Microgrid design, control, and performance evaluation for sustainable energy management in manufacturing

This research studies the capacity sizing, control strategies, and performance evaluation of the microgrids with hybrid renewable sources for manufacturing end use customers towards a distributed sustainable energy system paradigm. Microgrid technology has been widely investigated and applied in commercial and residential sector, while for manufacturers, it has been less explored and utilized. To fill the gap, the dissertation first proposes a cost-effective sizing model to identify the capacities as well as control strategies of the components in microgrids considering a commonly used energy tariff, i.e., Time of Use (TOU). Then, the sizing model is extended by integrating control strategies for both microgrid components and manufacturing systems considering a typical demand response program, i.e., Critical Peak Pricing (CPP), where customer side load adjustment is highly encouraged. After that, the control strategy of the manufacturers in an overgeneration mitigation-oriented demand response program is further investigated based on the identified optimal size of onsite microgrid to minimize the energy cost. Later, the system is analyzed from its higher level of abstraction where a prosumer community is developed by aggregating such manufacturers with onsite microgrid system. To enhance the reliable energy operation in the community, the performance of the microgrid is investigated through the estimation of the lifetime of Battery Energy Storage System (BESS), a critical design parameter the architecture. Finally, conclusions are presented and future research on real-time joint control strategy for both microgrids and manufacturing systems and identification as well as optimal energy management of the controllable loads in manufacturing system are discussed --Abstract, page iii

Simulation Modeling for Energy-Flexible Manufacturing: Pitfalls and How to Avoid Them

Due to the high share of industry in total electricity consumption, industrial demand-side management can make a relevant contribution to the stability of power systems. At the same time, companies get the opportunity to reduce their electricity procurement costs by taking advantage of increasingly fluctuating prices on short-term electricity markets, the provision of system services on balancing power markets, or by increasing the share of their own consumption from on-site generated renewable energy. Demand-side management requires the ability to react flexibly to the power supply situation without negatively affecting production targets. It also means that the management and operation of production must consider not only production-related parameters but also parameters of energy availability, which further increase the complexity of decision-making. Although simulation studies are a recognized tool for supporting decision-making processes in production and logistics, the simultaneous simulation of material and energy flows has so far been limited mainly to issues of energy efficiency as opposed to energy flexibility, where application-oriented experience is still limited. We assume that the consideration of energy flexibility in the simulation of manufacturing systems will amplify already known pitfalls in conducting simulation studies. Based on five representative industrial use cases, this article provides practitioners with application-oriented experiences of the coupling of energy and material flows in simulation modeling of energy-flexible manufacturing, identifies challenges in the simulation of energy-flexible production systems, and proposes approaches to face these challenges. Seven pitfalls that pose a particular challenge in simulating energy-flexible manufacturing have been identified, and possible solutions and measures for avoiding them are shown. It has been found that, among other things, consistent management of all parties involved, early clarification of energy-related, logistical, and resulting technical requirements for models and software, as well as the application of suitable methods for validation and verification are central to avoiding these pitfalls. The identification and characterization of challenges and the derivation of recommendations for coping with them can raise awareness of typical pitfalls. This paper thus helps to ensure that simulation studies of energy-flexible production systems can be carried out more efficiently in the future

Demand-Side Flexibility in Power Systems:A Survey of Residential, Industrial, Commercial, and Agricultural Sectors

In recent years, environmental concerns about climate change and global warming have encouraged countries to increase investment in renewable energies. As the penetration of renewable power goes up, the intermittency of the power system increases. To counterbalance the power fluctuations, demand-side flexibility is a workable solution. This paper reviews the flexibility potentials of demand sectors, including residential, industrial, commercial, and agricultural, to facilitate the integration of renewables into power systems. In the residential sector, home energy management systems and heat pumps exhibit great flexibility potential. The former can unlock the flexibility of household devices, e.g., wet appliances and lighting systems. The latter integrates the joint heat–power flexibility of heating systems into power grids. In the industrial sector, heavy industries, e.g., cement manufacturing plants, metal smelting, and oil refinery plants, are surveyed. It is discussed how energy-intensive plants can provide flexibility for energy systems. In the commercial sector, supermarket refrigerators, hotels/restaurants, and commercial parking lots of electric vehicles are pointed out. Large-scale parking lots of electric vehicles can be considered as great electrical storage not only to provide flexibility for the upstream network but also to supply the local commercial sector, e.g., shopping stores. In the agricultural sector, irrigation pumps, on-farm solar sites, and variable-frequency-drive water pumps are shown as flexible demands. The flexibility potentials of livestock farms are also surveyed

