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In this paper we report on further success of our work to develop a multi-method energy optimization which works with a digital twin concept. The twin concept serves to replicate production processes of different kinds of production companies, including complex energy systems and test market interactions to then use them for model predictive optimizing. The presented work finally reports about the performed flexibility assessment leading to a flexibility audit with a list of measures and the impact of energy optimizations made related to interactions with the local power grid i.e., the exchange node of the low voltage distribution grid. The analysis and continuous exploration of flexibilities as well as the exchange with energy markets require a “guide” leading to continuous optimization with a further tool like the Flexibility Survey and Control Panel helping decision-making processes on the day-ahead horizon for real production plants or the investment planning to improve machinery, staff schedules and production
infrastructure.
The conversion of space heating for private households to climate-neutral energy sources is an essential component of the energy transition, as this sector as of 2018 was responsible for 9.4 % of Germany’s carbon dioxide emissions. In addition to reducing demand through better insulation, the use of heat pumps fed with electricity from renewable energy sources, such as on-site photovoltaics (PV) systems, is an important solution approach.
Advanced energy management and control can help to make optimal use of such heating systems. Optimal here can e.g. refer to maximizing self-consumption of self-generated PV power, extended component lifetime or a grid-friendly behavior that avoids load peaks. A powerful method for this is model predictive control (MPC), which calculates optimal schedules for the controllable influence variables based on models of the system dynamics, current measurements of system states and predictions of future external influence parameters.
In this paper, we will discuss three different use cases that show how artificial intelligence can contribute to the realization of such an MPC-based energy management and control system. This will be done using the example of a real inhabited single family home that has provided the necessary data for this purpose and where the methods are implemented and tested. The heating system consists of an air-water heat pump with direct condensation, a thermal stratified storage tank, a pellet burner and a heating rod and provides both heating and hot water. The house generates a significant portion of its electricity needs through a rooftop PV system.
One of the major challenges impeding the energy transition is the intermittency of solar and wind electricity generation due to their dependency on weather changes. The demand-side energy flexibility contributes considerably to mitigate the energy supply/demand imbalances resulting from external influences such as the weather. As one of the largest electricity consumers, the industrial enterprises present a high demand-side flexibility potential from their production processes and on-site energy assets. In this direction, methods are needed with a focus on enabling the energy flexibility and ensure an active participation of such enterprises in the electricity markets especially with variable prices of electricity. This paper presents a generic model library for an industrial enterprise implemented with optimal control for energy flexibility purposes. The components in the model library represent the typical technical units of an industrial enterprise on material, media, and energy flow levels with their operative constraints. A case study of a plastic manufacturing plant using the generic model library is also presented, in which the results of two simulation with different electricity prices are compared and the behavior of the model can be assessed. The results show that the model provides an optimal scheduling of the manufacturing system according to the variations in the electricity prices, and ensures an optimal control for utilities and energy systems needed for the production.
The twin concept is increasingly used for optimization tasks in the context of Industry 4.0 and digitization. The twin concept can also help small and medium-sized enterprises (SME) to exploit their energy flexibility potential and to achieve added value by appropriate energy marketing. At the same time, this use of flexibility helps to realize a climate-neutral energy supply with high shares of renewable energies. The digital twin reflects real production, power flows and market influences as a computer model, which makes it possible to simulate and optimize on-site interventions and interactions with the energy market without disturbing the real production processes. This paper describes the development of a generic model library that maps flexibility-relevant components and processes of SME, thus simplifying the creation of a digital twin. The paper also includes the development of an experimental twin consisting of SME hardware components and a PLC-based SCADA system. The experimental twin provides a laboratory environment in which the digital twin can be tested, further developed and demonstrated on a laboratory scale. Concrete implementations of such a digital twin and experimental twin are described as examples.