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Integration of Heat Pump Storage Systems in Manufacturing Systems via Data Farming and Monte Carlo Simulation
The electrification of industrial energy demand is essential for effective climate protection and a successful energy transition. In production systems with fluctuating heating and cooling demands, heat pumps can make a significant contribution to electrification and increased efficiency in a demand-oriented production with automated standby operation. In order to dimension a suitable heat pump storage system, well-founded statistical information about the production system is required. For the creation of stochastic ...
Automatic Time Series Segmentation as the Basis for Unsupervised, Non-Intrusive Load Monitoring of Machine Tools
Detailed energy monitoring and benchmarking at the individual component level is necessary to increase energy efficiency in complex production systems. Non-intrusive load monitoring (NILM) provides an economical solution for operational state detection and load disaggregation without the need for large-scale use of fine-grained energy meters. Existing supervised NILM approaches require detailed training data including control information about individual devices. Unsupervised approaches, on the other hand, often ...
Dimensioning of Heat Pump Systems Based on Pinch Analysis and Energy Monitoring Data
In this paper, typical process chains of metal processing/gear manufacturing are examined according to the pinch method with regard to their potential for heat recovery and their suitability for heat pump applications. The focus is on machine tools and parts washing machines as fluctuating heat sources and sinks. Heat sources at a low temperature level, such as the cooling of machine tools, are becoming increasingly important in contrast to conventional fossil waste heat sources due to the electrification of energy ...
Total Site Utility Systems Optimisation for Milk Powder Production
This study applies the Total Site Heat Integration method, in conjunction with a detailed process and utility model, to investigate three methods to increase the energy efficiency of the utility supply system for milk powder production. Sequentially explored opportunities are: (1) increasing boiler efficiency through condensing economisers, (2) waste heat recovery from the chiller unit, and (3) Combined Heat and Power (CHP) for electricity production. The basis for the analysis is the anticipated future milk powder ...
Signal based non-intrusive load decomposition
Driven by both regulatory and monetary interests the development of energy monitoring systems has been accelerated in recent years. Thus, a large amount of data is collected and stored in huge databases. This is a decisive step towards sustainable production systems since you can’t improve what you don’t know. This paper aims to use the datasets currently available and to combine databases to gather additional information on production systems, in particular energy flows. Therefore, an algorithm has been developed ...
Nachhaltige Emissionsreduzierung durch erneuerbare Eigenstromversorgung
Ein vielversprechender Weg der Emissionsreduktion durch Industrieunternehmen ist, selbst in erneuerbare Energieanlagen zu investieren. Die wirtschaftliche Beurteilung dieses Schrittes erfordert eine detaillierte Betrachtung der gesetzlichen Regelungen. Da es für viele Strompreisbestandteile umfangreiche Ausnahmeregelungen gibt, können die Stromkosten je nach Standort und Unternehmen variieren, sodass eine exakte Bestimmung individuell erfolgen muss.
System efficient integration of standby control and heat pump storage systems in manufacturing processes
Prerequisite for system efficiency towards an industrial energy transition is the reducing of energy demand on the process level. In typical manufacturing systems with machine tools and washing machines, the proper design of intelligent standby control and heat pump storage system (HPS) represent high efficiency. The integration of HPS is complicated due to high non-continuity, especially when implementing a standby control system. Our approach aims at designing one single HPS for multiple heat sources and sinks. ...
Predictive Simulation-based Optimisation of Cooling System Including a Sprinkler Tank
Prerequisite for an efficient cooling energy system is the knowledge and the optimal combination of different operating conditions of individual compression and free cooling chillers. The performance of cooling systems depends on its part load performance and its condensing temperature, which are often unknown. Recorded energy data remains unused and manufacturers' data significantly differs from the real performance. For this purpose, manufacturer and real data are combined and continuously adapted to form partial ...
Energy Efficiency Measures for Batch Retort Sterilization in the Food Processing Industry
The purpose of this study is to highlight the energy saving potentials of a batch retort sterilization process operated by steam and to develop concepts for improving its energy efficiency. By using the methodical approach of the Onion Diagram and the recovery of low grade heat sources, four comprehensive improved energy efficiency concepts have been developed. Two concepts increase the initial product temperature resulting in lower transient steam consumption rates and a decreased energy demand. The other two options ...
Increasing energy efficiency of milk product batch sterilisation
The food industry is a large energy consumer and most heat demands in food processing are low-temperature. The aim of this study is to develop and simulate innovative retrofits or redesigns that unlock the heat recovery potential of industrial batch sterilisation processes. The case study focuses on the whey cream process, although the method and results apply to similar batch sterilisation processes. The initial situation is compared to energy efficient designs based on “Energy Storage” and “Rescheduling”. Using a ...