Energy inspection

Complex energy structures require simulation models

The complexity of energy structures is based on two factors:

  1. a high degree of interconnectivity between energy and material flows and
  2. the coupling of energy provision, energy distribution, and energy use.

The energy requirement of these dynamic systems is typically difficult to determine using the internal resources of a single company. It should also be noted that the requirement (production technology and mechanical engineering) and the provision (energy technology and building facilities) are often calculated by different planners or even by professionals in different disciplines.

This results in uncertainty in the planning process.

What makes Limón's simulation models stand out?

The unique combination of production, energy, and simulation know-how allows a comprehensive and extensive perspective of the individual situation.

The use of special dynamic simulation models reduces the project costs and is a key component for determining the optimum parameters for supplying useful energy.

The use of practically oriented models guarantees simulation models that can be individually adapted to each customer's situation.

What are uncertainties in the process of planning plants and buildings?

Overdimensioning of production or energy supply plants

Planned degrees of efficiency are not reached

High infrastructure costs


Limón's simulation models are the ideal tool to
analyze and optimize your energy flows.

Where are simulation models used?

Operational facilities and machines

Simulation models for plants and machines in manufacturing are used with the following goals:

  • Increase energy efficiency
  • Determine the optimum schedule for existing units
  • Dimension units in the planning process
  • Conduct cost-benefit analyses
  • Virtual commissioning

Special block libraries are used to reduce the amount of effort required for modeling each project.



Limón offers its customers material flow simulations for production processes.
The goal of these simulation models is:

  • Optimization of material flows and productivity
  • Significance of starting points for each production plant
  • Provision of information for the current product range
  • Taking disruptive factors and shipment issues into account

The simulation is depicted in 3D to show each process as realistically as possible. Various simulators can be used to this end. The data are forwarded to other simulation levels by way of an interface.




Sometimes it makes sense to simulate a building with all of its HVAC technology to better understand the reasons for its high energy demand. In this case, the environmental conditions such as temperatures and solar radiation at the site are taken into account, also allowing comparisons with different sites. In combination with the internal loads of each machine and plant, it is then possible to determine the interior climate set for the building. The energy efficiency of the HVAC units and their control structure can be optimized as well.


  • Design of control concepts
  • Optimization of control parameters


In der Ebene der Energieversorgung erfolgt die Abbildung der gesamten Energieversorgungsstruktur. Beispiele für die Anwendung von Simulation für die Energieversorgung sind:

  • Dimensionierung von Bereitstellungsanlagen durch Simulation in Kombination mit mathematischer Optimierung
  • Transparenzsteigerung durch Simulation einer durchgeführten Optimierung

Beispielsweise werden die einzelnen Anlagenkomponenten zur Wärme-, Kälte- und Druckluftversorgung simuliert. Aufbauend auf einer Modellbibliothek sind viele Standardkomponenten bereits vorhanden. Diese können entweder generisch verwendet oder durch konkrete Parameter auf die spezifische Anlage eingestellt werden. In diesem Fall ist eine unabhängige Simulation ebenfalls sinnvoll.


Energy and cost efficiency with the Limón building block system


In the simulation model,

  • a comprehensive examination of the customer's energy situation is performed in the scope of one simulation project
  • depending on the task at hand, either partial or individual models will be used from the Limón building block system, allowing existing or planned plants or processes to be mapped efficiently. Several variants and sets of parameters can easily be reviewed and analyzed with regard to their profitability and energy efficiency.

This procedure ensures the highest possible degree of energy efficiency of measures, process parameters, and plant parameters. At the same time, using existing basic models reduces the project costs.

FAQ - frequently asked questions about Limón's simulation models


Plants are often oversized because of uncertainties about the energy requirement of machines and plants (complex energy structures). It is important to note that the requirement (production technology, mechanical engineering) and supply (energy technology, building technology) are designed by different planners or even by people of different subject areas. Degrees of efficiency for energy provision that were originally intended often remain unattainable, resulting in high infrastructure costs.

Another consequence of complex structures is the flawed planning and calculation of energy efficiency measures for manufacturing companies. Individual measures impact one another and lead to deficits in other production areas. The term used in this case is planning deficits. Moreover, the profitability of individual measures cannot be reliably determined, as the calculation of potential savings is flawed or not possible (calculation deficit). Often, the data for production machines is only the connected load and not actual numbers on consumption.


A simulation-based energy efficiency analysis requires a combination of knowledge on production, energy, and simulations. Standardized solutions can only be successful up to a point due to specific processes. The greatest potential is based on individual solutions that are only possible by looking at processes in close detail. Thanks to Limón's process understanding and its specially developed simulation building blocks, the right models can be used to calculate efficiency potential. This includes the entire production system from the individual process to the technical building equipment and the production control.


A simulation provides a comprehensive look at the energy situation. Depending on the task at hand, either partial or individual models will be used.

Our approach: 


  1. Task definition and goal statement
  2. Data collection and system analysis
  3. Modeling
  4. Verification and validation
  5. Experiments and analyses to develop and evaluate measures
  6. Innovative supply concept


Sample application

In the scope of a project with the southern Hessian energy provider HSE AG, Limón developed a dynamic simulation for an innovative concept for energy supply based on renewable energy and cogeneration. The energy is provided by a cogeneration unit, a solar thermal system, and a geothermal reservoir. The simulation allows the energy flows to be examined over a given time frame. This in turn facilitates the technical feasibility assessment and the development of a smart control system.


Simulations are not only helpful when planning to build new systems or buildings. They are also a useful tool for overhauls of existing operations. Targeted dimensioning of the process or machine parameters is a prerequisite for the efficient development of measures and their profitable realization. Mapping and analyzing interdependencies as well as different energy efficiency actions are key components of simulation-aided planning.


The analysis of different variants over defined time frames (sensitivity analysis) is conducted based on the parametrization in models in the simulation. With modeling and the simulation, we can discover entirely new potential for you. Improved transparency lets you lower your operation costs, reduce your investment costs, and increase your planning security. It is also possible to examine the entire production all at once, substantially shortening project times, especially when planning new projects.

  1. Simulation models can be modified much more easily than the real system
  2. Testing on the real system would require too much cost and effort
  3. Depiction of dynamic system behavior
  4. Reproducible experiments on the model
  5. Simulation results provide inferences and solutions for the real problem
  6. Illustrate/structure complex interconnected systems with a variety of interdependencies
  7. Depiction of specific system characteristics



Test our simulation expertise.
Request more information now.