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50 records · Page 3

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DOE OSTI2024

Novel PCM-based fin and tube heat exchanger system for building heating and cooling applications

In the United States, the building sector accounts for 40% of all energy use, and buildings are responsible for more than two-thirds of electricity consumption. Buildings remain the major driver of energy-related carbon emissions, and such emissions are projected to increase in the years ahead because of urbanization and population growth. To accomplish the low carbon energy goal in the building sector, phase change material (PCM)–based thermal energy storage (TES) is increasingly being adopted because it offers several advantages, such as reducing building peak load and energy consumption, enabling large scale deployment of renewables, and improving grid stability. The integration of TES with thermally anisotropic building envelopes (TABEs) is a promising solution because, TABE can redirect natural thermal energy from a building using hydronic loops to TES, and the stored energy can be used later for heating and cooling applications. In this study, we experimentally investigate the thermal performance of a novel fin-tube heat exchanger TES system designed for potential integration with a TABE. An experimental rig for a 5-gal PCM fin-tube heat exchanger system with water as the heat transfer medium is described which records temperatures at the heated and cooled boundaries of the system. Experimental observations provide insight into the role a TES system can play in offsetting a building’s heating and cooling demand and also offer a means to characterize the performance of PCMs for building applications. The scale and study presented in this work will help in the design of future thermal storage systems optimized for storage capacity while also accounting for overall system costs for building applications.

Tamraparni, Achutha↗

DOE OSTI2024

Simulation & Analysis of the Hydronic Shell Retrofit System as a Solution for Deep Energy Retrofits and Electrification of Large Multifamily Housing Communities in Cold Climate

According to the 2020 residential energy consumption survey, there are 32 million multi-family buildings in the United States, and approximately 42% of these have poor or no insulation (US EIA 2020). Electrification of buildings with heat pump is one of the key strategies to achieve the goal of 90% reduction of greenhouse gas emissions in buildings by 2050 (U.S. Department of Energy 2024a). Building electrification will also enable greater penetration of variable renewable energy sources. However, replacing the natural gas dominated heating system by electrical appliance will increase the electrical load in heating dominated climate. It is crucial to well-insulate the building envelope to mitigate the stress in the grid from electrification. The hydronic shell (HS) system discussed next can achieve dual objective of envelope retrofit with space heating system electrification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1980

Solar space heating for the Visitors Center, Stephens College, Columbia, Missouri

The solar energy system located at the Visitors' Center on the Stephens College Campus, Columbia, Missouri is discussed. The system is installed in a four-story, 15,000 square foot building. The solar energy system is an integral design of the building and utilizes 176 hydronic flat plate collectors which use a 50 percent water ethylene blycol solution and water-to-water heat exchanger. Solar heated water is stored in a 5,000 gallon water storage tank located in the basement equipment room. A natural gas fired hot water boiler supplies hot water when the solar energy heat supply fails to meet the demand. The designed solar contribution is 71 percent of the heating load.

Source record↗

DOE OSTI2025

Modular Hydronic Room Conditioning System

This project presents the development and validation of high-fidelity numerical models for fin-tube heat exchangers to enable accurate performance prediction and informed design optimization. The modeling framework integrates detailed geometric specifications, thermophysical property data, and system-level constraints to simulate the heat exchanger’s behavior under a range of operating conditions. The model is calibrated using real-world product specifications and validated against experimental data collected from controlled cooling and heating tests. In cooling mode, the model captures the overall trends in capacity and outlet air temperature but tends to underpredict latent effects, especially at lower air flow rates. In heating mode, the simulation consistently overestimates both the thermal capacity and outlet air temperature, indicating the need for refinement in air-side heat transfer assumptions. Despite these deviations, the model provides a solid foundation for optimization, allowing key design variables to be tuned within physical and performance-based constraints. This research advances the ability to simulate, validate, and optimize fin tube heat exchanger designs with greater confidence and efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

Geothermal-integrated thermally anisotropic building envelope for energy and peak-demand reduction

