Why is storing excess energy crucial to the energy transition?

The energy transition, which Germany, among others, has undertaken, aims to have the majority of the country's energy come from renewable sources - wind, solar, hydroelectric and geothermal - by 2050. This is a key step toward CO₂ emissions reduction, decarbonization and independence from fossil fuels. However, renewable energy poses new challenges. Unlike traditional sources such as coal and gas, energy production from RES is unstable and dependent on weather conditions, leading to periodic energy surpluses.

The heating industry here faces a special opportunity and challenge at the same time - Power-to-Heat technology can efficiently convert excess electricity into heat, supporting the heating sector during periods of increased heating demand. This approach makes it possible to generate heat from surplus energy, allowing sustainable production and stabilization of the energy system.

An example of a situation that reveals these problems was the so-called Mother's Day in Germany in 2016. Intense sunshine and strong winds caused photovoltaic systems and wind turbines to produce excess energy at the time, exceeding market demand. This resulted in the phenomenon of negative energy prices - producers had to pay consumers for the excess to avoid overloading the grid. Such situations show that the lack of energy storage or alternative use during periods of overproduction can lead to huge economic losses and instability in the energy system.

That's why a key challenge in the context of the energy transition is the development of technologies that make it possible to store surplus energy or convert it into other, useful forms - first and foremost, into heat that can be supplied to district heating systems and used when there is a need for heating energy.

What are the challenges of managing excess energy in industrial plants? The customer's problem

German company ELWA has been in the market for years as a specialist in Power-to-Heat (P2H) systems. ELWA designs and manufactures systems that convert surplus electricity into heat for efficient energy storage and further use. Due to the challenges posed by the volatility of energy production from renewable sources, ELWA sought a solution that would manage excess energy in a stable and secure manner , while providing high flexibility and scalability. The systems had to be modular so that the company could gradually expand the infrastructure as heat demand increased. A key goal was to create a system that would work for both small and large loads, offering a wide power range and full integration with other energy units.

The company also expected systems that would provide high availability and ease of servicing. Maintaining operational stability required technologies that minimized the risk of downtime and facilitated maintenance. In addition, the system had to be versatile enough to allow components to be replaced quickly and without disrupting production continuity.

Due to the high variability of renewable energy production, continuous control and monitoring of process parameters such as temperature and pressure was a key requirement. Indeed, effective management of surplus energy requires precise real-time monitoring of these variables. To meet these needs, it was necessary to implement an advanced measurement system that guarantees the safety and efficiency of the entire P2H process.

How does a three-phase power controller reduce energy consumption and lower operating costs in Power to Heat systems? Our solution

ELWA, in cooperation with JUMO, has implemented an advanced Power-to-Heat system that precisely manages surplus electricity by converting it into thermal energy. The solution features a modular design, which allows it to scale quickly according to growing energy needs - without the risk of destabilizing the system.

In key elements of the system, our partner ELWA used a three-phase power regulator JUMO TYA 202, which precisely controls resistive loads. This regulator equalizes power distribution throughout the system, which increases energy efficiency and optimizes costs. By using an economy circuit in a three-phase (star-delta) arrangement, the system significantly reduces energy consumption, and an additional power management function enables efficient load distribution in the network. In addition, the real-time power management function allows ELWA to flexibly adjust the load according to the current demand, which reduces energy losses and ensures efficient use of surplus energy, especially with variable energy from RES.

The JUMO dTRANS p02 DELTA pressure transmitter continuously monitors system pressure, allowing for immediate response to process variables, preventing overloads and ensuring operational stability. The JUMO safetyM STB/STW temperature limiter, on the other hand, provides constant control over temperature levels, protecting the system from overheating and extending its service life.

Responsible for central control is the JUMO mTRON T PLC, which combines all system components into a single, integrated control unit. Its modular design provides flexibility, allowing rapid addition of new units or expansion without downtime. This versatile unit integrates PLC functions, Ethernet communications, as well as process visualization, offering full control over process parameters. The JUMO mTRON T also provides advanced monitoring and configuration options through an intuitive control panel.

In our proposed solution, we have taken into account the needs for high availability and ease of system servicing. We have enabled quick replacement of components, which minimizes service downtime and ensures continuous operation. In addition, thanks to its modular architecture, the system can be expanded at any time, allowing ELWA to dynamically adapt to changing energy requirements - guaranteeing full control over energy surpluses and their efficient use.

How do advanced control systems optimize surplus energy management? Customer benefits

With the modular Power-to-Heat system, ELWA has gained an effective tool for managing surplus energy - surpluses are immediately converted into heat, eliminating the risk of paying for negative energy prices and making full use of available resources.

Operational security and high availability are key benefits of our proposed solution. Components such as the TYA 202 power regulator and the dTRANS p02 DELTA pressure transmitter ensure reliable and stable operation, and minimize the risk of service downtime.

The P2H system also brings significant savings, optimizing energy costs by evenly distributing loads and simplifying maintenance. The high efficiency and durability of components reduce operating costs while promoting production stability.

The integrated JUMO mTRON T control system enables convenient monitoring of process parameters, and its intuitive interface allows rapid response to changing demands. The modular P2H system gives ELWA full control over the process, increasing efficiency and supporting business growth.

Is Power-to-Heat technology the future of surplus energy management?

Power-to-Heat technology offers a modern approach to managing excess energy, especially with the growing share of renewables in the energy mix. P2H allows for the efficient conversion of surplus energy into heat, eliminating the problem of negative energy prices and enabling full utilization of resources. By using P2H systems, industrial plants and CHP plants can achieve greater operational stability, reduce costs and effectively manage production variables due to the volatility of RES.

We recommend considering the implementation of Power-to-Heat systems in plants that want to optimize their energy processes. Modular solutions, such as those offered by JUMO, allow for flexible adaptation to changing needs and easy expansion as demand increases.

P2H technology will evolve over time, adapting to changes in the energy market and the growing demand for efficient energy storage. We encourage companies to invest in such solutions to gain energy independence, reduce operating costs and prepare for future energy challenges.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

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