Energy costs are high - This especially impacts companies in processing industries. Process chains are subject to fluctuations in performance, which are hidden, but available potential reserves.

These can be activated with Dynamic Energy Management. This is made possible by new technologies. IT-automation, digitalisation and database systems require the use of mathematical methods. Special visualisation of the results and participation in success create an intensive dialogue between "man and machine".

Energy efficiency
Dynamic energy management is the synchronous management of the flow of energy and materials in real time. In the production process, the consumption of products and the consumption of energy are continuously monitored. The recycling process chains are also measured. It does not matter whether energy is generated of from biological waste or the recycling of process heat. What is decisive, is the fact that the input and output are recorded as data series and evaluated. This is the basis for all activities for increasing energy efficiency (Fig.1).

The application is carried out with an energy management information system (EM information system) by Roesberg Engineering. This is a special database software into which the algorithms of Dynamic Energy Management are integrated. After evaluation and optimisation, the energy efficiency of the process chain can be increased by more than 25%. In addition, a new level of transparency on-site produces a continuous improvement of the processes.

Special graphs of the EM information system show the evaluation of input and output data for the process chains. These enable the teams to smooth out fluctuations in performance and increase energy efficiency.

Pump storage technology
Fig. 2 shows the specific energy consumption in a large sewage plant. In the early morning, this is extremely high. The causes for this are a low intake of waste water and unregulated pumps. Here, electricity can be saved every day by implementing pump storage technology.
Pipeline systems are usually equipped with pumping stations. These can be used as pump storage facilities. Dynamic Energy Management demonstrates that intake fluctuations can be transformed into a constant intake by means of pump storage technology.

Fig. 3 shows the input and output for a large sewage plant. In this case, the treatment of sewage is the production. The electricity consumption is almost constant. The fluctuations in intake due to consumers is extremely large. By cushioning this with the aid of pump storage technology, energy efficiency is increased by 25%. For this sewage treatment plant, energy costs of €1.1 million per year can be saved.

Energy specifications
The energy specifications "Ve" are important for the management of energy. These are precisely calculated with the EM software. There are two basic applications:

• for production, where Ve = energy consumption/quantity of material
• for energy generation, where Ve = fuel quantity/energy generated

Innovative processes
Investigations confirm the positive effect of Dynamic Energy Management in various industries:

• the processing industry can increase overall energy efficiency
• municipal sewage treatment plants can become up to 100% independent in regard to energy
• Wineries can cover up to 50% of their energy requirements with wine residues
• Non-ferrous metal foundries can save more than 25% of their energy requirements

In order to motivate teams, it is advisable to let them participate in the success. Integration into business improvement management is simple. The evidence is provided via the Input/Output balance of Dynamic Energy Management. The dividend is paid to the team members on a quarterly basis according to their attendance.

Benefits
The benefit of Dynamic Energy Management for the entire processing industry is illustrated in many ways: The energy efficiency of production is increased by more than 25%. Process chains within the company are continuously improved. The generation of biogas from organic residues is increased. These examples are only a small illustration of the possibilities which exist.