Smart Manufacturing using Control and Optimization

Indiana University-Purdue University Indianapolis (IUPUI)Energy management has become a major concern in the past two decades with the increasing energy prices, overutilization of natural resources and increased carbon emissions. According to the department of Energy the industrial sector solely consumes 22.4% of the energy produced in the country [1]. This calls for an urgent need for the industries to design and implement energy efficient practices by analyzing the energy consumption, electricity data and making use of energy efficient equipment. Although, utility companies are providing incentives to consumer participating in Demand Response programs, there isn’t an active implementation of energy management principles from the consumer’s side. Technological advancements in controls, automation, optimization and big data can be harnessed to achieve this which in other words is referred to as “Smart Manufacturing”. In this research energy management techniques have been designed for two SEU (Significant Energy Use) equipment HVAC systems, Compressors and load shifting in manufacturing environments using control and optimization. The addressed energy management techniques associated with each of the SEUs are very generic in nature which make them applicable for most of the industries. Firstly, the loads or the energy consuming equipment has been categorized into flexible and non-flexible loads based on their priority level and flexibility in running schedule. For the flexible loads, an optimal load scheduler has been modelled using Mixed Integer Linear Programming (MILP) method that find carries out load shifting by using the predicted demand of the rest of the plant and scheduling the loads during the low demand periods. The cases of interruptible loads and non-interruptible have been solved to demonstrate load shifting. This essentially resulted in lowering the peak demand and hence cost savings for both “Time-of-Use” and Demand based price schemes. The compressor load sharing problem was next considered for optimal distribution of loads among VFD equipped compressors running in parallel to meet the demand. The model is based on MILP problem and case studies was carried out for heavy duty (>10HP) and light duty compressors (<=10HP). Using the compressor scheduler, there was about 16% energy and cost saving for the light duty compressors and 14.6% for the heavy duty compressors HVAC systems being one of the major energy consumer in manufacturing industries was modelled using the generic lumped parameter method. An Electroplating facility named Electro-Spec was modelled in Simulink and was validated using the real data that was collected from the facility. The Mean Absolute Error (MAE) was about 0.39 for the model which is suitable for implementing controllers for the purpose of energy management. MATLAB and Simulink were used to design and implement the state-of-the-art Model Predictive Control for the purpose of energy efficient control. The MPC was chosen due to its ability to easily handle Multi Input Multi Output Systems, system constraints and its optimal nature. The MPC resulted in a temperature response with a rise time of 10 minutes and a steady state error of less than 0.001. Also from the input response, it was observed that the MPC provided just enough input for the temperature to stay at the set point and as a result led to about 27.6% energy and cost savings. Thus this research has a potential of energy and cost savings and can be readily applied to most of the manufacturing industries that use HVAC, Compressors and machines as their primary energy consumer

