Zusammenfassung Auf dem Weg zur Erreichung der gesetzten Klimaziele in Deutschland muss der Anteil erneuerbarer Energien an der Stromerzeugung stetig ausgebaut werden. Die damit einhergehende zunehmende Fluktuation der Erzeugungsleistung stellt die Stromnetze vor große Herausforderungen. Da knapp 44 % des Strom- und rund ein Viertel des Wärmeverbrauchs in Deutschland auf die Industrie entfällt, bietet diese signifikantes Potenzial, Schwankungen im Stromnetz durch die Anpassung des Stromverbrauchs an das Stromangebot im Sinne von Demand Response mittels Energieflexibilität auszugleichen. Bislang erschwert neben regulatorischen Rahmenbedingungen insbesondere eine fehlende einheitliche Modellierung & Kommunikation von Energieflexibilität sowie deren Einbettung in bestehende Unternehmens-IT-Infrastrukturen eine optimale und automatisierte Vermarktung. Im Rahmen des Forschungsprojekts SynErgie wurden hierfür informationstechnische Anforderungen erhoben, Datenmodelle zur Beschreibung von Energieflexibilität und eine übergeordnete IT-Architektur entwickelt. Mit Hilfe einer unternehmensspezifischen Plattform und einer zentralen Marktplattform kann der Informations- und Kommunikationsfluss von der Maschine/Anlage bis zur Flexibilitätsvermarktung und wieder zurück abgebildet werden. Eine Vielzahl verschiedener Services unterstützt hierbei ein Unternehmen von der Identifikation bis hin zur automatisierten und standardisierten Vermarktung von Energieflexibilität. Durch die Einsatzmöglichkeiten und Wirkansätze von IT wurden Grundsteine für nachhaltigkeitsbezogene Effekte des industriellen Energieverbrauchs gelegt, welche in den kommenden Monaten in einer Modellregion in und um Augsburg mit Industrieunternehmen, Netzbetreibern und weiteren Serviceanbietern getestet werden.
Economic solutions for the integration of volatile renewable electricity generation are decisive for a socially supported energy transition. So-called energy-flexible factories can adapt their electricity consumption process efficiently to power generation. These adaptions can support the system balance and counteract local network bottlenecks. Within part of the model region Augsburg, a research and demonstration area of a federal research project, the potential, obstacles, effects, and opportunities of the energy-flexible factory were considered holistically. Exemplary flexibilization measures of industrial companies were identified and modeled. Simulations were performed to analyze these measures in supply scenarios with advanced expansion of fluctuating renewable electricity generation. The simulations demonstrate that industrial energy flexibility can make a positive contribution to regional energy balancing, thus enabling the integration of more volatile renewable electricity generation. Based on these fundamentals, profiles for regional market mechanisms for energy flexibility were investigated and elaborated. The associated environmental additional expenses of the companies for the implementation of the flexibility measures were identified in a life-cycle assessment, with the result that the negative effects are mitigated by the increased share of renewable energy. Therefore, from a technical perspective, energy-flexible factories can make a significant contribution to a sustainable energy system without greater environmental impact. In terms of a holistic approach, a network of actors from science, industry, associations, and civil society organizations was established and actively collaborated in a transdisciplinary work process. Using design-thinking methods, profiles of stakeholders in the region, as well as their mutual interactions and interests, were created. This resulted in requirements for the development of suitable business models and reduced regulatory barriers.
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.
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