Optimal CHP System Configuration and Real-time Operations Management in Manufacturing Industry

Abstract

Advanced application of Combined Heat and Power (CHP) systems as an on-site energy generation is subject not only to optimal system configuration, but also continuous operations management. This is vital in manufacturing plants where several types of energy forms are required dynamically. However, existing shortcomings and challenges have hindered the maximum utilisation of CHP technology as a potential on-site energy generation option. Consequently, this study on the one hand addresses optimal CHP configuration through integrated sizing and operational strategy selection. This is achieved through simulation of on-site energy system operation where comprehensive models of individual components and their potential operational strategies are formulated. Moreover, real-time operations management of CHP systems is developed and evaluated to enable optimal integration of controllable energy supply options into on-site energy systems. Thus, the concept of real-time optimisation is implemented to track a changing optimum. The proposed solution consists of two modules, i.e. the simulation module and optimisation module that can interact with the dynamic operating environments. The simulation module represents comprehensive modelling of individual components and the required interactivity with an operating environment. This also keeps the system operation history and provides look-ahead capability to impact past decisions and future system fluctuations. Moreover, the optimisation module guarantees economic dispatch of the energy system components in addition to unit commitment at short time intervals. The developed modules’ interaction decomposes the problem formulation to cope with concurrent computation and communication requirements. This will overcome the limitations of traditional optimisation techniques to simultaneously encompass system complexity and operational aspects in real-time. On the whole, the developed Real-time Integrated Simulation and Optimisation methodology (RISO) assures practical and intelligent control of potential components on a continuous basis. As a result, the proposed solution provides successful CHP system integration into the manufacturing plants to assure optimal configuration and operations management. Moreover, the generic and comprehensive control strategy facilitates the required foundation to integrate multiple and different types of on-site energy system technologies, such as intermittent renewable energy suppliers.