1. Introduction
The Green Deal Industrial Plan strengthens the competitiveness of Europe’s net-zero industry and accelerates the transition to climate neutrality by creating a more favorable environment for increasing European Union (EU) production capacity for the net-zero technologies and products needed to meet Europe’s ambitious climate goals [
1]. This approach intends to make factories greener by the implementation of a sustainable energy supply to warehouses, office buildings, and industrial sheds. The industry sector, as one of the highest energy consumers in the EU, accounted for 25.1% of final energy consumption in 2022. Within the industrial sector, the highest energy consumers in the EU in 2022 were the chemical and petrochemical industry, the non-metallic minerals industry, and the paper, pulp, and printing industry [
2]. Electricity (33.3%) and natural gas (31.2%) accounted for nearly two-thirds of the final energy consumption in the EU’s industry sector in 2022 [
2]. In addition, the building sector is one of the most energy-consuming sectors, representing, at the EU level, 40% of the final energy consumption and 36% of Greenhouse Gas (GHG) emissions. Electricity consumption represents around 35% of buildings’ energy needs [
3,
4]. To reach the aforesaid challenging goals, EU countries have put in place several measures in recent years to reduce energy consumption in buildings and increase the exploitation of Renewable Energy Sources (RESs) with the so-called “Fit for 55” package that aims to reduce GHG emissions by at least 55% by 2030, with respect to 1990, and increase the share of renewable energy in the market by up to 40%.
In the industrial sector, buildings, warehouses, and halls constitute large energy consumers with a high demand for electricity, heating, and cooling to guarantee both an adequate level of comfort for workers and the proper conservation of goods (e.g., in the case of warehouses for food products). The installation of RES plants close to the aforesaid facilities can reduce their carbon footprint. Photovoltaic (PV) modules, either installed on the roofs, integrated with the facades of buildings, or adopted in parking lots, as well as small wind turbines and hydro plants, can also provide sustainable energy to industrial sites. On the other hand, to cover the thermal needs (heating, steam, hot water) of industrial facilities in a sustainable way, thermal solar collectors, geothermal heat pumps, and boilers fed by renewable sources are usually adopted, together with Combined Heat and Power (CHP) units [
5] comprising microturbines and internal combustion engines fed by natural gas and biogas, and also by hydrogen produced by electrolyzers directly fed by RES plants. When cooling energy is also needed, Combined Cooling, Heat, and Power (CCHP) plants [
6] are typically installed by coupling one or more CHP units with absorption chillers. Nowadays, several industrial sites are converting to green sites by adopting many of the above technologies and transforming their buildings into real prosumers, as highlighted in [
7], where a multi-energy industry facility offering flexibility services in the electricity markets is analyzed. As reported in the scientific literature, and as illustrated in
Figure 1, more and more papers focus on “green warehouses” and “sustainable warehouses”, proposing mathematical models and tools to optimize and simulate the design and operation of warehouses.
Battery Energy Storage Systems (BESSs) are usually installed at green industrial sites in order to mitigate the stochasticity of RES sources and loads, and to exploit the variability of electricity prices. RESs and BESSs can also provide ancillary services to the network and jointly work with the electric mobility infrastructure, as discussed in [
8], where the example of a beverage company in northern Germany with electrical industrial forklifts, power-to-heat plants, wind turbines, PV systems, and energy storage devices (thermal, electrical, and hydrogen) is described and analyzed in detail. Moreover, RES generation and BESS systems can be exploited not only for the provision of active power but also for the exchange of reactive power to satisfy the reactive power demand of loads and to provide voltage support, even at night [
9]. All these technologies and best practices are now commonly used in new logistics parks, as reported in the literature. For instance, the interaction between green logistics practices, the circular economy, and Industry 4.0 technologies is explored in [
10], while a detailed review of key green practices in warehouses is proposed in [
11]. In [
12], the advantages of installing Microgrids (MGs) with wind, solar and battery technologies in sustainable factories and warehouses are illustrated, while in [
13] the authors report on a new methodology to optimally locate and size wind turbines, solar power systems, and batteries in industrial facilities, with the aim of reducing net supply-chain costs. A similar point of view is adopted by the authors in [
14], where the exploitation of the local production of energy from wind and solar sources is seen as a way to decarbonize manufacturing, transportation, and warehousing operations. On the other hand, in [
15], a multi-objective optimization model is defined in order to minimize the global costs of an industrial site acting as a prosumer within the electricity market. As mentioned above, it is important to note that many industrial prosumers have MGs within their sites. In [
16], the concept of industrial MGs is defined and real-world applications are described, with the aim of illustrating the main power control and energy management strategies in this context. In [
17] an industrial MG with wind turbines, CHP units and BESS systems is analyzed by also including the possible application of demand response strategies.
