Fraunhofer Institute for Manufacturing Engineering and Automation IPA
Sector-Coupled Energy Systems
Our research for a future-proof electrical supply
The energy transition is reshaping the requirements for industrial energy systems. Ensuring a continuous balance between energy generation and consumption remains essential – across small and medium-sized enterprises as well as large-scale industry. At the same time, rising electricity prices and increasing uncertainty in future energy markets are placing additional pressure on decision-makers. Climate neutrality is becoming a key driver in strategic planning.
Our research focuses in particular on heating and cooling applications, which account for approximately 75% of industrial energy demand. In this context, sector coupling is a critical enabler. Our aim is not only to reduce energy costs in the short term, but to develop sustainable, economically viable, and future-oriented integrated energy systems.
Designing such systems requires careful consideration of energy carriers, suitable technologies, dynamic operating strategies, and the integration of energy storage. These aspects depend on thermal energy levels, site conditions, production processes, and individual business objectives. We provide independent, technology-neutral guidance to identify and implement optimal solutions tailored to specific requirements.
Focus areas
- Optimizing the operation of interconnected energy generation, storage, and distribution systems
- Designing future-proof industrial energy systems
- Developing and integrating technologies based on techno-economic analysis
- Advancing control and regulation strategies for complex energy systems
- Enabling cost-effective decarbonization of industrial process heat supply
Optimizing integrated energy generation, storage, and distribution systems
The efficient operation of industrial energy systems relies on the seamless integration of all components. Our research explores how generation, storage, and distribution assets can be intelligently interconnected to ensure reliable, flexible, and cost-effective energy supply for industrial processes.
Our research covers:
- Optimization of thermal energy networks in combination with energy storage based on advanced mathematical optimization methods
- Transient simulation of industrial high-temperature heat pump systems
Learn more: Efficient Heat Supply at Mercedes-Benz AG - Optimization of combined heat and power (CHP) systems powered by renewable gases (e.g., biogas, hydrogen, wood gas), integrated with energy storage – demonstrated in the SynErgie collaborative project
Learn more about the SynErgie project. - Optimization of thermal process systems using CFD-based simulation approaches
Designing future-proof industrial energy systems
Future-proof energy systems must be technically efficient, economically viable, and flexible enough to meet evolving requirements. We develop tailored planning approaches that effectively integrate energy carriers, production processes, and storage solutions.
Our research covers:
- Techno-economic design of industrial energy systems based on genetic and mathematical optimization methods
Learn more: Low-Emission Factory Operation at Liebherr-Werk Ehingen GmbH - Design of energy recovery systems for industrial waste streams
Learn more: Flexible Energy System with Biogas Utilization for the Food Industry - Flexible energy system planning
Learn morer: Energy System Planning for Maximum Flexibility at Herma - Development and evaluation of hydrogen integration concepts
- Techno-economic design of industrial energy systems based on genetic and mathematical optimization methods
Developing and integrating technologies under techno-economic considerations
Innovative technologies are developed with a strong practical focus and evaluated for their economic viability. We examine how new systems can be integrated into existing production processes and the benefits they deliver.
Our research covers:
- Development of bivalent supply concepts using CFD simulations
Learn more: Energy Flexibility through Bivalent Melting Furnaces - Energy integration of carbon capture systems into production processes, accounting for future certification prices
- Development of bivalent supply concepts using CFD simulations
Developing and testing advanced control concepts for future energy systems
Dynamic energy systems require intelligent control strategies. We develop and test concepts that enable efficient operation of production processes and the effective integration of renewable energy.
Our research covers:
- Development of dynamic control concepts
- Laboratory testing of control systems using a thermal hardware-in-the-loop test bench
- Testing of sector-coupled scenarios in the Industrial Energy Lab (heating, cooling, electricity)
Shaping future-proof energy systems together
Get in touch with us. We provide independent, technology-neutral support to help you identify the best solution for your specific requirements – efficient, cost-effective, and future-proof.