Buildings consume large amounts of energy for heating and cooling, while peak electricity demand places significant stress on the power grid. This paper presents a reduced-order co-simulation framework and load-oriented supervisory control strategy for a geothermal-integrated thermally anisotropic building envelope with a ground loop (TABE+GL). In TABE+GL, a hydronic loop embedded in the building envelope is directly coupled with a geothermal ground loop, allowing for bidirectional heat exchange between the envelope, the ground, and the indoor environment. A hybrid co-simulation framework was established by coupling a reduced-order resistor–capacitor (RC) thermal network model with EnergyPlus augmented with GHEDesigner modules. The RC model generated feasible heat flux options under three operating modes, and EnergyPlus predicted sensible loads, energy use, and pump energy demand. At each simulation step, a supervisory control algorithm selected the optimal loop configuration and duty factor that maximizes useful TABE geothermal utilization without exceeding the predicted sensible load, thereby avoiding overheating or cooling. Case studies were conducted for Los Angeles, California, Charleston, South Carolina, and Denver, Colorado. Results showed that the proposed framework reduced HVAC electricity consumption by 43%–67%, natural gas use for space heating by 11%–38%, and peak electricity demand by 43%–88%. These results highlight the potential of combining reduced-order envelope modeling, direct geothermal coupling, and load-oriented supervisory control to improve whole building energy performance and reduce peak demand across diverse weather conditions.

Howard, Daniel [Southern Adventist University]↗

DOE OSTI2025

Modular Hydronic Room Conditioning System (CRADA NFE-24-10120 Final Report)

This project presents the development and validation of high-fidelity numerical models for fin-tube heat exchangers to enable accurate performance prediction and informed design optimization. The modeling framework integrates detailed geometric specifications, thermophysical property data, and system-level constraints to simulate the heat exchanger’s behavior under a range of operating conditions. The model is calibrated using real-world product specifications and validated against experimental data collected from controlled cooling and heating tests. In cooling mode, the model captures the overall trends in capacity and outlet air temperature but tends to underpredict latent effects, especially at lower air flow rates. In heating mode, the simulation consistently overestimates both the thermal capacity and outlet air temperature, indicating the need for refinement in air-side heat transfer assumptions. Despite these deviations, the model provides a solid foundation for optimization, allowing key design variables to be tuned within physical and performance-based constraints. This research advances the ability to simulate, validate, and optimize fin-tube heat exchanger designs with greater confidence and efficiency.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Pushing the Envelope-Moving Dynamic Building Envelope Thermal Energy Storage Systems Mainstream: Preprint

Buildings contribute to nearly 40% of the U.S. national energy consumption and a significant portion of CO2 emissions. More importantly, disadvantaged communities are disproportionately affected by energy burden and thermal discomfort in their homes. This paper will discuss two novel DOE's BTO supported thermal energy storage (TES) integrated dynamic building envelope technologies, their ability to harvest ambient energy, and improve energy efficiency by reducing HVAC loads and peak electricity demand while enhancing energy and thermal resilience in buildings. The paper will also discuss the recent advancements that have made these systems more affordable and easier to integrate into new and existing buildings. The first solution is a thermally anisotropic building envelope (TABE) system that can redirect ambient thermal energy (heat or coolness) from diurnal outdoor conditions, solar irradiance, and night sky radiation from the envelope to a hydronic loop. The redirected thermal energy can be stored in a TABE-integrated thermal energy storage system and use the stored energy to offset HVAC energy use and peak demand. The second solution is an innovative plug-and-play thermal switch in the form of insertable plugs integrated with a phase change material (PCM). The plug can vary its thermal resistance based on the indoor and outdoor conditions, thus allowing preferential directional heat flow, and enhancing utilization of free ambient cooling and heating to charge/discharge the PCM, much like a solid-state economizer. While the fist solution can be actively controlled, the second solution is passive, requiring no external power, and work solely based on the ambient temperature.

anisotropic envelope↗

DOE OSTI2024

Pushing the Envelope—Moving Dynamic Building Envelope Thermal Energy Storage Systems Mainstream

