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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Modeling and Energy Analysis of Refrigeration Systems in Supermarkets: A Case Study

Refrigeration systems are the single largest consumer of electricity in supermarkets, accounting for approximately 40–60% of total store electricity use. As supermarkets face increasing pressures to improve efficiency and reduce operational costs, understanding the energy performance of refrigeration systems in supermarkets has become essential. In this paper, we investigate the energy performance and patterns of the refrigeration system using field measurements in one supermarket. The compressor coefficient of performance (COP) averaged 4.5 during nighttime steady-state operation, providing a practical efficiency benchmark. We develop simple physical-based load models for the display cases in the supermarket, where the refrigeration system uses R404A. The results show the display case models achieve a good agreement with measured data, validating its utility for energy estimation during unoccupied hours. Finally, the analysis reveals several challenges of data collection systems for refrigeration systems in the supermarket industry as well.

Chen, Yimin [ORNL] (ORCID:0000000338181655)↗
DOE OSTI2021

Low global warming potential (GWP) refrigerant supermarket refrigeration system modeling and its application

As an environmentally friendly low global warming potential (GWP) refrigerant, Carbon dioxide (CO 2 ) has continuously gained popularity and research attention as alternative refrigerant for supermarket refrigeration system. In this paper, to fulfill the increasing need of accurate Low-GWP supermarket refrigeration models for development of supervisory level control and optimization strategies, a high fidelity model is developed for CO 2 transcritical supermarket refrigeration system which includes compressor rack of low temperature (LT) compressors and medium temperature (MT) compressors, air-cooled gas cooler, evaporator, expansion valves and other auxiliary equipment. A resistance-capacity model structure is proposed to simulate the display cases. Semi-thermodynamic models are proposed to estimate reciprocating compressors volumetric efficiency and power consumption. Furthermore the zone modeling approach is used for evaporator simulation, and air-cooled gas cooler is modeled with distributed modeling method. The expansion valve simulation is based on orifice flow model. To calibrate these models, both manufacture performance data and experimental data are used. The experiments are conducted with a full instrumental CO 2 supermarket refrigeration system installed in Oak Ridge National Lab Flexible Research Platform (FRP). The simulation model can predict the system performance, including power consumption, cooling capacity, mass flow rate, temperature, and pressure, with high accuracy (within ±4%) compared to experimental data. In addition, this developed model has been used to create the system optimum high side pressure for high side expansion valve control, and to generate wide operating range simulation data for developing the batter-equivalent commercial refrigeration system model which can be used in grid interactive control development.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Low Carbon Technology Strategies: Supermarket

This document includes steps that building owners and operators can implement to achieve smart, healthy, and low-carbon supermarkets within their existing building portfolios. Supermarkets include built-up refrigeration systems and refrigerated display cases and often use packaged rooftop units for heating, cooling, and ventilation.

analytics↗
DOE OSTI2023

Dynamic model-based feature extraction for fault detection and diagnosis of a supermarket refrigeration system

With the increasing concerns over climate change and carbon emissions, fault detection and diagnostics (FDD) of low–global warming potential (GWP) refrigerant supermarket refrigeration systems has gained great attention from academic and industrial sectors. Various FDD approaches have been developed to detect, identify, and diagnose faults to save energy, improve food quality, and protect the environment. Here, to mitigate the difficulty of collecting high-quality steady-state operational data in field operations faced by most model-based FDD methods, this study developed dynamic models of a low–GWP refrigerant (CO 2 ) supermarket refrigeration system. The model accuracy was validated using manufacturer data and experimental data. Simulations were conducted to predict the system dynamic response under two common operational faults—evaporator air path blockage fault and the display case door open fault—to identify fault patterns and define key dynamic behavior indexes for supporting FDD algorithm development.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Development of a simplified calibrated building simulation model of a supermarket for proposed ECMs and control strategies impact evaluation