While MGs are purely physical systems and can be installed in industrial contexts to provide a local and reliable energy supply, it should not be forgotten that green industrial sites can now also be an active part of virtual power plants and energy communities. In the first case, we deal with aggregated systems of energy assets remotely and automatically optimized to dispatch services for distribution or wholesale markets [
18], while in the second case we mainly refer to Renewable Energy Communities (RECs) [
19] as aggregated legal entities made of members (natural persons, small and medium enterprises, local authorities, etc.) that decide to jointly share energy locally produced by an RES in order to obtain environmental, economic and social community benefits, rather than final ones [
20,
21]. Many examples of energy communities can be found in the residential and tertiary sectors [
22,
23], but an excellent solution to maximize shared energy is also to bring together residential and industrial members. The latter is usually characterized by peaks in electricity demand at central times of the day, coinciding with peaks in PV production. Indeed, in [
24] the authors prove that an REC can achieve economic profitability, including the industrial demand of a desalination unit, while the study reported in [
25] highlights that the industrial sector presents a good opportunity to install RESs and provide renewable energy to closed city members. On the other hand, demonstrates how the aggregation of different types of distributed storage systems in RECs is a way to maximize the self-consumption of the community and provide ancillary services to the electric power system [
26]. In [
27], an optimal planning approach for renewable energy communities is proposed. A similar approach is presented in [
28], where demand response with Electric Vehicles (EVs) is also considered. In [
29], the impact of RECs on the grid is investigated.
Several considerations can also be made in relation to environmental issues at industrial sites, where not only office buildings, warehouses and halls are responsible for environmental emissions. A significant amount of emissions is due to transportation, i.e., the means of transport used to move goods within industrial sites, the vehicles (vans and trucks) used to deliver freight or transport goods to other destinations, and the vehicles used to load and unload trains and ships. As set out in the European Commission’s latest regulations, a gradual and massive reduction in CO
2 emitted by the transport sector is planned. Regarding light-duty vehicles, the regulations indicate a 50% reduction by 2030, with zero emissions by 2035, while for heavy-duty vehicles, a progressive reduction, of 45% by 2030, 65% by 2035, and 90% by 2040, is envisaged [
30]. As reported by the Italian Association MOTUS-E, nowadays, in many EU countries, light commercial EVs constitute less than 10% of annual new registrations, and even smaller percentages are found for electric trucks [
30]. The proliferation of the EV infrastructure, coupled with RES plants used to directly charge them, will have an impact on public utilities and buildings [
31], and also on the industrial sector, where many companies still use highly polluting vehicles, thus improving air quality in urban areas. Electric mobility infrastructures have a significant impact on the electric power system, considering the current deployment of quick, fast, and ultra-fast charging stations, which can lead to maximum charging power values of around 43 kW in alternating current, and greater than 300 kW in direct current systems, for each station. The increase in charging power allows for a reduction in charging times, which is particularly important in industrial applications, such as logistics, where EVs need to be parked for short periods during the day and therefore require fast charging; at the same time, they can also be charged at low/medium power at depots, typically during overnight charging. In any case, an increase in the number of EVs will mean an increased deployment of charging infrastructure, both in terms of the number of chargers and the total power supplied, which will have a significant impact on electricity distribution networks. In order to maximize the potential of electricity grids without creating congestion and inefficiencies, it is necessary to define intelligent EV smart-charging strategies and promote an optimized integration of e-mobility infrastructure and RES systems [
32]. This implies the modulation of the charging power as a function of different factors, such as electricity prices, the availability of RES, current operating conditions, and the vulnerabilities of power networks. Furthermore, by implementing Vehicle-to-Everything (V2X) technologies, namely, Vehicle-to-Grid (V2G) and Vehicle-to-Building (V2B), EVs can truly take an active role in the electricity system and behave like BESSs [
33]. They can be charged when electricity purchase prices are lower, the grid is not overloaded, or when there is a surplus of energy available from an RES; conversely, they can supply electricity to the grid (V2G) or to a building (V2B) when electricity purchase prices increase, or when the grid needs additional power to cover the decrease in RES production or the lack of energy supply from conventional power plants. This helps to reduce the variability of energy production by RESs and to increase the self-consumption of renewable energy, which is also beneficial from an economic point of view. The importance of these recent innovations in the field of electric mobility can also be seen in the literature, where an increasing number of scientific articles on the subject can be found, as shown in
Figure 2.
