Modular Energy Demand Modeling of Manufacturing Processes for Energy Efficiency Improvement

The decarbonization of manufacturing processes through energy efficiency is complex due to diverse process requirements and technical interactions between processes. However, to identify energy efficiency potentials systematically transparency about the current energy demand is required. This paper presents a modular modeling approach to classify and determine process-specific energy needs. For the modeling of energy demands, a classification of the manufacturing processes by process modules is implemented. By the introduction of energetic operations, the minimum, assistant and loss energy demand are modeled. The method is applied in a vacuum annealing furnace and in a production line for the assembly of housings. The validation of the furnace shows a 4,85% and of the production line 4% deviation between modeling and measurement of the total energy demand. The energy loss demand amounts to 61,8% for the furnace and 35,86% for the production line, which are the starting points for an energy efficiency improvement in further research.