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Hybrid simulation and energy market based optimization of cement plants

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This paper presents an approach for equipping a cement plant with a wind power plant, a battery storage and an optimized control in order to reduce electricity supply cost and carbon dioxide (CO2) emissions as cement manufacturing is a traditional energy-intensive industrial process, that accounts for around 5% of global CO2 emissions. Therefore, a hybrid simulation model of a cement plant with an integrated optimized control algorithm, a wind turbine model including 24-h forecasts, and market access to the German day-ahead electricity market and the FRR market was built up. The results show, that applying only an optimized control of the cement plant without offering its flexibilities and renewable power supply in combination with a battery storage only causes a slight benefit. Adding flexibility and marketing to the model provides significant cost savings. Adding renewable energy sources and a battery storage to the cement plant can cause a further significant decrease of electricity supply cost per produced ton cement under certain conditions. Regarding the CO2 emissions, installing a wind turbine has an decreasing impact, depending on the location.

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D. Steber and P. Bazan are also a members of “Energy Campus Nürnberg”, Fürther Str. 250, 90429 Nürnberg, Germany. Their research was performed as part of the “Energy Campus Nürnberg” and supported by funding through the “Aufbruch Bayern (Bavaria on the move)” initiative of the Bavarian state. The thyssenkrupp AG and its Corporate Function Technology, Innovation and Sustainability together with thyssenkrupp Resource Technology and thyssenkrupp TechCenter Control Technology provided support to the preparation of the use case and the system configuration as well as the project execution.

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Correspondence to Reinhard German.

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Bazan, P., Steber, D. & German, R. Hybrid simulation and energy market based optimization of cement plants. Comput Sci Res Dev 32, 65–77 (2017). https://doi.org/10.1007/s00450-016-0305-8

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  • Demand side management
  • Frequency restoration reserve
  • Day-ahead electricity market
  • Redox flow battery
  • Renewable energy sources
  • CO2