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DC grids in industry

DC grids in industry The forward-thinking DC technology at Phoenix Contact enables sustainable and regenerative energy feed-in, storage, and distribution. Discover our DC solutions for safe DC microgrid applications.

Employees in a production hall with the schematic representation of a DC grid

Innovative DC technology for more sustainability right now Sustainability is more than a buzzword – it has always been our mission.

Join Phoenix Contact on the way to a world with renewable energy that is efficiently stored and distributed. This will make electrical energy available for use anytime, anywhere. This is why at Phoenix Contact, we focus on concepts and solutions for the safe use of DC technology in microgrids.

Sustainability starts with the right use of DC technology.

Dr. Christian Helmig, Vice President, Field Device Connectors and Dr. Martin Wetter, Executive Vice President, Innovation - Phoenix Contact GmbH & Co. KG

Engineer in a production hall for automobiles

Direct current – the industrial energy system of the future? From generation to storage and supply

In today’s world, most end devices are already powered by direct current (DC). Both charging stations and electric drives in industrial environments are operated with direct current generated from alternating current. For this reason, various companies working on the DC-INDUSTRIE and DC-INDUSTRIE 2 project researched an integrated, DC-based smart grid.

Employees working on machine building at Phoenix Contact

The idea is that the direct current generated by renewable energy sources directly supplies the loads in the grid – such as machines, motors, and conveyor belts – with electricity and thereby reduces conversion losses.

Due to networking in the DC grid, it is also possible to feed the braking energy of a system back into the grid as electrical power. Surpluses produced are collected in energy storage systems and fed back into the grid when necessary. This reduces the feed-in power by up to 80%. In addition, both the peak load and the load on the public grid can be reduced.

Advantages of a DC grid

Increased energy efficiency through energy recovery, reduced conversion losses, and the use of renewable energy, and energy storage
Resource optimization through up to 55% less copper consumption, reduced equipment costs, and smaller footprints
Avoidance of production downtime due to failures in the supply network
Basis for the intelligent control of energy flows

The DC grid in industry at a glance

Interactive image map: Representation of a DC grid in industry with the stations: solar, wind, battery storage system, power-to-X, production, and office

Solar power

Photovoltaic systems are important generators of renewable energy. They produce direct current and can therefore be integrated efficiently into a DC grid without the need for conversion to AC. We will be happy to advise you on all aspects of feed-in management, photovoltaic applications, and surge protection for rooftop PV systems.

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Wind power

The energy from wind turbine generators can be fed into a DC grid from the DC intermediate circuit via DC/DC converters. Coupling via an AC grid is no longer necessary. Find our solutions for wind turbine generators, modular condition monitoring, and lightning current measurement here.

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Charging infrastructure

The bidirectional connection of e-charging stations to a DC grid enables vehicle batteries to be charged and also used as energy storage at short notice. As a manufacturer of DC charging technology, Phoenix Contact supplies components for the development and installation of DC charging stations for e-vehicles. Find out now about DC charging cables, DC charging controllers, and DC power electronics.

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Power-to-X

Energy surplus from solar plants and wind turbine generators can be used efficiently through electrolysis to produce fuels (power-to-fuel), hydrogen and methane (power-to-gas), ammonia and methanol (power-to-liquid), or other chemicals. These substances are in turn used to generate electrical energy and thus take on the role of energy storage. Energy storage systems ensure stability in DC grids. Electrolysis is also based on direct current, which makes it expedient to integrate power-to-X systems into a DC grid. Find out now about components for monitoring, automating, and digitalizing electrolysis.

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Office and lighting

Many office communication devices, such as PCs and displays, as well as LED lighting technology, require DC voltage internally. Power supply units with rectification and DC intermediate circuits are required to connect these loads to an AC grid. However, if these loads are integrated into a DC grid, a significant part of the input circuit of the power supply units can be saved. This saves on components, weight, and volume.

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Robots and conveyor belts

DC motors are considered as drives in DC grids. However, the three-phase motors that were previously used can also be integrated efficiently into a DC grid through the DC intermediate circuit in frequency converters. This reduces peak loads, particularly in the case of powerful robots and conveyor belts. In addition, the braking energy in a DC grid can be recovered efficiently by recuperation.

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Energy storage systems

Battery storage systems are used for grid support in DC grids. Excess energy can be stored and made available when needed. By integrating energy storage systems, peak loads when starting up large machines, for example, are also reduced and the public supply network is relieved. We will show you innovative solutions for energy storage systems.

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Connection to the AC grid

With a bidirectional connection to the AC grid, it is possible to feed in power from the AC grid to the DC grid, and to feed excess energy from the DC grid into the public supply network.

Grid management

Efficient grid management enables the intelligent control of energy flows. By analyzing data, bottlenecks can be identified and avoided. This helps to ensure optimum use of the available energy.

