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A pharmaceutical facility located in Southern Germany is experiencing a trend of growing cooling loads to be met by the chilled water plant composed of ten chillers of greatly varying cost effectiveness. With a capacity shortfall inevitable, the question arises whether to install an additional chiller or improve the utilization of the existing chillers, in particular those with low operating costs per unit cooling, through the addition of a chilled water thermal energy storage (TES) system. To provide decision support in this matter, an optimization environment was developed and validated that adopts mixed integer programming as the approach to optimizing the chiller dispatch for any load condition, while an overarching dynamic programming based optimization approach optimizes the charge/discharge strategy of the TES system. In this fashion, the chilled water plant optimization is decoupled but embedded in the TES control optimization. The approach was selected to allow for arbitrary constraints and optimization horizons, while ensuring a global optimum to the problem. The results show that a relatively small TES tank provides significant economic and operational benefits. Yet, in order to facilitate long-term supply security, a larger TES tank capacity was decided on and the TES system was constructed in 2008.

Analysis of Thermal Energy Storage for a Pharmaceutical Company Analyse eines thermischen Energiespeichers für ein pharmazeutisches Unternehmen