Calibrated building energy simulation is an important pathway to more energy-efficient buildings, but the information requirements of some approaches to this problem are significant. This is particularly true for supermarkets and other so-called “big-box” retail stores. Another characteristic of supermarkets is the significant interaction between Heating Ventilating and Air Conditioning (HVAC) and refrigeration systems in these buildings. These buildings could contain a wide variety of systems and a degree of load diversity that makes calibrated modeling a challenge. This paper describes a simplified approach that uses OpenStudio and EnergyPlus to combine known building parameters with “typical” parameters, resulting in a simplified building that is amenable to calibration. This approach was applied to a big-box store located in Nashville, Tennessee, and a calibrated model was obtained that was used to study potential energy conservation measures. Further, the paper also explores the capabilities of whole-building energy modeling tools, such as EnergyPlus, for modeling the HVAC controls and sequences and their impact evaluation. Although some measures are precluded by the model simplicity, several measures were found to improve the efficiency of the model and demonstrate that the simplified modeling approach is effective. Practical Application: This paper introduces a hybrid approach of building energy model calibration using limited information available from the actual building in combination with characteristics of a “typical” building of the same type. This hybrid approach would also be applicable for other building types than discussed in this paper to calibrate the building energy model using limited information from the actual building.

42 ENGINEERING↗
DOE OSTI2023

A DYNAMIC ENERGY MODEL FOR DISPLAY CASES CONSIDERING FAULTS IN SUPERMARKETS FOR LOW GWP REFRIGERANTION

Display cases are widely used in supermarkets to demonstrate commercial goods for customers, like milk, frozen food, ice-cream, etc. There are two types of display case: open case and closed case. The goods inside display cases need to stay within a stable temperature range to meet the quality standards. However, due to variety of faults (e.g., leaving door opening), it is hard to maintain a stable temperature. The associated energy consumption from display cases is extremely high due to faults. There is a need for a dynamic energy model to accurately predict the good temperature and energy consumption under faults. A dynamic model is developed based on operation data collected through field tests in a low global warming potential (GWP) refrigeration system, at Oak Ridge National Laboratory.

Li, Yanfei↗
DOE OSTI2024

Evaluation of Low Environmental Impact Distributed Scroll Booster Technology for Supermarket Refrigeration

A distributed scroll booster refrigeration system is proposed as an alternative for current refrigeration systems used in supermarket applications. The distributed scroll booster system is configured to enable the use of low-pressure refrigerants such as R-1234yf, which has a global warming potential (GWP) of less than 1, in a cycle configuration that employs a two-stage compression process. This scroll booster system is comprised of medium-temperature compressors (high stage) coupled with low-temperature compressors (low stage). This two-stage system architecture allows both low-temperature and medium-temperature refrigerated display cases to be integrated in the same system. By design, this system reduces the refrigerant charge, produces higher efficiencies (two-stage compression), uses existing components minimizing cost impact, and will be able to use ultra-low GWP class A2L (low toxicity and low flammability) refrigerants such as R-1234yf when standards and building codes are updated (expected by 2025).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

From Chills to Thrills: Revolutionizing Energy Efficiency and Load Flexibility in Supermarket Refrigeration

Open-vertical medium-temperature refrigerated display cases comprise nearly 50% of total case lineups in a typical supermarket, with more than 80% of their cooling load attributed to infiltration of warm and moist air from the surrounding space. The infiltration takes place across the air curtain system of the display case. While the air curtain acts as a thermal shield and as a cooling mechanism to maintain product temperature, it also entrains large amounts of heat and moisture from the adjacent space. Additionally, from food safety and quality standpoints, these fixtures are vulnerable to electric outages and traditionally cannot participate in load flexibility events. This paper describes key features of an innovative design of a self-contained, water-cooled, medium-temperature, open-vertical display case. The novel concept will eliminate the inefficient air curtain system and incorporate a hybrid radiant and low-airflow convective cooling design with a thermal-energy-storage-coupled heat exchanger integrated into the refrigeration circuit. The focus of this paper is on evaluating the thermal performance of the novel hybrid design in maintaining target product temperature. It presents thermal performance findings from thermo-fluid system modeling and robust state-of-the-art laboratory experiments used to validate those models. Load flexibility attributes from thermal energy storage are not discussed. A controlled-environment chamber at the National Renewable Energy Laboratory was leveraged to validate the thermal performance of the novel technology. Final results from bench-scale experiments indicate the proposed design maintained mean product temperatures within food safety guidelines.

commercial refrigeration↗
DOE OSTI2024

From Chills to Thrills: Revolutionizing Energy Efficiency and Load Flexibility in Supermarket Refrigeration: Preprint

