Prerequisite for an efficient cooling energy system is the knowledge and optimal combination of different operating conditions of individual compression and free cooling chillers. The performance of cooling systems depends on their part-load performance and their condensing temperature, which are often not continuously measured. Recorded energy data remain unused, and manufacturers’ data differ from the real performance. For this purpose, manufacturer and real data are combined and continuously adapted to form part-load chiller models. This study applied a predictive optimization algorithm to calculate the optimal operating conditions of multiple chillers. A sprinkler tank offers the opportunity to store cold-water for later utilization. This potential is used to show the load shifting potential of the cooling system by using a variable electricity price as an input variable to the optimization. The set points from the optimization have been continuously adjusted throughout a dynamic simulation. A case study of a plastic processing company evaluates different scenarios against the status quo. Applying an optimal chiller sequencing and charging strategy of a sprinkler tank leads to electrical energy savings of up to 43%. Purchasing electricity on the EPEX SPOT market leads to additional costs savings of up to 17%. The total energy savings highly depend on the weather conditions and the prediction horizon.

In the fight against anthropogenic climate change, the benefit of the integration of fluctuating renewable energies (wind and photovoltaics) into the electricity grid is a widely proved concept. At the same time, a fluctuating and decentralised supply of energy, especially at lower voltage levels, leads to a local discrepancy in the power balance between generation and consumption. A possible solution in connection with demand side management is the grid-oriented flexibilisation of energy demand. The present study shows how the use of an innovative hybrid-redundant high-temperature heat system (combined heat and power (CHP), power-to-heat system (PtH), gas boiler) can contribute to a flexibilisation of the electrical energy demand of plastics processing companies. In this context, the flexibilisation potential of a company is to be understood as the grid-related change of the energy supply through a change of the energy sources within the framework of the process heat supply. For this purpose, an omniscient control algorithm is developed that specifies the schedule of the individual system components. A sensitivity analysis is used to test the functionality of the control algorithm. Determination of the electrical flexibilisation potential is carried out via a comprehensive simulation study using Monte Carlo methods. For this purpose, the residual load curves of four characteristic distribution grids with a high share of renewable energies as well as heat load profiles of injection moulding machines are taken into consideration. A frequency distribution provides information on the electrical flexibilisation potential to be expected depending on the various combinations. The evaluation is carried out using a specially introduced logic, which identifies grid-relevant changes in the company's power consumption as flexibilisation potential based on a reference load curve. The results show that a reliable energy supply for production is possible despite flexibilisation. Depending on the grid under consideration, there are differences in the exploitation of the potential, which essentially depends on the installed renewable capacity. Depending on the scenario under consideration, an average of up to 1486 kWh_el can be shifted in a positive direction and 1199 kWh_el in a negative direction.

Industrial companies need to measure, evaluate and predict their energy demand to use this knowledge to improve plant control and achieve further energy efficiency. Within the framework of contribution, two model cases from the food and plastic sector are described, which implement the concepts of a “smart consumer” with the focus on demand-side management and smart control approaches. Simulations show how improved operation of the technical building infrastructure saves energy by using the example of a hall climate control and refrigeration. In addition, the specific energy-saving measures are described and the future realisation potential is discussed. Further it is shown that there are regional differences when considering demand-side management measures.