There are several papers in the scientific literature dealing with the optimal design and operation of MGs, nanogrids, energy communities, and prosumer buildings, but only a few of them refer to industrial applications, and, in particular, to logistics. These types of decision problems are typically formalized by mathematical programming models, usually Mixed Integer Linear Programming (MILP) models with different time horizons, an equivalent year or several years, for optimal design problems, and a day or a week for optimal operation problems, the latter being typically used to define an Energy Management System (EMS). There are also some papers that combine optimal design with optimal management, where the main objective is to optimally size the energy system, but that provide, at the same time, some suggestions on how to operate it on a daily basis for some typical days. In general, MILP models are considered to be a good compromise for representing real system behavior well, albeit with some approximations in the representation of the physical relationships describing the different technologies, without greatly increasing the computational effort. In [
34], a day-ahead EMS for the optimal operation of an MG with renewable generation and CHP units is presented, taking into account reactive power flows and voltage phenomena. In [
35], a methodology to optimally design a multi-vector energy hub created to supply electricity and heat to a set of buildings within a sustainable district acting as a local energy community is described, while in [
36] the authors describe a stochastic optimization model to optimally manage the energy infrastructure of the Savona Campus, seen as a local energy community, while considering innovative bidding strategies within the electricity markets. The impact of electric mobility on the optimal design of renewable energy collective self-consumers is investigated in [
37], whereas in [
38], a methodology is proposed to optimally design a local energy community that consumes energy from an MG with RES and storage systems. The issue of disordered EV charging demand and its impact on distribution networks is investigated in [
39], where the authors propose a bi-level optimal dispatching scheme for a community charging station, considering time-of-use and real-time pricing mechanisms. The integration of EVs with power-to-gas technologies is investigated in [
40], where a scheduling model based on demand response is proposed. A smart energy infrastructure integrating different types of batteries and EV charging stations is analyzed in [
41], and, similarly, in [
42], the focus is on the integration of V2G with stationary batteries. In [
43], several EMS and advanced energy control strategies are proposed to investigate the potential of the interaction between buildings and EVs, while in [
44], the focus is on EV smart-charging strategies in facilities characterized by the integration of RES and electric mobility. With regard to V2B applications, it is worth mentioning the study reported in [
45], where the benefits of EVs acting as storage systems in buildings operating in island mode are evaluated, and the analyses carried out in [
46,
47] that investigated how V2B can improve the energy and economic key performance indicators of a prosumer building.
The research described in the present paper contributes to the growing field of REC optimization and provides a practical example of integrating advanced energy management technologies in the industrial sector. In particular, an EMS for an industrial MG, owned and operated by a greentech company located in the north of Italy, is presented. The peculiarity is that the site where the MG is installed is the only industrial member of an REC whose other members are only residential users, some of them just consumers and some of them producers. The Low-Voltage (LV) MG has a ring topology with only renewable power plants, namely PV modules, a centralized BESS, and some charging stations for a fleet of EVs, including company cars and delivery trucks able to exploit V2G. As far as the electrical demand of the site, the loads are represented by two warehouses, an office building and the EVs when connected to the dedicated chargers. The site has a Medium-Voltage (MV) connection to the public network with which it can exchange energy in both directions (absorption and injection). The EMS has been conceived in order to optimize the daily operation of the MG, trying to minimize a multi-objective function. On the one hand, it must minimize the net operating costs related to the sale and purchase of energy from the external network; on the other hand, the EMS should follow a desired power exchange profile with the external network, provided by the REC manager in order to maximize the energy shared within the REC, which is incentivized. The aforesaid profile can be the result of another EMS, the one used by the REC manager not described here, which aims to maximize the incentives for the REC members. A further objective of the industrial MG EMS is to limit the inductive or capacitive reactive power exchange with the network in particular time periods, in order to avoid overvoltages or undervoltages in the distribution system; hence, reactive power exchange penalties are included in net operating costs. The multi-objective function that characterizes the EMS in this paper has been defined precisely to take into account two aspects: achieving the objectives of the industrial user, who typically wants to minimize his energy bill, and maximizing the REC incentives. Thus, the EMS was developed to assess whether or not these objectives are in conflict.
