Intelligent cogeneration optimization
Reduction of energy costs, maximization of economic performance, and real-time predictive control.
BRAINWATT® optimizes cogeneration unit operation based
on actual energy demand and market economic variables
Con BRAINWATT® cogeneration becomes a dynamic,
intelligent system focused on real costs.
Reduced overall energy costs
Maximized economic performance of the cogeneration unit
Setpoints always aligned with prices and actual demand
Higher operational efficiency
Less waste, less rigidity, more value
Value-oriented intelligent control
Traditional management = limited performance
Cogeneration plants often operate with:
- Static setpoints
- Rigid control logic
- Regulation based only on equipment parameters
- Low responsiveness to energy prices (PUN, gas, contracts)
- No forecasting of electrical or thermal demand
Result:
Uncontrolled energy costs and undervaluation of CHP assets
The BRAINWATT® solution
BRAINWATT® iintroduces a new paradigm in cogeneration management to meet energy demand at the lowest possible cost.
AI + Predictive models + Digital Twin
Continuous optimization
Dynamic setpoints
Decision-making focused on minimizing total energy cost
Move to dynamic cogeneration plant management and discover how much you can save
with BRAINWATT®
Heavy Industry
Plants
- 2 trigeneratori da 1.560 kW
- 2 assorbitori da 750 kW e 1.185 kW
Implemented Measures
Optimisation of energy generation
BASELINE
- CHP #1 at full power
- CHP #2 in electricity-following mode
Results
Annual savings
Energy generation costs
Plastics Industry
Plants
- 1 trigeneration unit - 2.676 kW
- 1 boiler - 2,5 MWt
- 3 chiller - 350 kW each
Implemented Measures
BASELINE
- Electricity-following mode
Results
Energy generation costs
Food Industry
Plants
- 1 CHP unit - 800 kW
- 2 photovoltaic systems - 303,6 kWp + 695,9 kWp
- 1 thermal power plant - 2 MWt
Implemented Measures
BASELINE
- Fixed setpoint
Results
Hospital
Plants
- trigeneration units - 850 kW each
- 3 boilers - 4 MWt each
- 3 chillers - 2,5 MWf each
Implemented Measures
BASELINE
- Electricity-following mode
Results
Frequently asked questions on
Predictive Optimization of Cogeneration (CHP)
What is intelligent cogeneration optimization?
Intelligent cogeneration optimization transforms static management of cogeneration units (CHP) into a dynamic, predictive system.
Through BRAINWATT®, this approach uses Artificial Intelligence algorithms and Digital Twin models to analyze thermal and electrical demand in real time. By correlating this data with economic variables such as gas prices and the PUN (National Single Price), the platform adjusts setpoints to consistently ensure the minimum total energy cost.
How do dynamic setpoints improve the economic performance of a cogeneration unit?
Unlike control strategies based on fixed machine parameters, dynamic setpoints allow plant operation to adapt to the hourly economic conditions of the market.
BRAINWATT® software continuously evaluates whether it is more cost-effective to produce energy on-site, purchase it from the grid, or integrate photovoltaic generation. This operational flexibility maximizes the economic benefits of CHP and reduces waste by aligning production with actual costs.
Does the integration of optimization software replace the existing PLC or SCADA?
No, adding a higher-level intelligence layer does not replace existing control systems such as PLCs or SCADA, but integrates with them.
BRAINWATT® interfaces with the site’s automation infrastructure to send optimal setpoints while preserving all safety logic and operational constraints of the equipment. This ensures performance improvement without compromising operational continuity or plant safety.
Which variables are analyzed for predictive cogeneration control?
Effective predictive control requires analysis of multiple energy and environmental factors.
The BRAINWATT® platform processes hourly forecasts based on the facility’s electrical and thermal demand, system thermal inertia, and renewable energy production. By integrating this information with updated energy costs and the actual efficiency curves of the cogeneration unit, the system generates a proactive control plan to balance energy procurement and on-site generation.
Is it possible to support market mechanisms such as UVAM or interruptibility?
Yes, dynamic management systems are designed to respond to opportunities in balancing and ancillary service markets.
BRAINWATT® allows the integration of specific parameters to support participation in UVAM schemes (Mixed Enabled Virtual Units), interruptibility programs, or load-following strategies. This capability transforms the technical asset into a financial instrument that can promptly respond to changes in the energy market.
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