a single level of steam, but that the presence of additional steam levels resulting from turbines requires a more holistic approach to the synthesis of steam networks.