Industrial Energy Management System Implementation

The problem

Large manufacturing facilities increasingly combine complex production loads with on-site generation and battery storage. Coordinating these resources requires an operating strategy that can reduce electricity costs without disrupting production.

What I implemented

As implementation lead, I developed and implemented an optimization strategy for a BYD automotive manufacturing plant in Chongqing. The system coordinated:

• a 60 MW manufacturing load;
• a 60 MW/240 MWh battery energy storage system; and
• 10 MW of solar generation.

The work was conducted with the State Power Investment Corporation and the manufacturing plant, linking production operations with the scheduling of distributed energy resources.

Result and research connection

The implemented strategy was projected to provide approximately US$4 million in annual operating-cost savings. The project also revealed an important physical limit: when production equipment is already highly utilized, short-term rescheduling alone provides limited flexibility. That observation helped motivate my subsequent research on spare production capacity, inventories, and seasonal industrial flexibility.