A strong novelty of the paper is the introduction of a multi-objective function that considers the trade-off between the interest of the REC to maximize the shared energy and the interest of the single REC member that, in principle, is mainly the minimization of its own net operating costs. In addition, the case study is innovative, considering an industrial user member of an REC, not only exploiting common RESs and BESS but also the V2G application of electric trucks.
The results of the EMS application demonstrate significant improvements in energy efficiency and cost savings for the industrial user, highlighting the potential benefits for the inclusion of similar members within RECs. The EMS takes into account also the capability curves of inverters, that are inherently non-linear: therefore, the EMS is formalized as a Mixed Integer Quadratically Constrained Quadratic Programming (MIQCQP) problem.
The paper is organized as follows. In
Section 2, the MILP mathematical models are described by reporting the multi-objective function and all the constraints and decision variables used to model the MG.
Section 3 presents all the relevant technical and economic data concerning the installed technologies and the operation parameters. In the same section, the main results of the analysis are discussed for the two main scenarios, i.e., the one where we only minimize the operating costs of the MG and the one where only the deviation of the power exchange with the external network from the reference profile supplied by the REC manager is minimized. Finally, concluding remarks are given in
Section 4, where future developments of the work are also envisaged.
2. Materials and Methods
This section provides a detailed insight into the mathematical model of the EMS. The EMS has been modelled as a MIQCQP problem, with continuous and binary decision variables and with linear and quadratic constraints and a quadratic objective function. For each technology installed in the MG, the operational constraints are presented and commented upon.
2.1. Methodology Overview
The flowchart representing the proposed methodology is presented in
Figure 3. The manager of the REC is in charge of defining the optimal power exchange profile of the REC members in order to maximize the shared energy within the REC that is, in turn, incentivized. The REC manager provides reference signals to the members, representing a reference active power to possibly be exchanged with the local distribution network. Each member is supposed to be equipped with an EMS (with the exception of pure consumer members) that must define the optimal scheduling of generation units and storage systems locally installed, along with the EV charging infrastructure.
Figure 3 highlights the main inputs and outputs of the EMS of the
i-th member, that is supposed to be equipped with PV, BESS, and EV charging stations, with the possibility of exploiting V2G. The active power that is actually exchanged by each member with the local distribution network is the one that is accounted for in the assessment of the shared energy.
2.2. Photovoltaic System
The decision variables associated with the PV systems are both continuous and binary ones. Regarding active power, decision variables are continuous and are, namely, the actual active power production, and the curtailed active power, , with and , where B is the number of busses of the MG and T is the number of time intervals into which the optimization horizon is divided. Concerning reactive power, the continuous decision variables are the injected inductive reactive power and the injected capacitive reactive power ; the binary decision variables are and , respectively, equal to 1 when the PV inverter at bus b injects inductive or capacitive reactive power at the time interval t and 0 otherwise.
The only input data are the available active power, and the size of the PV inverter, . The available active power varies depending on the bus since, even if the MG is located in a limited geographical area, PV panels may have different orientations, tilt angles, and shading.
