The benefits of energy flexibility measures have not yet been conclusively assessed from an ecological, economic, and social perspective. Until now, analysis has focused on the influence of changes in the energy system and the ecological and economic benefits of these. Therefore, the objective of this study was to perform a life cycle sustainability assessment of energy flexibility measures on the use case of a bivalent crucible melting furnace in comparison with a monovalent one for aluminum light metal die casting. The system boundary was based on a cradle-to-gate approach in Germany and includes the production of the necessary process technologies and energy infrastructure and the utilization phase of the crucible melting furnaces in non-ferrous metallurgy. The LCSA is performed for different economic and environmental scenarios over a 25-year lifetime to account for potential adjustments in the energy system and volatile energy prices. In summary, it can be said that over the entire service life, no complete ecological, economic, and social advantage of energy flexibility measures through a bivalent system can be demonstrated. Only a temporarily better life cycle sustainability performance of the bivalent furnace can be shown. All results must be considered with the caveat that the bivalent crucible melting furnace has not yet been investigated in actual operation and the calculations of the utilization phase are based on the monovalent crucible melting furnace. To further sharpen the results, more research is needed and the use of actual data for bivalent operation.

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Simulationsmodelle der virtuellen Inbetriebnahme eignen sich als Grundlage für digitale Zwillinge von Produktionsanlagen, da sie das Verhalten dieser Anlagen abbilden und häufig bereits aus der Entwicklungsphase zur Verfügung stehen. Der Stand der Technik zeigt allerdings, dass zwischen dem Verhalten der Modelle und dem der realen Systeme noch erhebliche Diskrepanzen bestehen. In diesem Beitrag wird eine Methodik zur Kompensation von Diskrepanzen exemplarisch an einer Fräsanlage untersucht.   The simulation models of virtual commissioning are suitable as a basis for digital twins of production systems, as they represent the behavior of these systems and often already are available from the development phase. However, the state-of-the-art shows that there are considerable discrepancies between the behavior of the models and that of the real systems. In this paper, a methodology for the compensation of discrepancies, using a milling plant as an example is investigated.