Open-vertical medium-temperature refrigerated display cases comprise nearly 50% of total case lineups in a typical supermarket, with more than 80% of their cooling load attributed to infiltration of warm and moist air from the surrounding space. The infiltration takes place across the air curtain system of the display case. While the air curtain acts as a thermal shield and as a cooling mechanism to maintain product temperature, it also entrains large amounts of heat and moisture from the adjacent space. Additionally, from food safety and quality standpoints, these fixtures are vulnerable to electric outages and traditionally cannot participate in load flexibility events. This paper describes key features of an innovative design of a self-contained, water-cooled, medium-temperature, open-vertical display case. The novel concept will eliminate the inefficient air curtain system and incorporate a hybrid radiant and low-airflow convective cooling design with a thermal-energy-storage-coupled heat exchanger integrated into the refrigeration circuit. The focus of this paper is on evaluating the thermal performance of the novel hybrid design in maintaining target product temperature. It presents thermal performance findings from thermo-fluid system modeling and robust state-of-the-art laboratory experiments used to validate those models. Load flexibility attributes from thermal energy storage are not discussed. A controlled-environment chamber at the National Renewable Energy Laboratory was leveraged to validate the thermal performance of the novel technology. Final results from bench-scale experiments indicate the proposed design maintained mean product temperatures within food safety guidelines.

commercial refrigeration↗
DOE OSTI2021

Connected Loads – Grid Connected Appliances: Commercial Refrigeration System Fault Detection and Diagnostics

As one of the most energy-intensive end-uses in the commercial buildings sector, supermarkets consume around 50 kWh/ft 2 (or 537.6 kWh/m 2 ) of electricity annually, or more than 2 million kWh of electricity per year for a typical store. The biggest consumer of energy in a supermarket is its refrigeration system, which accounts for 40–60% of its total electricity usage and is equivalent to about 2–3% of the total energy consumed by commercial buildings in United States, or around 0.5 quadrillion Btu (or 0.53 quadrillion KJ). Also, the supermarket refrigeration system is one of the biggest consumers of refrigerants. Current supermarket refrigeration systems rely on high global warming potential hydrofluorocarbon refrigerants. Reducing refrigerant usage or using environment friendly alternatives can result in significant climate benefits. Transcritical CO2 refrigeration systems have attracted more attention in recent years because of their zero-carbon emission advantages compared with traditional refrigerants. These systems are widely used in commercial buildings such as supermarkets. The refrigeration system can also be adapted to handle flexible building loads and be integrated into grid response transactive control to balance the supply and demand of the electric grid. Even minor improvements in the efficiency and operational reliability of supermarket refrigeration systems can create significant value in terms of saving energy, improving food quality, protecting the environment, reducing carbon footprint, and enhancing electric grid resilience.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Connected Loads – Grid Connected Appliances: Deployment IoT Solution for Fault Detection and Diagnostics

As one of the most energy-intensive end-uses in the commercial buildings sector, supermarkets consume around 50 kWh/ft 2 ( or 537.6 kWh/m 2 ) of electricity annually, or more than 2 million kWh of electricity per year for a typical store. The biggest consumer of energy in a supermarket is its refrigeration system, which accounts for 40–60% of its total electricity usage and is equivalent to about 2–3% of the total energy consumed by commercial buildings in United States, or around 0.5 quadrillion Btu (or 0.53 quadrillion KJ). Also, the supermarket refrigeration system is one of the biggest consumers of refrigerants. Current supermarket refrigeration systems rely on high global warming potential hydrofluorocarbon refrigerants. Reducing refrigerant usage or using environment friendly alternatives can result in significant climate benefits. Transcritical CO2 refrigeration systems have attracted more attention in recent years because of their zero-carbon emission advantages compared with traditional refrigerants. These systems are widely used in commercial buildings such as supermarkets. The refrigeration system can also be adapted to handle flexible building loads and be integrated into grid response transactive control to balance the supply and demand of the electric grid. Even minor improvements in the efficiency and operational reliability of supermarket refrigeration systems can create significant value in terms of saving energy, improving food quality, protecting the environment, reducing carbon footprint, and enhancing electric grid resilience. For decarbonization, the new administration has set a target to reduce greenhouse gas emissions by 50– 52% by 2030 and targeting a carbon-neutral economy by 2050. For electrification, the goal is to achieve 100% clean electricity by 2035. Such decarbonization and electrification in the building sector require that energy consumption in buildings be reduced significantly. Therefore, the building sector must continuously adopt new technologies to achieve its energy and carbon emission goals. One of the most fundamental technologies is the Internet of Things (IoT). IoT has proven to be an effective solution for the building domain, including building information/energy modeling, smart buildings, etc. Although much progress has been made in the development of IoT-based building energy systems, there is still a lack of reliable, scalable, and affordable IoT-based automated fault and degradation diagnostics (AFDDs) solutions. Such solutions would enable deployment of advanced algorithms into real systems to archive the projected energy benefits. This study reviews existing IoT solutions developed for building energy– related application and developed a simple but effective AFDD IoT deployment solution, including developing a suitable IoT architecture and conducting easy and scalable deployment by leveraging a common cloud-based IoT service.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Dataset of low global warming potential refrigerant refrigeration system for fault detection and diagnostics