The following continuous decision variables are considered to be positive:
The active power production is given by the difference between the available power and the curtailed quantity, as follows:
The curtailed power can be, at most, equal to the available one, as follows:
The relation between active and reactive power, also known as the capability curve of the inverter, is given by Italian technical standards (see CEI 0-16). The capability curve for PV inverters with a rated power lower than 400 [kW] is the one depicted in
Figure 4. Since it is formed by a circular sector, it can be described with linear and quadratic constraints, as follows:
2.3. Battery Energy Storage System
The decision variables associated with the BESS are both continuous and binary. Regarding active power, the continuous decision variables are the charging and discharging power, and , while the binary decision variables are and , respectively, equal to 1 when the BESS at bus b is in charging or discharging mode at the time interval t and 0 otherwise. Another continuous decision variable is the State of Charge (SOC) of the BESS, . Concerning reactive power, the continuous decision variables are the injected inductive reactive power and the injected capacitive reactive power ; the binary decision variables are and , respectively, equal to 1 when the BESS inverter at bus b injects inductive or capacitive reactive power at the time interval t and 0 otherwise.
The input data were as follows: the BESS inverter rating, ; the maximum charging and discharging power, and ; the charging and discharging efficiencies and ; the self-discharge rate, ; the capacity of the BESS, ; and the minimum, maximum, and initial SOC, respectively, indicated by , and .
The following continuous decision variables are considered positive:
The charging and discharging powers must be limited by the maximum values provided by the manufacturer, as follows:
The following simultaneous charging and discharging of the BESS are forbidden:
Regarding reactive power, Standard CEI 0-16 states that the capability curve of BESS inverters is circular, or may possibly be horizontally sectioned if the maximum charging and discharging powers are lower than the inverter rating or if they are considered to be dependent on SOC, cases that are not taken into account here. The standard capability curve is shown in
Figure 5. The relevant constraints are as follows:
As the decision variables are positive, four sets of constraints (from (23) to (26)) are needed to model the capability curve of the inverter. Constraints (20) to (22) forbid the simultaneous injection of inductive and capacitive reactive power by the BESS inverter.
The energy content of the BESS follows the energy balance and must be limited between a minimum and a maximum value defined by the manufacturer. In addition, due to the structure of the discretized energy balance, the initial SOC must be set in accordance with the input data in the following formulas:
where Δ is the duration of the time interval.
2.4. Electric Vehicles
The decision variables associated with the EVs, and the related charging stations are both continuous and binary. It is supposed that each EV has one charging station available; therefore, no waiting time is modelled. Regarding active power exchange, it is assumed that some EVs are enabled to V2G and are therefore able to exchange a bidirectional power flow with the MG. The continuous decision variables are the charging and discharging power, and , while the binary decision variables are and , with , where is the number of EVs that can be connected at the bus b. and are, respectively, equal to 1 when the v-th EV is charging or discharging at bus b at the time interval t and 0 otherwise. Another continuous decision variable is the SOC of the EVs, . Concerning reactive power, the continuous decision variables are the injected inductive reactive power and the injected capacitive reactive power ; the binary decision variables are and , respectively, equal to 1 when the charger of the v-th EV installed at bus b injects inductive or capacitive reactive power at the time interval t and 0 otherwise.
Input data involving EV chargers is the rating of the EV charger converters, , the maximum charging and discharging power, and and the charging and discharging efficiencies, and . Regarding the availability of the EVs at the charging stations, input data are the sets of arrival, departure and stopover times for each EV, respectively, and , and a binary coefficient , equal to 1 if the v-th EV is present at bus b at time t or 0 otherwise (i.e., equal to one for each t belonging to ). Regarding the energy content of the EV battery, the input data are the capacity of the battery , the minimum SOC of the EV, , the expected minimum and maximum SOC at arrival time, and , and the expected minimum SOC at the departure time, .
The following continuous decision variables are considered positive:
Charging and discharging powers must be limited by the maximum values, which are evaluated as the minimum between the maximum power that can be exchanged by the charging equipment and the one that can be exchanged by the EV, as follows:
Charging and discharging of the EVs are possible only when the EV is present at the facility, as follows; in any case, the simultaneous charging and discharging of the EVs is forbidden:
The Italian standards do not provide specific references for the exchange of reactive power by dedicated inverters for EV chargers; therefore, a circular capability curve is applied as follows:
EV chargers can exchange reactive power only when the EVs are present at the facility, as stated by (40). The same constraints state that inductive and capacitive reactive power cannot be injected simultaneously.
Since the capability curve is fully circular, four quadratic sets of constraints are needed to model it (from (41) to (44)).