Shrestha, Som↗

DOE OSTI2022

Incorporating two-dimensional conduction modeling techniques into an energy simulation program: The EnergyPlus radiant system example

Due to the inherent complexity of multi-dimensional solutions for transient conduction in a multilayered building element, most heat balance-based algorithms assume that conduction occurs only in one dimension—through the building element between the inside and outside environments. Usually, since the length and width of the elements are much greater than the thickness of the element, this is a valid assumption. However, there are some cases such as hydronic radiant slabs where this assumption may not lead to an accurate estimate of the energy consumption of the system. In a hydronic radiant slab, water tubes are embedded in a slab, and hot or chilled water is circulated to meet any heating or cooling loads. The energy consumption of such a system will depend highly on the temperature of the water being sent to the slab (i.e., produced by the boiler or chiller). The temperature of the water that must be sent to the slab will depend on the spacing of the tubes, the multilayer construction of the building element, and the boundary conditions to which the construction is exposed. Thus, to accurately predict the energy consumption of such a system, a transient two-dimensional heat conduction model must be integrated with a heat balance-based simulation. This paper demonstrates the potential loss of accuracy associated with the one-dimensional radiant system models by providing a comparison of one- and two-dimensional solutions using EnergyPlus.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Performance Assessment of a Dual-purpose HP-TES for a Typical Year Comparing Different Climate Zones

Complete electrification of heating and cooling systems in the United States would overload the existing electrical grid. To this end, recent research efforts have focused on energy storage as one way to reduce ever-increasing peak electricity demands. One such technology is heat pump integrated thermal-energy storage (HP-TES) systems, which can enable load-shifting and reduce demand during peak hours. In this work, a Modelica model of a 4-Ton, dual-mode (heating and cooling) HP-TES system using a room-temperature phase-change material (PCM) integrated through a secondary hydronic loop was developed and simulated for a typical meteorological year in Riverside, CA (ASHRAE Climate Zone 2B), and Chicago, IL (ASHRAE Climate Zone 5A), for a DOE small office prototype building. The COP improvement and demand reduction were analyzed during the time-of-use peak hours along with the required recharge cycle energy demand. A typical summer in Riverside, CA resulted in model-predicted peak COP increases of 50 – 100% compared to the baseline heat pump, especially at higher outdoor temperatures, coupled with maximum peak energy reductions of 22%. During shoulder and winter season simulations, heating energy savings were higher as outdoor temperatures dropped below the PCM phase change temperature. For Chicago, IL, backup heating was necessary to meet the required system capacity for very cold ambient conditions, resulting in winter peak energy savings between 16 – 60% when accounting for backup heating requirements. The recharge energy was found to be mostly below the baseline HP energy during the peak. With improved component selections and controls, the recharge energy may be reduced. The outcomes from the simulations can provide first-order estimates for potential peak energy savings, challenges, and required controls in any location before conducting any field testing.

25 ENERGY STORAGE↗

DOE OSTI2023

Modeling Assessment of Residential Air-to-Water Heat Pumps Coupled with Cooling Thermal Storage