FAQs: DC technology

View of a production hall for automobiles from above

Person with tablet on which energy data is displayed

An employee working on a control cabinet

Why is direct current a new trend?

The industrial sector in particular is looking for suitable solutions to achieve climate targets. In times of climate change, the world is dealing with rising energy costs, scarce resources, and an increasing demand for energy. One approach to solving this problem is to switch from an AC power grid to a DC grid in factories. Renewable power generation, energy storage, and energy recovery are keywords of climate change that can be implemented in a DC microgrid. This reduces energy consumption and cuts peak loads (peak shaving). The effect relieves and stabilizes the supply network. The design of a DC grid for industry is one approach for a future with sustainable industrial production.

What does direct current have to do with sustainable production?

In a DC-based microgrid, electric power is generated through the efficient integration of renewable energy from carbon-neutral production. This energy is used by electrical loads in a DC grid directly, without further conversion from DC to AC. The process saves conversion losses, which in turn enables reductions in energy consumption. In addition, it is possible to use all of the braking energy of lifting processes. The energy that would otherwise be lost as heat is fed back into the DC grid as electrical energy. Energy storage systems collect excess DC power for later use.
A combination of sustainable power generation, energy recovery, and energy storage ensures greater sustainability and increased energy efficiency in factories.

What is the savings potential?

In addition to savings in energy consumption, using a DC grid also results in potential material and space savings.

Energy losses can be reduced by approximately 6% to 8% through the elimination of DC-AC conversions. In addition, the use of suitable energy storage leads to a reduction of feed-in power from the public grid by up to 80%. The complete use of braking energy also enables 15 to 20% more energy savings, depending on the application. Due to these factors, the energy efficiency in DC grids increases significantly compared to AC grids.

The potential in terms of material and space savings is also considerable. In DC grids, up to 40% of the copper and insulation material used can be saved while maintaining the same performance. In times of scarce resources, this is significant. DC devices are also significantly smaller than AC devices. The reduced material expenditure saves further space.

What is the disadvantage of DC-AC conversion?

The conversion of direct current to alternating current or direct voltage to alternating voltage involves losses, since energy is also required for conversion. This increases energy consumption, and energy efficiency suffers as a result. In addition, DC-AC inverters are necessary. They require corresponding space in the application – space that is saved by not converting.

Supplying direct current straight to loads replaces the previous DC-AC-DC conversions. This increases energy efficiency, as a purely DC grid typically consumes 6 to 8% less energy than an AC grid. Further savings are possible through the use of braking energy and immediate storage of direct current.

What are the dangers of DC grids?

In DC applications, electric arcs can damage contacts and housing parts and, in the worst case, also pose a hazard to users. Under the circumstances, a new approach to connector development is required. Various technologies for DC connectors have been developed by Phoenix Contact in research projects. With extinguishing techniques in connectors, innovative approaches have now been found to protect operators from the dangers of the electric arc.

We trust in DC grids Phoenix Contact is an expert partner for the use of DC grids in industry

As one of 39 partners from industry and research, we were also part of ZVEI’s DC-INDUSTRIE 2 research project, which was funded by the German Federal Ministry for Economic Affairs and Climate Action. Naturally, Phoenix Contact is also involved in the direct successor project, the ODCA (Open Direct Current Alliance), as a founding member and board member.

Dr. Christian Helmig, Vice President, Field Device Connectors and Dr. Martin Wetter, Executive Vice President, Innovation of Phoenix Contact GmbH & Co. KG in front of a DC distribution system

With regard to the necessary energy revolution in industrial production and the associated maximum use of renewable energy, the working group has set itself the goal of supplying production plants with direct current in an efficient, safe, and robust manner.
Phoenix Contact is involved in national and international task forces and is conducting intensive research on the use of industrial DC grids in the field of factory automation with a focus on future-proof electrical installations.
One of the central topics that Phoenix Contact is dealing with, for example, is the avoidance of electric arcs in the DC connector sector.

From theory to practice DC grids in production and in buildings

Phoenix Contact is going even further, however, because research alone is not enough for us. As an innovation leader and expert in electrical installation, we wanted to take the first step, be present, gain experience, and solve problems.
One promising area of application for DC grids is the field of automotive production. When one of our partners in the ODCA planned to install a DC grid as a pilot system, we were able to provide quick support with our DC-capable components.

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Employees planning a building with a DC grid

We have also installed a DC grid in Building 60 on our own campus in Blomberg. In doing so, we have created a blueprint for industrial DC grids, from planning right through to the finished installation. Naturally, we are trusting in our own products and developing further DC-capable components as part of the project. And of course, the installed technologies and solutions are also available to our customers in our drive to empower the All Electric Society.

Direct current empowering carbon-neutral production

Building 60 – an electrifying example of a DC grid

The new building 60 in Blomberg also has its own industrial DC grid and fully exploits the potential of renewable energy forms.

To the G60 DC application