Abstract HVAC and refrigeration system fault detection and diagnostics (FDD) has attracted extensive studies for decades; however, FDD of supermarket refrigeration systems has not gained significant attention. Supermarkets consume around 50 kWh/ft 2 of electricity annually. The biggest consumer of energy in a supermarket is its refrigeration system, which accounts for 40%–60% of its total electricity usage and is equivalent to about 2%–3% of the total energy consumed by commercial buildings in the United States. Also, the supermarket refrigeration system is one of the biggest consumers of refrigerants. Reducing refrigerant usage or using environmentally friendly alternatives can result in significant climate benefits. A challenge is the lack of publicly available data sets to benchmark the system performance and record the faulted performance. This paper identifies common faults of supermarket refrigeration systems and conducts an experimental study to collect the faulted performance data and analyze these faults. This work provides a foundation for future research on the development of FDD methods and field automated FDD implementation.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Energy Efficiency and Performance Evaluation of Self-Contained, Medium Temperature, Reach-In Refrigerated Display Cases

This project was part of an effort by Commonwealth Edison Company (ComEd) to evaluate the energy and peak demand saving potential of emerging technologies in the Chicago area. This document focuses on the assessment of energy-efficient, medium-temperature, self-contained refrigerated display cases utilizing environmentally friendly refrigerants. The results of this evaluation will be considered by CLEAResult to develop a new energy efficiency rebate measure for ComEd's incentive programs. This rebate measure will become an addition to the Technical Reference Manual (TRM). In 2016, the United Nations passed the Kigali Montreal Protocol Amendment which placed restrictions on certain types of refrigerants. In compliance with this amendment, the US Environmental Protection Agency (EPA) placed a ban on the manufacture of refrigeration systems using hydrofluorocarbons including R134a starting in January 2020. Although the ban has halted manufacture, the EPA continues to allow the use of these refrigerants. Therefore, it is critical to provide incentives for replacing these refrigerants with other environmentally friendly and energy-efficient alternatives. The energy-efficient refrigerator cases evaluated here (referred to as EE Case A and B) contain environmentally-friendly refrigerants in compliance with the EPA hydrofluorocarbon ban. These consist of natural refrigerant propane (R290), and HFC drop-in hydrofluoroolefin R513a, respectively. These cases also contain other energy-efficient components including efficient lighting, more robust evaporator and condenser fans and different-sized heat exchangers. EE Case A is also built with materials that better insulate the case, which improves energy efficiency. To ascertain the energy efficiency contribution of these design components, the consumption of the evaporator and condenser fan motors, compressor, and lighting/controller were evaluated individually. The medium-temperature, self-contained reach-in refrigerated display case was selected due to its widespread use in convenience stores and small supermarkets. Self-contained refrigeration has also seen increased use in restaurants due to curbside pickup during the COVID-19 pandemic. For this study, the refrigerated display cases' performance was evaluated in a controlled environmental chamber at representative indoor dry-bulb and humidity conditions found in supermarkets within ComEd's service territory climate zone. The test method used in this project was foundationally inspired by the ANSI/ASHRAE 72-2018 method of testing. However, modifications to the ANSI/ASHRAE test methodology were implemented to better represent customer operation of the units. In addition to the indoor supermarket conditions, the cases were also evaluated at the "upper target," or environmental conditions used in ANSI/ASHRAE 72-2018. The case total power and case components were metered to obtain their daily power (kW) and energy consumption(kWh). The cases were filled with thermal filler mass to replicate thermal mass of product loading. Additionally, product simulators were used to provide product temperature information. Door actuators were mounted to each of the cases' three doors to replicate regular door openings and effects of shopper traffic.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Efficient Refrigerated Display Cases - Can They Flex Their Power? Preprint