This study explored the performance and operating cost viability of air-to-water heat pumps (AWHPs) coupled with thermal energy storage (TES) in efficient new residential construction. AWHPs are an emerging technology in this country, but offer promise in terms of high efficiency, fully contained and factory charged outdoor refrigeration system, and hydronic delivery capabilities, which facilitates zoning, ducts in conditioned space, and TES integration for summer load-shifting. Although this AWHP+TES strategy is not yet mainstream, the authors feel that in ten years as decarbonization efforts proceed and TOU rates become more common, strategies such as this will be more accessible. Validated EnergyPlus simulation models were developed based on detailed monitoring data collected over several years at Pacific Gas and Electric's CVRH laboratory test homes located in Stockton, California. One of the CVRH test homes (1,962 ft 2 two-story) had been testing various AWHP systems and configurations over the past six years. The validated model was then updated with high efficiency IECC ZERH envelope and component requirements for climate zones 1-5, including ducts in conditioned space thermal distribution. Simulations were completed for the 1,962 ft 2 home in each climate zone for a minimum efficiency ASHP, an AWHP coupled with a fan coil, and an AWHP coupled with TES sized to eliminate summer on-peak compressor operation. To maintain consistency in reporting energy use estimates, all cases were run with a similar indoor thermostat control strategy to pre-cool the house below the nominal 76 degrees Fahrenheit set point prior to the on-peak period and float slightly above the set point during the peak period. The AWHP+TES configuration was controlled to alternately condition the indoor space or to charge the TES tanks prior to the beginning of the on-peak. Three composite TOU rates were developed based on existing TOU rates across the U.S. to provide differing economic scenarios to evaluate customer bill impacts throughout the summer. Two of the TOU rates had short three-hour peak periods, while the third rate had a longer seven-hour duration peak period. AWHP modeling projections were based on the observed field performance of the Chiltrix CX34 variable speed unit. Other products on the market or entering the market in the near term would likely perform differently.

25 ENERGY STORAGE↗

DOE OSTI2024

Thermally Anisotropic Building Envelope Integration into Panelized Metal Construction: Laboratory Evaluation in Guarded Hot Box

The Thermally Anisotropic Building Envelope (TABE) is an active building envelope system that can exchange thermal energy with a storage medium to reduce the building’s energy demand. TABE redirects thermal energy along thin conductive layers in the building envelope to hydronic loops that are connected to thermal energy storage (TES), where it will be available to offset future energy demand when the conditions are favorable. TABEs can also be connected with a geothermal loop to reduce the building’s heating and cooling loads. Due to the importance of thermally conductive metal layers to TABE function, this technology has potential for easy adoption into panelized metal construction. In this study, we illustrate the construction process of prototype metal panels containing TABE and the laboratory evaluation in Oak Ridge National Laboratory’s rotatable guarded hot box. The thermal performance of the prototype panel was assessed for both baseline and operational cases and the total heat flow extracted from the panel by TABE was quantified.

Howard, Daniel↗

NASA NTRS1980

Experimental evaluation of thermal energy storage

The technical performance of commercially available thermal energy storage (TES) residential heating units under severe weather conditions is discussed. The benefits and costs of TES to the user and utility companies were assessed. The TES issues, research and development needs, and barriers to commercialization were identified. The field tests which determined the performance characteristics for the TES are described and the TES systems, which included both ceramic and hydronic systems, are compared.

Asbury, J. G.↗

DOE OSTI2020

Development and Validation of a Simulation Testbed for the Intelligent Building Agents Laboratory (IBAL) Using TRNSYS

This paper documents the development and validation of a dynamic primary cooling and thermal storage system simulation testbed. The system simulation testbed, sIBAL, is based on the Intelligent Building Agents Laboratory (IBAL) at the National Institute of Standards and Technology (NIST), which is a research infrastructure and testbed for the development, evaluation, and demonstration of intelligent control algorithms. The sIBAL testbed developed in this project will serve as a virtual twin of the real facility for future control algorithm development. The details of the methodologies used to develop and validate the simulation testbed, which replicates the dynamic behaviors of the primary cooling and ice storage system in the IBAL facility, are presented. The simulation testbed was developed in TRNSYS using built-in component models and MATLAB functions to replicate the two water-cooled chillers, a thermal storage tank, pumps, valves and other components for four different operation modes. Experiments on IBAL components were designed and executed to generate experimental data for model development and verification of the simulation platform. The validation of the simulation results was carried out in two phases: 1) independent component simulations for the chillers and thermal storage tank, and 2) a combined testbed simulation of the entire hydronic system. Comparison of simulation results to the experimental data obtained from the IBAL facility showed errors within 1 °C for the temperatures outputs of both the chiller and the thermal storage model. The error is within an acceptable range for further intelligent control algorithms development. The findings from the study are summarized and presented along with areas where additional research is needed. In addition, data filtering procedures and model refinement measures utilized to improve the accuracy and accelerate the computation time of the simulation are presented.

cooling systems↗