Energy-aware coordination of machine scheduling and support device recharging in production systems

Electricity generation from renewable energy sources is crucial for achieving climate targets, including greenhouse gas neutrality. Germany has made significant progress in increasing renewable energy generation. However, feed-in management actions have led to losses of renewable electricity in the past years, primarily from wind energy. These actions aim to maintain grid stability but result in excess renewable energy that goes unused. The lost electricity could have powered a multitude of households and saved CO2 emissions. Moreover, feed-in management actions incurred compensation claims of around 807 million Euros in 2021. Wind-abundant regions like Schleswig-Holstein are particularly affected by these actions, resulting in substantial losses of renewable electricity production. Expanding the power grid infrastructure is a costly and time-consuming solution to avoid feed-in management actions. An alternative approach is to increase local electricity consumption during peak renewable generation periods, which can help balance electricity supply and demand and reduce feed-in management actions. The dissertation focuses on energy-aware manufacturing decision-making, exploring ways to counteract feed-in management actions by increasing local industrial consumption during renewable generation peaks. The research proposes to guide production management decisions, synchronizing a company's energy consumption profile with renewable energy availability for more environmentally friendly production and improved grid stability

Material and energy flows of the iron and steel industry: status quo, challenges and perspectives

Integrated analysis and optimization of material and energy flows in the iron and steel industry have drawn considerable interest from steelmakers, energy engineers, policymakers, financial firms, and academic researchers. Numerous publications in this area have identified their great potential to bring significant benefits and innovation. Although much technical work has been done to analyze and optimize material and energy flows, there is a lack of overview of material and energy flows of the iron and steel industry. To fill this gap, this work first provides an overview of different steel production routes. Next, the modelling, scheduling and interrelation regarding material and energy flows in the iron and steel industry are presented by thoroughly reviewing the existing literature. This study selects eighty publications on the material and energy flows of steelworks, from which a map of the potential of integrating material and energy flows for iron and steel sites is constructed. The paper discusses the challenges to be overcome and the future directions of material and energy flow research in the iron and steel industry, including the fundamental understandings of flow mechanisms, the dynamic material and energy flow scheduling and optimization, the synergy between material and energy flows, flexible production processes and flexible energy systems, smart steel manufacturing and smart energy systems, and revolutionary steelmaking routes and technologies

Steelmaking Technology and Energy Prices: The Case of Germany

We examine the relationship between the choice of steelmaking technology and energy prices in Germany using data beginning 1970. The analysis indicates that technology choice began to cointegrate with comparative energy prices in the early 90s. The short and long-run effects of energy prices are captured in a partial adjustment model; the ratio of electricity to coal prices is seen to exert sizeable influence on the short and long-term deployment of the electric arc furnace for secondary steelmaking. If current trends in energy prices continue, the share of secondary steelmaking in total steel production is expected to increase rather slowly

Integration of Renewables in Power Systems by Multi-Energy System Interaction

This book focuses on the interaction between different energy vectors, that is, between electrical, thermal, gas, and transportation systems, with the purpose of optimizing the planning and operation of future energy systems. More and more renewable energy is integrated into the electrical system, and to optimize its usage and ensure that its full production can be hosted and utilized, the power system has to be controlled in a more flexible manner. In order not to overload the electrical distribution grids, the new large loads have to be controlled using demand response, perchance through a hierarchical control set-up where some controls are dependent on price signals from the spot and balancing markets. In addition, by performing local real-time control and coordination based on local voltage or system frequency measurements, the grid hosting limits are not violated

Coordinating industrial production and cogeneration systems to exploit electricity price fluctuations

Las fluctuaciones en el precio de la electricidad, procedentes de la aplicación de programas de respuesta de la demanda, son una oportunidad para que las industrias que cuenten con sistemas de cogeneración puedan reducir sus costes de producción mientras hacen que la red eléctrica sea más estable y segura en su conjunto. Dada la cantidad de factores involucrados y la dificultad que esto supone a la hora de tomar decisiones, en esta tesis se presenta una metodología basada en optimización dinámica que permite la gestión óptima de ambos sistemas y se aplica en simulación al caso de estudio de una industria azucarera. Como principales resultados, se ha obtenido que utilizando la metodología propuesta los costes variables de producción se pueden reducir hasta un 2.55% si se utiliza una tarifa por tramos típica, y en torno a un 5.41% si se utilizan los precios dados por el mercado eléctrico directamente.Departamento de Ingeniería de Sistemas y AutomáticaDoctorado en Ingeniería Industria

Exact and Heuristic Algorithms for Energy-Efficient Scheduling

The combined increase of energy demand and environmental pollution at a global scale is entailing a rethinking of the production models in sustainable terms. As a consequence, energy suppliers are starting to adopt strategies that flatten demand peaks in power plants by means of pricing policies that stimulate a change in the consumption practices of customers. A representative example is the Time-of-Use (TOU)-based tariffs policy, which encourages electricity usage at off-peak hours by means of low prices, while penalizing peak hours with higher prices. To avoid a sharp increment of the energy supply costs, manufacturing industry must carefully reschedule the production process, by shifting it towards less expensive periods. The TOU-based tariffs policy induces an implicit partitioning of the time horizon of the production into a set of time slots, each associated with a non-negative cost that becomes a part of the optimization objective. This thesis focuses on a representative bi-objective energy-efficient job scheduling problem on parallel identical machines under TOU-based tariffs by delving into the description of its inherent properties, mathematical formulations, and solution approaches. Specifically, the thesis starts by reviewing the flourishing literature on the subject, and providing a useful framework for theoreticians and practitioners. Subsequently, it describes the considered problem and investigates its theoretical properties. In the same chapter, it presents a first mathematical model for the problem, as well as a possible reformulation that exploits the structure of the solution space so as to achieve a considerable increase in compactness. Afterwards, the thesis introduces a sophisticated heuristic scheme to tackle the inherent hardness of the problem, and an exact algorithm that exploits the mathematical models. Then, it shows the computational efficiency of the presented solution approaches on a wide test benchmark. Finally, it presents a perspective on future research directions for the class of energy-efficient scheduling problems under TOU-based tariffs as a whole

Energy efficiency in the iron and steel industry : cases of Zimbabwe and South Africa

Includes bibliographical references.This study looks at possible improvements of energy efficiency in the iron and steel industry in Zimbabwe and the case of South Africa is studied also for comparison. Data required was obtained through field visits and international databases. The fieldwork findings, analysis and published literature contributed to the conclusions and recommendations. There is a relationship between technology advancement, energy efficiency and energy intensity. The more modern technology a country's steel industry adopts the more energy efficient it becomes and so lowers its energy intensity. Countries such as South Korea, Japan and Germany have adopted modern technologies and they are among the most efficient steel producers and have the lowest energy intensities while India and China have low levels of modern technologies, low efficiencies and high intensities. ZISCO, the iron and steel industry of Zimbabwe has a relatively high energy intensity (closer to China and India) compared to South Africa and other developing country producers. ZISCO has both new and old technology while industry in South Africa, which has retired most old technology and closed all its less efficient plants, is largely using new and even state of the art technology in some of its plants. In Zimbabwe the national economic and industrial policies have had negative impacts on the growth and development of its iron and steel industry. ZISCO needs policies that support the adoption of energy efficient technology, create a level playing field for downstream steel industries since ZISCO has the potential to influence growth of this sector and the sector has prospects for significant foreign currency earnings. The study recommends a restructuring of ZISCO to improve productivity, and energy efficiency through replacement of old technologies in the medium to long term and implementation of some identified less capital-intensive options that are typical in an integrated steel mill