This work addresses the internal
and Total Site Water Network design
with water mains. A Material Recovery Pinch Diagram is used for freshwater
targeting and a Water Integration Network design with a water main
framework, and a mathematical model is formulated for total cost optimization.
The Pinch-based method can target an optimum number of water mains,
flow rates, and concentrations in the water mains, which can achieve
the identified freshwater target. The proposed method can be used
for both single and multiple contaminants and applied on both process
and total site scales. Two case studies are used to illustrate the
application procedure of the proposed method for single- and multiple-contaminant
cases. The case study results showed that the optimum number of water
mains is three in both single-contaminant and multiple-contaminant
Total Site Water Network designs (excluding freshwater and wastewater
mains). In the single-contaminant case, the water network of internal
integration with three water mains can achieve a total annual cost
reduction of 82% compared to direct Water Integration and a total
annual cost of 42% in the multiple-contaminant case. The proposed
method is beneficial as it provides a graphical interface for the
water main targeting and design, and the mathematical optimization
enables the selection of optimum options with a minimum cost. To pursue
a more accurate design, water piping cost based on real plant locations
should be incorporated in future studies.