The research project pursues the overarching goal of covering all arising energy consumptions during the production of calcium silicate masonry (CS) units in simulation-based optimization models. As a result, a resource-efficient control of the production is to be provided.

For the realization of this project, a methodology is required, by means of which all resulting energy consumption can be continuously measured precisely and brought into a dependency on all influencing parameters. Under these conditions, energy consumption profiles can be generated and suitably integrated into an existing simulation and optimization tool, in order to establish the energy factor as an objective for the resource-optimal control of the manufacturing process.

To account for the influence of frequently changing external factors (e.g. outside temperature, resource type), the consumption is continuously monitored by suitable measuring equipment and integrated automatically by adjusting the consumption profile in the model. Like this, the accuracy of the prediction through simulation can be further increased. By means of continuous measurement, it is furthermore possible to identify and interpret target deviations and to arrange countermeasures.

On the basis of first case studies on the integration of energy consumption in the simulation model – including some required model assumptions – the potential of the methodology could be estimated. Accordingly, just by implementing smaller organizational measures, almost 10% of the arising energy consumption can be saved during the hardening process. This deployed optimization method, is now to be expanded to other areas of the CS manufacturing process and to be integrated into a generic optimization tool.
In a further step of development, the system will be designed for an automated, operational use. Through continuous abstraction of all findings, the transferability of the methodology to other sectors of the process industry is provided.