The Challenges and Opportunities of Energy-Flexible Factories: A Holistic Case Study of the Model Region Augsburg in Germany

Economic solutions for the integration of volatile renewable electricity generation are decisive for a socially supported energy transition. So-called energy-flexible factories can adapt their electricity consumption process efficiently to power generation. These adaptions can support the system balance and counteract local network bottlenecks. Within part of the model region Augsburg, a research and demonstration area of a federal research project, the potential, obstacles, effects, and opportunities of the energy-flexible factory were considered holistically. Exemplary flexibilization measures of industrial companies were identified and modeled. Simulations were performed to analyze these measures in supply scenarios with advanced expansion of fluctuating renewable electricity generation. The simulations demonstrate that industrial energy flexibility can make a positive contribution to regional energy balancing, thus enabling the integration of more volatile renewable electricity generation. Based on these fundamentals, profiles for regional market mechanisms for energy flexibility were investigated and elaborated. The associated environmental additional expenses of the companies for the implementation of the flexibility measures were identified in a life-cycle assessment, with the result that the negative effects are mitigated by the increased share of renewable energy. Therefore, from a technical perspective, energy-flexible factories can make a significant contribution to a sustainable energy system without greater environmental impact. In terms of a holistic approach, a network of actors from science, industry, associations, and civil society organizations was established and actively collaborated in a transdisciplinary work process. Using design-thinking methods, profiles of stakeholders in the region, as well as their mutual interactions and interests, were created. This resulted in requirements for the development of suitable business models and reduced regulatory barriers.