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Industrial parks and industrial plants

Grafik Monitor Industrie

The cost of energy and the requirements and opportunities of the energy transition, such as new generation and storage technologies, hydrogen technology, emission restrictions and costs, have a significant impact on business processes in all industrial sectors. Maximum security of supply and plant efficiency are a must here.

Industrial or chemical parks supply the local companies with energy, electricity, gas, district heating, hydrogen, steam, cooling, etc. They obtain the primary energies they need from their own power plants, from upstream suppliers, from stock exchanges or from storage facilities. The same applies to the media supply of an industrial park (e.g. coke gas, crucible gas, furnace gas, natural gas, hydrogen, water, compressed air, cooling, etc.). On the consumption side, it is important to consider and forecast demand load profiles; delivery obligations may also apply.

Similar structures can be found in all industrial plants with energy-intensive production, e.g.

  • Aluminium industry
  • Automotive plants
  • Automotive suppliers
  • Glass industry
  • Iron and steel works
  • Paper industry
  • Cement industry
  • Waste disposal and incineration plants

The optimisation of a portfolio including its own generation facilities, storage, external purchases and the marketing of surplus energy, achieves economic and ecological benefits such as

  • lower pollutant emissions
  • lower demand for conventional primary energy sources for self-generation
  • lower procurement costs in the case of external procurement
  • lower operating costs
  • higher revenues, e.g. on the electricity exchanges and on the balancing power market

and helps to ensure security of supply for the plants and consumers at the lowest possible overall cost.

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Optimal practical suggestions

Achieving these goals and finding the optimal supply for the industrial site/plant is a highly complex task due to the multitude of boundary conditions. The software calculates - based on a very detailed image/model of the plants and possible procurement and supply contracts - proposals for the optimal operation of the entire plants.

BelVis ResOpt delivers consistent optimisation results for all time horizons (long-term, medium-term, day-ahead, intraday/online) and considers all boundary conditions (purchase contract conditions, procurement costs, quantity restrictions of supply contracts, current plant availabilities, compliance with supply load profiles, fulfilment of concluded OTC, spot market and standard service contracts). This results in practical solutions that can even be executed fully automatically via our BelVis Workflow application

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Your optimisation options

BelVis ResOpt finds the best deployment variant among many and transforms the complexity of your industrial plant into clear statements and simple efficiency.

Let us convince you of the benefits of BelVis ResOpt deployment optimisation for your industrial park/plant in a study on feasibility and financial savings potential.

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BelVis ResOpt: Functional and user-friendly

The prototype of an industrial park or industrial plant, including all generation units, storage facilities, contracts and restrictions, is conveniently set up in BelVis ResOpt using the fully graphical user interface and standard components from the BelVis ResOpt toolbox. Alternatives can be obtained from the base model allowing to calculate and compare different business models and time horizons. In addition, BelVis ResOpt provides functions and tools for load forecasting of consumers, recalculation and analysis, billing preparation, trade optimisation, OTC transactions and much more.

We will be pleased to advise you on the optimization possibilities for your industrial park / industrial plant.

Scalability and decentralised use

The BelVis ResOpt optimisation model, the number of components, forecasts and automatically running sub-processes can be adapted to the scale of your task (large industrial park to smaller industrial plant). The IT infrastructure is scalable from the highly secure dual computer system on your servers to the cost-effective KISTERScloud solution in the security-certified KISTERS Data Centre. In the case of production facilities at several locations, additional revenues can be achieved by bundling procurement and marketing, if necessary.

We will be pleased to advise you on the optimization options for your industrial park/plant.

System overview (simplified)
Image: System overview (simplified). Source: KISTERS AG
Konsistent planning for all time horizons
Image: Konsistent planning for all time horizons. Source: KISTERS AG

Project example

Optimising power plant and energy use in the metallurgical plant network

The efficient use of energy is an economically decisive factor for voestalpine Stahl GmbH as a subsidiary of the international steel and technology group of voestalpine AG based in Linz. In addition to the steel-producing sites in Linz and Donawitz, voestalpine also operates gas and steam power plants with a capacity of 377 and 55 MW, respectively, which convert the energy contained in the steelworks' waste gases into electricity, process steam and district heating as efficiently as possible. The energy control centre in Linz controls the utility supply of the Linz smelter with the blast furnace gas, coke gas and crucible gas produced during steel production, as well as purchased natural gas if necessary.

Technical-economic optimisation of plant operation

The question "How to operate a steel plant as (energy) efficiently as possible?" becomes a complex task that can no longer be solved reliably and quickly enough manually, considering thermodynamic behaviour, a large number of different delivery obligations and rapidly changing market prices. Those responsible at voestalpine Stahl GmbH rely on the BelVis ResOpt optimisation solution.

The power plant optimiser has a thermodynamic and a market-based optimisation component as well as extensive forecasting options. The most important target variables of the optimisation are firstly the economic market deployment, secondly the optimisation of physical variables such as calorific value/gas quantity of the mixed gas station and minimisation of natural gas and electricity power peaks, and thirdly the improvement and consolidation of the deployment plans of the technical units (power plant and smelter plants) with regard to the deployment and mix of different types of gas.

Download technical article "Efficient energy use in the steel mill?“


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