IW Gussputz increases profits and saves €45,500 annually through peak shaving and energy trading
IW Gussputz, a well-known metalworking company near Darmstadt, was faced with rising production costs due to its high energy requirements. As electricity prices rose, so did operating costs, so a way had to be found to ensure stable and predictable energy prices in the long term.
The company had already taken steps towards energy independence and installed a 490 kW solar system. However, the company soon realized that much of the energy generated was being fed into the grid and not used on-site.
To solve this problem, IW Gussputz partnered with HIS-Energy to optimize energy consumption and reduce the high costs of peak load. The goal was to maximize the efficiency of the PV self-consumption system and significantly reduce energy costs.
The solution: Intelligent battery storage and energy management
HIS-Energy recognized that solar power alone would not be enough to achieve IW Gussputz's energy saving goals. In order to optimize self-consumption and reduce peak loads, HIS decided to integrate a battery storage system and an intelligent energy management system.
The most important components of the HIS-Energy solution
The battery storage (HISbatt): A 184 kVA / 466 kWh battery storage system efficiently stores the excess energy from the photovoltaic (PV) system and prevents it from being fed into the grid. This storage system can then be used to cover peak demand or to optimize self-consumption, reducing dependence on grid power.
Energy management system (HIS-EMS): This advanced system monitors and controls energy flows in the company and dynamically optimizes the generation, storage and consumption of electricity. It ensures that excess energy generated by the PV system is not wasted, but is used to charge the battery storage or to meet immediate energy needs.
PV self-consumption, peak shaving and energy trading (Multi-Use): By integrating the battery storage system into the energy management system, self-consumption of solar power has been significantly increased. This means that a larger proportion of the electricity generated by the PV system can be used on site, meaning less electricity has to be purchased from the grid. In addition, consumption charges have been significantly reduced by reducing short-term electricity peaks. In addition, the battery generates additional income during the night by participating in electricity trading markets such as intraday and day ahead.
Technical Overview & Calculations
HIS-Energy battery storage: Optimized self-consumption at IW Gussputz
Before installing the battery storage system, IW Gussputz faced the problem that the solar system generated a lot of electricity, but this remained unused during periods of low production activity. This excess energy was fed into the grid at a low price, which led to financial losses compared to self-use.
By installing the battery storage system, IW Gussputz was able to significantly increase its own consumption of solar energy by storing excess energy and using it at a later date to cover demand during peak production or when energy consumption is high. This reduces the need for expensive grid electricity.
By using the battery storage system, IW Gussputz can consume an additional 80,610 kWh from its 490 kWp solar power plant itself. Without the battery system, these 80,610 kWh would have been fed into the grid, which would have brought the customer a benefit of €0.07 per kWh. However, since the customer uses this energy themselves, they have to take less electricity from the grid, resulting in a higher cost advantage of €0.18 per kWh (€0.25 per kWh grid costs minus €0.07 feed-in benefit). This corresponds to an annual saving of €14,509 (0.18 x 80,610).
HIS-Energy Peak Shaving: Reduced electricity costs for IW Gussputz
Until now, IW Gussputz incurred significant costs due to peak loads, which at times reached up to 345 kW and caused electricity costs of €5,875 per month.
By implementing the HISbatt energy storage solution and the HIS energy management system, this problem was effectively solved. By optimizing energy consumption and reducing peak load to 240 kW, the company now saves €1,790 per month. This corresponds to an annual saving of €21,480.
Together with the savings from improved self-consumption, this results in a total annual cost reduction of €35,989.
Results: Efficient energy supply
IW Gussputz made a conscious decision to invest in a battery storage system to meet the challenges of ever-increasing electricity costs that many companies in the industry face. Although the installation of a photovoltaic system was already a positive step, it became apparent that the savings potential remained limited without additional energy storage and peak load management.
To maximize the efficiency of the PV system and minimize dependence on expensive grid power, IW Gussputz worked closely with HIS-Energy. The HIS team, consisting of experienced engineers and energy management experts, carried out a detailed analysis of the company's specific needs and developed a tailor-made solution.
"Our goal was not just to deliver a technical solution, but to help IW Gussputz secure its energy supply in the long term and make the battery storage system a worthwhile strategic investment," says Jonas Mechler, energy management specialist at HIS-Energy. After a thorough analysis of the company's production peaks and energy consumption, HIS developed a solution that seamlessly integrates into the existing energy grid with solar system and maximizes energy self-sufficiency. This approach ensures that the solar energy generated is used as efficiently as possible, reducing dependence on expensive grid power during peak demand and allowing the battery storage system to participate in energy trading at night. This is an excellent example of combining cost-saving and profit-generating strategies for industrial customers.
The partnership between IW Gussputz and HIS-Energy went far beyond the sale of a battery storage system. HIS-Energy accompanied the entire project from planning and implementation to ongoing maintenance and optimization.
Optimizing ROI through HIS-EMS multiple use
IW Gussputz expects the initial investment to be fully recouped within a few years, followed by annual savings of around €36,000. In addition, the company plans to use the battery storage system for night-time energy trading (intraday, day ahead) and potentially generate another €9,500 per year by participating in the APEX spot markets. This strategy, known as multi-use, which uses both front-of-the-meter and behind-the-meter applications, could increase the total annual savings to €45,500. This is achieved with just one 184kW/466kWh battery storage system (BESS) and intelligent energy management systems from HIS Renewables GmbH.
In addition to the immediate financial benefits, the investment also offers long-term benefits such as increased energy independence, improved energy efficiency and a reduced carbon footprint.
By combining the PV system with a battery storage system, IW Gussputz is not only able to cover its current energy needs, but is also prepared for future fluctuations in production requirements and electricity prices in the grid. This flexibility and reliability form a solid basis for the company's long-term energy strategy.
Conclusion: A model for energy efficiency
IW Gussputz is a prime example of how companies can reduce their energy costs, improve operational efficiency and generate profits by strategically combining solar systems, battery storage and intelligent energy management.
With annual savings of almost €45,500, the long-term benefits of this investment are obvious. This case shows that economic efficiency and environmental sustainability can go hand in hand.
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