Finally, the SOC of the EV batteries is described by the energy balance. The energy balance is defined for the stopover time intervals, when the
v-th EV is present at the facility, as follows:
The EV SOC must always lie between a minimum and a maximum value, provided by the manufacturer, as follows:
At the arrival times, the EV SOC should be within an expected range, as follows:
At the departure times, the EVs must have a proper SOC in order to be able to perform their daily activities, as follows:
2.5. Connection to the Distribution Network
The MG is supposed to be connected to the local MV distribution network by means of a step-down transformer. The decision variables are both continuous and binary. Regarding active power, the continuous decision variables are the active power withdrawn from the distribution network and the active power injected into the distribution network, respectively, and , while the binary decision variables are and , respectively, equal to 1 when active power is sold to the external network or when it is withdrawn from the distribution network. Regarding reactive power, the continuous decision variables are the inductive and capacitive reactive power provided by the distribution network to the MG, and , while the binary decision variables are and , respectively, equal to 1 if inductive or capacitive reactive power is provided by the external network and 0 otherwise.
The data input is the size of the connection transformer, .
The following continuous decision variables are considered positive:
The active power exchange is limited by the rating of the transformer, as follows:
The active power exchange cannot be bidirectional in the same time interval, as follows:
A circular capability curve is considered for the transformer, modelled through four sets of quadratic constraints (the simultaneous withdrawal of inductive and capacitive reactive power from the external network is, again, forbidden), as follows:
2.6. Optimal Power Flow
In order to model the active and reactive power flows over the MG internal lines and in order to evaluate the effect of those flows on bus voltages, OPF equations are implemented within the model of the EMS. Since classical OPF equations are inherently non-linear, a linearization like the one proposed in [
34] has been applied. The formulas are as follows:
where
and
are the per-unit active and reactive power flows over the link between busses
b and
k,
and
are the per-unit voltage modules at the sending and receiving end of the links, and
and
are the voltage phases at the sending and receiving end of the links.
,
,
and
are the continuous decision variables.
and
are obtained as follows:
where
and
are the per-unit resistance and reactance of the link between busses
b and
k.
Voltage modules must be limited between a minimum and a maximum value, as follows:
Node 1 is considered a slack node; therefore, it is set as the following phase reference node:
2.7. Nodal Power Balances
Active and reactive power balances must be satisfied at each time instant at each node.
For node 1, the active and reactive power balances are as follows:
where
is the system power base.
For the other nodes, the active and reactive power balances are as follows:
where
and
are the active and the reactive power demands of the bus
b at time
t.
2.8. Renewable Energy Community
Even though the Italian legislation about RECs has still not provided clear rules about the role of BESS and V2G-enabled EVs within the incentive calculation mechanism on shared energy, the authors decided to include the following additional constraints:
These constraints prevent the discharging of BESS and EVs when active power is injected into the external network, since up to this moment it is not clear whether the discharged active energy would be taken into account or not for the calculation of the REC shared energy, as the stored energy could have been previously withdrawn from the external grid, rather than being locally generated by PV systems.
2.9. Objective Function
The objective function is made of two terms. The first term is related to the minimization of the net operating costs of the MG, which consider the purchase cost of active energy from the external network, the sale revenues derived from the sale of active energy to the external network, and the penalties on reactive power exchange with the external network. During the central hours of the day, the Distribution System Operator (DSO) sets a penalty for the withdrawal of inductive reactive power from the network, while during off-peak hours, it sets a penalty for the injection of inductive reactive power into the network. This is done in order to avoid, respectively, undervoltages during peak hours and overvoltages during off-peak hours. The second term aims to represent the behavior of the industrial MG within an REC. These are the input signals about the active power that each user must exchange with the external network and, through it, with the other members of the REC provided by the REC manager. These signals should be able to maximize the shared energy in the REC and, therefore, the relevant incentives, in the following formulas:
where
and
are the unitary purchase costs and unitary sale revenues in [€/kWh],
and
represent reference signals of purchased and sold active power that the aggregator of the REC sent to each user;
and
are two weight coefficients; and
and
represent, respectively, the unitary penalties, in [€/kVArh], related to the withdrawal of inductive reactive power during the central hours of the day and the injection of inductive reactive power (dually, the withdrawal of capacitive reactive power) during off-peak hours.