Less heat is being lost on its way to consumers in Brønderslev.
This is one of the main results of the RACE innovation project, in which new technology has been tested in an existing district heating network under full operating conditions.
As part of the project, 13 intelligent bypasses have been installed across the network, collecting real-time data on parameters including pressure and temperature.
The data is combined with a digital twin and an AI controller that analyses network operation and sends recommendations for pressure and temperature back to the utility’s control system. This means that the technology has been tested in practice in a real district heating network while continuing to supply heat to customers every day.
The innovation project has been carried out by Brønderslev Forsyning, Aalborg University, Glaze, Develco, Broen/Agerkrantz Controls and Energy Cluster Denmark with support from the Danish Energy Technology Development and Demonstration Programme (EUDP).
The results show, among other things, that a greater share of the heat produced reaches consumers. During the winter period, energy utilisation increased from 85.8 to 88.5 per cent – an improvement of 2.7 percentage points.
“In many district heating networks, heat losses are typically between 10 and 20 per cent. This means that even a few percentage points can make a significant difference. In RACE, the improvement comes from better monitoring of temperature and pressure throughout the district heating network, giving the utility a much more precise picture of where the network can be operated with less energy loss,” says Henrik Sørensen, Section Manager at AAU Energy.
Results from the RACE project
- Energy utilisation at the plant improved by 2.7 percentage points in winter and 3.3 percentage points in summer.
- Energy consumption among customers decreased by 7.3% in winter and 26.3% in summer when adjusted for weather conditions.
- Differential pressure was reduced without compromising the heat supply to consumers.
Benefits for both operations and consumers
The results also show that consumers’ energy consumption fell by approximately 7.3 per cent during the winter period when adjusted for differences in weather conditions between 2024 and 2026. This is partly linked to improved operating conditions in the network, where more precise control of pressure, flow and temperature can reduce passive heat losses in individual household installations.
According to Brønderslev Forsyning, the benefits are primarily due to RACE making it possible to operate the network more actively. With new measurements and AI-based control, differential pressure can now be adjusted continuously throughout the day, whereas previously it was adjusted only a few times a year. This reduces the load on both pumps and pipes, limits unnecessary energy losses and provides customers with a more stable heat supply.
“This is a strong result, particularly because we have already worked systematically to optimise our district heating network. RACE has shown that there is still room to improve even further. And it is a win-win: we achieve more precise and energy-efficient operation, while our customers benefit from a stable and competitive heat supply,” says Poul Vestergaard Jensen, Head of District Heating at Brønderslev Forsyning.
Benefits even in an already optimised system
The project showed that the potential in Brønderslev did not lie in reducing the supply temperature further, as Brønderslev Forsyning has already worked extensively over the years to lower it. Instead, the potential was found in better control of pressure, flow and bypasses.
“One of the important lessons from RACE is that the future of district heating is not only about lowering temperatures. It is just as much about understanding the network better and controlling it more precisely. This is essential if district heating systems are to operate with lower temperatures, a wider range of heat sources and greater flexibility,” says Henrik Sørensen, Section Manager at AAU Energy.
According to Henrik Sørensen, RACE demonstrates that AI, digital models and intelligent control will become key tools in fourth-generation district heating. Lower temperatures, more new and renewable heat sources and increased flexibility require better knowledge of both the network and consumer demand, enabling future district heating systems to be operated proactively based on real-time input from the network and digital models.
Potential for other district heating companies
The project demonstrates significant and broad potential. Energy savings can be seen across most of the demonstration area and not only in the locations where the intelligent bypasses have been installed.
“This is not only relevant to Brønderslev. Many utilities can benefit from better data and more active control. The larger and more complex the network, the more important it becomes to know what is happening throughout the system and to be able to respond quickly. In RACE, we have collected and structured weather, sensor and SCADA data from the district heating network in an open and flexible data platform, allowing the data to be used directly for AI-based control. The RACE solution is system-independent and can easily be connected to other district heating plants, regardless of the SCADA system or production setup they use,” says Jakob Appel, Managing Partner at Glaze and lead partner in the project.
The experience gained from RACE will now be carried forward in the EUDP-funded RACE 2.0 project, where the technology will be expanded into new areas. The solution will include demand-side management for buildings and consumers, as well as more advanced interaction between heat production, distribution and consumption.