Energy End-Use : Industry

The industrial sector accounts for about 30% of the global final energy use and accounts for about 115 EJ of final energy use in 2005. 1Cement, iron and steel, chemicals, pulp and paper and aluminum are key energy intensive materials that account for more than half the global industrial use. There is a shift in the primary materials production with developing countries accounting for the majority of the production capacity. China and India have high growth rates in the production of energy intensive materials like cement, fertilizers and steel (12–20%/yr). In different economies materials demand is seen to grow initially with income and then stabilize. For instance in industrialized countries consumption of steel seems to saturate at about 500 kg/capita and 400–500 kg/capita for cement. The aggregate energy intensities in the industrial sectors in different countries have shown steady declines – due to an improvement in energy efficiency and a change in the structure of the industrial output. As an example for the EU-27 the final energy use by industry has remained almost constant (13.4 EJ) at 1990 levels. Structural changes in the economies explain 30% of the reduction in energy intensity with the remaining due to energy efficiency improvements. In different industrial sectors adopting the best achievable technology can result in a saving of 10–30% below the current average. An analysis of cost cutting measures for motors and steam systems in 2005 indicates energy savings potentials of 2.2 EJ for motors and 3.3 EJ for steam. The payback period for these measures range from less than 9 months to 4 years. A systematic analysis of materials and energy flows indicates significant potential for process integration, heat pumps and cogeneration for example savings of 30% are seen in kraft, sulfite, dairy, chocolate, ammonia, and vinyl chloride. An exergy analysis (second law of thermodynamics) reveals that the overall global industry efficiency is only 30%. It is clear that there are major energy efficiency improvements possible through research and development (R&D) in next generation processes. A comparison of energy management policies in different countries and a summary of country experiences, program impacts for Brazil, China, India, South Africa shows the features of successful policies. Energy management International Organization for Standardization (ISO) standards are likely to be effective in facilitating industrial end use efficiency. The effective use of demand side management can be facilitated by combination of mandated measures and market strategies. A frozen efficiency scenario is constructed for industry in 2030. This implies a demand of final energy of 225 EJ in 2030. This involves an increase of the industrial energy output (in terms of Manufacturing Value Added (MVA)) by 95% over its 2005 value. Due to normal efficiency improvements the Business as Usual scenario results in a final energy demand of 175 EJ. The savings possibilities in motors and steam systems, process improvements, pinch, heat pumping and cogeneration have been computed for the existing industrial stock and for the new industries. An energy efficient scenario for 2030 has been constructed with a 95% increase in the industrial output with only a 17% increase in the final energy demand (total final energy demand for industry (135 EJ)). The total direct and indirect carbon dioxide emissions from the industry sector in 2005 is about 9.9 GtCO 2 . Assuming a constant carbon intensity of energy use, the business as usual scenario results in carbon dioxide (CO 2 ) emissions increasing to 17.8 GtCO 2 annually in 2030. In the energy efficient scenario this reduces to 11.6 GtCO 2 . Renewables account for 9% of the final energy of industry (10 EJ in 2005). If an aggressive renewables strategy resulting in an increase in renewable energy supply to 23% in 2030 is targeted (23 EJ), it is possible to have a scenario of constant greenhouse gas (GHG) emissions by the industrial sector (at 2005 levels) with a 95% increase in the industrial output. Several interventions will be required to achieve the energy efficient or constant GHG emission scenario. For the existing industry measures include developing capacity for systems assessment for motors, steam systems and pinch analysis, sharing and documentation of best practices, benchmarks and roadmaps for different industry segments, access to low interest finance etc. A new energy management standard has been developed by ISO for energy management in companies. Its adoption will enable industries to systematically monitor and track energy efficiency improvements. In order to level the playing field for energy efficiency a paradigm shift is required with the focus on energy services not on energy supply per se. This requires a re-orientation of energy supply, distribution companies and energy equipment manufacturing companies. Planning for next generation processes and systems needs the development of long term research agenda and strategic collaborations between industry, academic and research institutions and governments

A means to an industrialisation end? Demand side management in Nigeria

Electricity is essential for economic development and industrialisation processes. Balancing demand and supply is a recurrent problem in the Nigerian electricity market. The aim of this work is to assess the technical and economic potential of Demand Side Management (DSM) in Nigeria given different future levels of industrialisation. The paper places industrialisation at the centrefold of the appraisal of DSM potential in Nigeria. It does so by designing industrialisation scenarios and consequently deriving different DSM penetration levels using a cost-optimisation model. Findings show that under the high industrialisation scenario by the year 2050 DSM could bring about 7 billion USD in cumulative savings thanks to deferred investment in new generation and full deployment of standby assets along with interruptible programmes for larger industrial users. The paper concludes by providing policy recommendations regarding financial mechanisms to increase DSM deployment in Nigeria. The focus on DSM serves to shift the policy debate on electricity in Nigeria from a static state versus market narrative on supply to an engagement with the agency and influence on industrial end-users

WoodCircus, Underpinning the vital role of the forest-based sector in the Circular Bioeconomy. D2.2 Resource Efficiency, Side Streams and Value Chain Analysis – WP2 Final Report

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