Simulation-based Optimization of Flexible Energy Systems in Manufacturing with Local Energy Production and Storage Components

Abstract

This paper introduces a simulation-based planning method that metaheuristically optimizes production planning and the control of components of a flexible energy system for energy intensive production. Significantly increasing energy efficiency and energy flexibility are key requirements and success factors, especially for energy-intensive manufacturers, amid rising energy prices, volatility, and the overall need to reduce the energy and pollution footprint. The considerable potential for an optimized integrated planning and control of production and energy system components remains unexhausted, due to the underlying planning complexity, combined with a lack of available planning methods. This paper aims to introduce a novel planning approach that provides an automated integrated planning functionality to improve energy efficiency and flexibility alongside production goals. The method considers fluctuating short-term energy markets as well as local hydrogen-based energy storage components. Both method development and evaluation are based on a case study in energy-intensive steel production. The achieved results show a significant benefit from the developed dynamic planning and optimization for different variables particularly in two different heat-treatment process technologies.