Case Study: a metals manufacturer transforms a legacy power plant into a revenue-generating grid asset with RoviSys

a metals manufacturer redirects 90 MW with RoviSys to become a market-responsive energy asset

A metals manufacturer that operates its own coal-fired power plant faced the challenge of unused generation capacity during market fluctuations. Historically, this excess power went underutilized, but leadership recognized a major opportunity to sell it to the grid during high-price periods to generate new revenue. The manufacturer engaged RoviSys, with whom they had a long-standing relationship, to develop a custom solution, as no off-the-shelf product existed to manage this level of complexity.

RoviSys designed and deployed a customized Windows-based control and intelligence system that interfaced with grid APIs. The solution included automated control logic to redirect entire pot lines, redundant alarming for guaranteed response times, and real-time dashboards for operators. This transformation allowed the manufacturer to redirect 90 MW during peak pricing to create a major new revenue stream without disrupting production. RoviSys helped turn the legacy plant into a flexible, market-responsive energy asset with immediate and substantial impact.