Optimal energy management for industrial facilities: enhancing efficiency and flexibility through coupled heat pump-thermal storage systems

In pursuit of the 2030 and 2050 sustainability targets, manufacturing industries—among the largest energy consumers—are under increasing pressure to reduce their environmental impact while maintaining competitiveness. A key strategy adopted by industries to achieve these goals is the electrification of consumption. However, for this strategy to be truly effective, it requires the integration of renewable energy sources and the enhancement of energy flexibility, enabling industries to use cleaner energy source and better manage their consumption and production based on factors such as climate conditions, electric grid requirements, and process needs. To achieve this, it is essential to optimize the management of the facility's energy assets. This work analyses the impact of optimal management on reducing costs, increasing operational efficiency, and enhancing flexibility, providing manufacturing industries with guidelines for implementing effective energy management. These strategies are crucial for reaching sustainability goals and improving competitiveness, depending on various energy-related objectives. An optimal energy management algorithm was developed based on a Mixed-Integer Linear Programming (MILP) approach. MILP was chosen for its ability to deliver fast, optimal solutions even in complex systems involving multiple energy carriers and diverse energy demands, as is typical in industrial facilities. These facilities require the management of various energy sources, each with distinct characteristics and constraints, as well as diverse energy demands, such as heating, cooling, and process requirements. Specifically, the model considers factors such as manufacturing process consumption patterns, load management, heat storage capacity and heat electrification technologies to optimise energy use based on specific objective while enhancing the facility’s energy flexibility. The system considers the use of an air source heat pump (ASHP) coupled with thermal energy storage (TES). The developed model can assess the synergy between these technologies and providing optimal management strategy, making it a fundamental tool for the day-to-day energy asset management of industrial facilities. A case study of a manufacturing facility in Italy was conducted to demonstrate the real-world application of the algorithm, supporting the company’s sustainability targets. The study, through the analysis of different scenarios, provides practical guidelines for determining optimal energy management as well as the optimal sizing of systems to meet these objectives. These insights offer industries a robust framework for implementing customized energy management strategies that align with their sustainability, economic, and flexibility needs.