Diese Studie beschreibt die Entwicklung eines betriebsunabhängigen Simulationsmodells für elektrifizierte Druckgießereien, die ihren Energiebedarf mit Hilfe eines Smart Grid Systems decken. Das Modell verwendet reale Wetter- und Börsenstrompreisdaten für den Simulationszeitraum. Mit Hilfe des Modells können die Stromkosten für eine Produktion zu einem bestimmten Zeitpunkt (Tages- und Jahreszeit) sowie die Wirtschaftlichkeit verschiedener PV-Anlagen- und Stromspeichervarianten ermittelt und verglichen werden. Zudem ermöglicht es die Untersuchung des Anteils der verschiedenen Energieträger für die jeweilige Konfiguration. Dies kann mit Hilfe des Modells für Standorte in ganz Deutschland durchgeführt werden. Darüber hinaus werden in dieser Arbeit beispielhafte Simulationsstudien vorgestellt, die den breiten Anwendungsbereich des Modells aufzeigen. Aus den Ergebnissen kann ein erster Überblick über Einsparungs- und Optimierungsmöglichkeiten gewonnen werden. Perspektivisch stellt das Modell eine Grundlage dar, um mittels simulationsgestützter Optimierung optimale Anlagenlayouts und Produktionszeitpunkte zu ermitteln.

This study describes the development of an operation-independent simulation model for an electrified die-casting foundry that uses a smart grid system to meet its energy needs. The model uses real weather and stock exchange electricity price data for the simulation period. The model can be used to determine and compare the cost of electricity for production at a given time (time of day and season) as well as the economics of different PV system and electricity storage options. It is also possible to analyze the share of different energy sources for each configuration. This can be done for sites throughout Germany. In addition, exemplary simulation studies are presented in this paper which demonstrate the wide range of applications of the model. The results provide an initial overview of the potential for savings and optimization. In the future, the model will provide a basis for determining optimum plant layouts and production times by means of simulation-based optimization.

The current energy crisis and high fossil fuel costs are challenging energy intensive industries such as non- ferrous foundries. It is therefore important to promote the transition to renewable energy sources with the electrification of melting units. This pilot study is the first to simulate the transition of conventional foundries to sustainable technologies. For this purpose, a simulation model based on a selected example company is developed. It takes into account the energy consumption and the logistical effects of a converted operation. The simulation model is implemented as a hybrid simulation combining a discrete event simulation at the plant level and a process simulation within the furnaces. The study shows how a sustainable energy supply can be achieved in foundries. The effects of efficiency as well as energy costs and emissions are also taken into account.

The current energy crisis and the high cost of fossil fuels pose major challenges for energy-intensive industries such as the non-ferrous foundry industry. Therefore, it is important to promote the transition to renewable energy sources with the help of the electrification of the melting units. In this pilot study, for the first time the conversion of conventional foundries to sustainable technologies is simulated. For this purpose, a simulation model is developed based on a selected example company. It considers the energy consumption and the logistical effects of a converted operation. The simulation model is implemented as a hybrid simulation combining a discrete
event simulation at the plant level and a process simulation within the furnaces. The study shows how a sustainable energy supply can be achieved in foundries. It also considers the impact of efficiency, energy costs and emissions.