Industrial load shifting potential

Industrial companies can support the power grid by temporarily reducing their load but also cut costs by marketing this flexibility. Within this workstream, WindNODE systematically identifies the technical, process-related and business requirements for industrial load shifting. The steps necessary to locate and market flexibility are tested and laid down in guidelines.

‘TARGET’ – algorithms and methods for future-oriented smart energy and load management

In the scope of this project, Fraunhofer IWU is developing an energy management system (‘TARGET’ system) that synchronises the energy offer and demand at production sites at maximum exploitation of renewable energy sources. This requires interventions at different planning and control levels of generation facilities and energy-relevant generation and building infrastructure. The energy management system should therefore be used at different levels of development in the demonstrators of the participating industrial partners Karosseriewerke Dresden and DECKEL Maho Seebach in order to make energy flows transparent, optimise energy consumption and allow energy supply-oriented production planning. Based on experience from model companies in Berlin, a guideline is drawn up which describes the introduction of flexibility management into industry and commerce and facilitates it for subsequent companies.


Raue, Strehle, Stoldt, Schlegel, Richter, Langer (2018): "Mehrstufiges multikriterielles Job Shop Scheduling - Heuristik zur Lösung des Job-Shop-Problems unter energetischen und wirtschaftlichen Zielgrößen“. In: wt Werkstatttechnik online, Ausgabe 4/2018, S. 210-216, VDI Fachmedien, Düsseldorf, April 2018.


Süße, Prell, Stoldt, Strehle, Richter, Schlegel, Putz (2019): "Load and energy management for factories through multi-stage production planning and optimization”. In: Procedia CIRP, Band 80/2019, S. 257-262, May 2019.


Süße, Stoldt, Schlegel, Putz (2019): "Decision support for planning techniques in energy efficiency projects". In: Procedia CIRP, Band 69/2018, S. 306-311, Copenhagen, May 2019.


Smart industrial load management in Berlin

In order to create the prerequisite for load shifting in times of low electricity prices, Siemens determines and predicts the electricity demand of thermal, mechanical and electrochemical production processes and production support processes at Berlin-Siemensstadt. Building on these predictions, a production control process to be developed in this project should calculate a production plan optimised at total cost and control processes with a capacity of some 2 MW. The gathered experience will then be used to also make the energy consumption of the production processes transparent, identify load reduction potentials and ultimately exploit these financially and economically in other industrial companies, businesses and administrations.

Load shifting potentials in the energy-intensive industry

In order to optimally flexibilise the energy-intensive industry, consisting of consumers, energy conversion plants as well as storage units, Fraunhofer IFF is developing fitting models and tools within the scope of this project. We work on the basis of a global view of the energy value chain and its interaction with operating processes as well as taking external market and grid signals into account. To this end, we are constructing a multi-energy system demonstrator in Magdeburg that simulates a company from the process industry and can be studied together with industrial partners. In this manner, we can simulate, evaluate and economically assess ancillary services through load shifting in energy-intensive processes.


Pelzer, Richter, Lombardi, Komarnicki (2017): "Energy intensive industry as the backbone for demand side flexibility”. In: International ETG Congress 2017 Die Energiewende – Blueprints for the new energy age, S. 611-616, Bonn, November 2017.


Caro-Ruiz, Lombardi, Richter, Pelzer, Komarnicki, Pavas, Mojica-Nava (2019): "Coordination of optimal sizing of energy storage systems and production buffer stocks in a net zero energy factory”. In: Applied Energy, Band 238, S. 851-862, March 2019.


Lombardi, Komarnicki, Zhu, Liserre (2019): "Flexibility options identifications within Net Zero Energy Factories”. In: 13th IEEE PowerTech 2019, Mailand, June 2019.


Market integration of industrial flexibility per interface between energy controlling and marketing platforms

Because of their operational requirements, many industrial companies have a proven energy controlling system and an existing data collection infrastructure. ÖKOTEC seeks to enhance such existing systems with a systemic interface at low cost. This interface is active at the industrial site’s measuring and control level and also incorporates the required algorithms and processes to assess flexibility for market use. Within this project, we are therefore conceiving an interface that makes it possible to integrate flexibility into marketing platforms or electricity markets via standardised and secure formats and data transmission paths. Trial implementation at industrial sites in combination with innovative forecast methods and dynamic availability analyses will then enable commercially and economically efficient operation.

Load shifting potentials in water supply and waste water disposal

The large load shifting potential of BWB should be gradually identified and exploited in this project for the optimisation of self-consumption or for ancillary services. We are therefore using a simulation tool to carry out an extensive study of the current installations, power consumption and peak loads. Moreover, we demonstrate new optimisation potentials in water supply and waste water disposal for different companies, for instance with regard to energy procurement, process optimisation, use of waste water heat, the feed-in of methane into the natural gas grid and the electrification of the vehicle fleet. This results in a list of measures with cost saving and load shifting potentials, of which the most efficient and innovative are implemented in the scope of a pilot project. We aim to implement the algorithms for the active control of production and energy flows.

Combined application of a battery farm for ancillary services and smart energy control of a large industrial manufacturing site

In the scope of this project, BMW Group combines batteries from its electric i3 models into a ‘battery farm’. With a planned total capacity of up to 15 MWh, the farm is connected to the grid beyond the grid node of the factory in Leipzig. In addition to marketing this energy, participation in the operating reserve market also enables local optimisation, e.g. covering short peak loads. The use of the batteries is an example of an economically useful second life application of established values from electric vehicles. In addition, we are making a significant contribution to sustainability and environmental protection. In this manner, we further the energy transition at the level of large industrial consumers. The modular structure of the battery farm enables us to use future battery generations and scale the total infrastructure.

BigBatt innovative energy hub in the Lusatia area

In the Lusatia area, LEAG is cooperating with Siemens and BTU Cottbus-Senftenberg (KWT) to expand various gas- and coal-fired power plants as well as large energy consumers such as the mining industry with new technologies in a targeted manner to build a sustainable bridge towards a new supply system. To further flexibilise the generation of electricity and to improve the support for system security, we are integrating a first large battery at the Schwarze Pumpe lighthouse. This requires a smart network of producers, consumers and storage units. To assist with this, we are developing a simulation model for the use of the large battery on the operating reserve market as well as other purposes. Based on this, we are defining recommended actions for large-scale batteries in new environments.

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