Refrigerated display cases are widely-used, critical equipment in supermarkets for maintaining product safety and quality. Energy-efficient medium temperature liquid-cooled refrigerated display cases can save 25-70% of the total supermarket energy, according to manufacturers. Traditionally, cases operate by maintaining a temperature around a user-input setpoint that is dependent on the product in the case. Although cases are major electrical energy consumers, they are hardly ever considered for implementing load-flexibility strategies. With added load-flexibility capabilities, refrigerated display cases can shed (reduce), or shift (by adding and subsequently shedding) load. Supermarkets can reduce their energy costs and enhance electric grid integrity by implementing these smart load-flexibility control strategies. Advanced controls can also enable load-shifting to coincide with optimum periods of renewable energy generation. This will further improve operational costs and reduce greenhouse gas emissions without compromising food safety and quality. In this research, we have evaluated the energy savings of liquid-cooled medium temperature display cases and developed load flexibility strategies leveraging an advanced controls system, a variable speed compressor, and heat rejection via a water-cooled condenser. This study further assessed the impact of load flexibility strategies in a controlled environment chamber for a single refrigerated display case.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
DOE OSTI2026

Experimental characterization and analysis of phase change material-based thermal energy storage system for refrigerated display case

Refrigerated display cases that are used to store and exhibit food products in supermarkets and retail spaces consume a significant portion of the buildings’ total electricity. Importantly, the refrigeration-related energy cost and demand charges are greatly affected by the time-of-use electricity pricing and demand rates, which are at their maximum during peak hours, typically when refrigeration energy consumption is also high. Using energy storage to shift the refrigeration load from peak to off-peak hours can greatly reduce the operational costs in the supermarket. This study demonstrates a phase change material-based thermal energy storage (TES) system, specifically designed in stackable units, that can be integrated with an open vertical refrigerated display case. We perform numerical and experimental characterization that includes finite-difference modeling for the TES, prototype fabrication, and laboratory evaluation, followed by a preliminary system-level analysis to predict the impact of TES on the refrigerated case performance, energy use, and energy cost. The results show that the dedicated latent TES for refrigerated cases can provide a specific energy of 50.4 Wh/kg and a specific power of 15.5 W/kg. The TES can be charged during 12 h of the off-peak period and discharged at various rates during 4 to 6 h of the peak period, thereby shifting the refrigeration load from the peak to the off-peak period. Consequently, annual cost savings up to 19% can be achieved, depending on the thermal load, the summer/winter peak electricity pricing, and the transition temperature of the phase change material used.

25 ENERGY STORAGE↗
DOE OSTI2022

Grey-box Fault Models and Applications for Low Carbon Emission CO2 Refrigeration System

CO2 refrigeration systems have attracted more attentions in recent years because of their zero-carbon emission advantages compared with traditional refrigerants. These systems are widely used in certain commercial buildings such as supermarkets. However, very limited energy studies have been done for such refrigeration systems under faults. Furthermore, this study investigated five common faults for supermarket transcritical CO2 refrigeration systems with display cases. The following major tasks were implemented for this study. (1) Five fault models (gray-box format) regarding the power consumption and supply air temperature were proposed for low- and high-temperature display cases, respectively. The models cover: ice accumulation on evaporator coil, evaporator fan partial failure, expansion valve failure, display door open, and condenser blockage. (2) These fault models were calibrated with field tests, and the modeling accuracies were in good agreement with measurement datasets. (3) The proposed fault models demonstrated more than 90% of fault detection for Fault Detection and Diagnostics (FDD) purposes for both field measurement and simulated data.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Gray-Box Fault Models and Applications for Low-Carbon Emission CO 2 Refrigeration Systems

CO 2 refrigeration systems have attracted more attentions in recent years because of their zero-carbon emission advantages compared with traditional refrigerants. These systems are widely used in certain commercial buildings such as supermarkets. However, very limited energy studies have been done for such refrigeration systems under faults. This study investigated five common faults for supermarket transcritical CO 2 refrigeration systems with display cases. The following major tasks were implemented for this study. (1) Five fault models (gray-box format) regarding the power consumption and supply air temperature were proposed for low- and high-temperature display cases, respectively. The models cover: ice accumulation on evaporator coil, evaporator fan partial failure, expansion valve failure, display door open, and condenser blockage. (2) These fault models were calibrated with field tests, and the modeling accuracies were in good agreement with measurement datasets. (3) The proposed fault models demonstrated more than 90% of fault detection for Fault Detection and Diagnostics (FDD) purposes for both field measurement and simulated data.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