Electric Vehicle Fleet as Flexible Electricity Storage

The ADC Pilot Factory project explores a new paradigm for industrial energy supply by introducing flexible and scalable direct current (DC) grids in manufacturing. At the core of this innovation is the use of electric vehicle (EV) fleets as modular, bi-directional storage systems, transforming them into active components of industrial energy management.

It is important to note that traditional alternating current (AC) grids can create inefficiencies when integrating renewable sources, such as photovoltaics (PV) and storage systems like EV batteries. This is due to repeated conversion losses. By adopting a DC-based infrastructure, the ADC Pilot Factory enables direct integration of PV plants, industrial loads, and EV charging stations, significantly reducing conversion stages and improving overall system efficiency. Also, conductor cross-sections of new industrial low voltage power cable installations can be considerably reduced or existing cable assets higher loaded because of better utilisation with DC operation.  

Within the scope of the project, EMOTION assumes a pivotal role as a manufacturer of charging stations, an operator of charging points, and a provider of e-mobility services, concurrently developing a novel bi-directional DC fast-charging solution. This technology enables EVs to consume renewable energy produced on-site and to feed energy back into the industrial grid during peak demand periods. This approach enables EV fleets to function as flexible and distributed energy storage units, thereby reducing the reliance on costly stationary battery systems.

At FILL GmbH, demonstration activities will show that integrating these systems can maximise self-consumption of renewable electricity, lower peak power demand, cut operational costs and reduce CO₂ emissions. For instance, optimised vehicle-to-grid (V2G) operation in combination with PV generation has been demonstrated to reduce peak demand by more than 15%, while delivering substantial economic and environmental benefits.

The approach positions EVs not just as a mobility solution, but as a strategic energy resource for the decarbonisation of industry. By integrating production processes, renewable energy generation, and bi-directional EV charging within a controlled DC grid, the ADC Pilot Factory demonstrates a commitment to climate-neutral, resilient, and cost-effective industrial energy systems, aligning with the objectives of the NEFI model region and the European Green Deal.

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