Site expansions or changes in production capacities are usually related with changes of utilities demands and/or utility system design. Despite several available and well established techniques for process synthesis and integration, very often, changes in process designs are made on the basis of intuition and experiences of engineers. In this paper possibilities of rational energy consumption and energy integration in an existing site for production of specialty chemicals were studied. On the basis of real process parameters and computer simulation results energy integration was re-examined. Total site analysis using modified Site Sink Source Profiles, which gives a profound insight into the site utility system configuration, heating-cooling demands and cogeneration design was performed. The existing site was found to be very well designed. With only few modifications additional 9% of hot utilities and 5% of cold utilities savings are possible. (c) 2005 Elsevier B.V. All rights reserved.