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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

Mechanical Design Progress of the In Situ Nanoprobe Instrument for APS-U

The In Situ Nanoprobe (ISN, 19-ID) beamline will be a new best-in-class long beamline to be constructed as part of the Advanced Photon Source Upgrade (APS-U) project [1, 2]. To achieve long working distance at high spatial resolution, the ISN instrument will be positioned 210 m downstream of the x-ray source, in a dedicated satellite building, currently under construction [3]. The ISN instrument will use a nano-focusing Kirkpatrick-Baez (K-B) mirror system, which will focus hard x-rays to a focal spot as small as 20 nm, with a large working distance of 61 mm. The large working distance provides space for various in situ sample cells for x-ray fluorescence tomography and ptychographic 3D imaging, allows the use of a separate, independent vacuum chambers for the optics and sample, and provides the flexibility to run experiments in vacuum or at ambient pressure. A consequence of the small spot size and large working distance are stringent requirements for high angular stability of the K-B mirrors (5 nrad V-mirror and 16 nrad H-mirror) and high relative stability be-tween focus spot and sample (4 nmRMS). Additional features include fly-scanning up to 2 kg mass, sample plus in situ cell, at 1 mm/s in vertical and/or horizontal directions over an area of 10 mm x 10 mm. Environmental capabili-ties will include heating and cooling, flow of fluids and applied fields, as required for electrochemistry and flow of gases at high temperature for catalysis. To achieve these capabilities and precise requirements we have used precision engineering fundamentals to guide the design process.

Kearney, Steven P.↗

DOE OSTI2021

Impacts of simultaneous operating faults on cooling performance of a high efficiency residential heat pump

Not provided.

Construction & Building Technology↗

DOE OSTI2024

Grid Interactive Micro-Distributed Refrigerated Display Case

commercial refrigeration↗

DOE OSTI2024

Identifying Molecular Scale Interactions of Nucleating Agents with Salt Hydrates for Thermal Energy Storage Applications

Latent heat based thermal energy storage is of interest as a method to mitigate and time-shift thermal load peaks and hence reduce energy demands for heating and cooling buildings. Notably, Glauber’s salt (GS) presents a good choice as a phase change material (PCM) for building applications because it has a melting point near room temperature (i.e., 32.4 °C), a large heat of fusion and energy density, and is low cost (~ $100/ton). However, there are several known limitations to using GS as a PCM, such as incongruent melting, high degree of supercooling, and formation of other hydration states, which renders GS unsuitable for practical use. Inorganic crystals acting as nucleating agents can avoid some of these issues with GS [1]. Understanding nucleation behavior through typical calorimetry experiments offers limited insight into the molecular-scale mechanisms. Here, we report isothermal titration calorimetry [2] to investigate the interactions between sodium sulfate salt and an organic nucleating agent - glycine. Our experiments provide qualitative and quantitative understanding of how glycine interacts with sodium sulfate across various temperatures. The findings offer insights into the nucleation onset temperature (24°C) and underscore the pivotal role of glycine's zwitterionic structure in facilitating nucleation. This preliminary work provides a foundation for subsequent exploration of nucleating agents that would be incorporated in different salt hydrate systems. 1. Purohit, B. K., and V. S. Sistla. "Inorganic salt hydrate for thermal energy storage application: A review." Energy Storage 3, no. 2 (2021): e212. 2. Velázquez-Campoy, Adrián, Hiroyasu Ohtaka, Azin Nezami, Salman Muzammil, and Ernesto Freire. "Isothermal titration calorimetry." Current protocols in cell biology 23, no. 1 (2004): 17-8.

calorimetry, nucleation & growth↗

DOE OSTI2025

High-performance windows improve thermal survivability of occupants during cold snaps

Exposure to low indoor air temperature is a major contributor to temperature-related mortality during extreme cold events, especially when power outages disrupt operation of space heating systems. This study explores the impact of high-performance windows on the thermal resilience of residential buildings during extreme cold weather and grid power outages, as well as their long-term benefits through energy efficiency and reduced risk of property damage. Building performance simulations were conducted for reference residential buildings in three construction vintages and two major U.S. cities located in cold climate zones, considering two types of extreme cold events: short and severe, and long and milder. Our research found that even houses compliant with current energy codes struggle to maintain safe indoor temperatures for more than a few hours during power outages, necessitating rapid evacuations. High-performance windows can extend the thermal survivability time by up to 3.8 days within a 7-day cold snap and significantly reduce risk of bursting frozen water pipes, depending on the building’s insulation and infiltration level, cold event severity, and occupant vulnerability. This extended thermal safety time is crucial in scenarios where reduced mobility complicates emergency responses in senior housing. In addition to boosting thermal resilience, upgrading older homes with high-performance windows can reduce heating energy consumption by over 18% and cooling energy by 15%. Our findings highlight the need to incorporate thermal resilience assessments into new designs or major retrofits, including the use of typical and extreme weather scenarios and advanced technologies like high-performance windows.

Krelling, Amanda F↗

DOE OSTI2024

Development and Experimental Validation of a Heat Transfer Model for Spilled Molten Salt Pools

A spill of radionuclide-bearing molten salt is one of the major postulated events that needs to be analyzed for liquid fluorine salt-cooled high-temperature reactor (FHR) or molten salt reactor licensing purposes. In this postulated event, radioactive source term materials (RSTMs) in the molten salt are discharged from the reactor vessel to the reactor building. The release of RSTMs from the spilled salt pool to the gas space in the reactor building is expected to be controlled by the cooling behavior of the spilled salt, including the growth and shrinkage of the solid crust on the surface of the spilled salt pool. This paper presents a simulation model for spilled salt pool heat transfer and validation efforts. The validation data come from two molten salt spill tests that were performed recently: the PELE2 test by the Rapid Experimental Laboratory of Kairos Power LLC (KP) and the Argonne salt cooling test conducted by Argonne National Laboratory. The former was a large-scale test involving kilograms of molten spilled FLiNaK salt, and the latter was a relatively smaller-scale test targeting various processes associated with a salt spill event. Both tests generated valuable data sets that can be used to assess salt cooling and validate evaluation models. This paper provides a new one-dimensional model that can simulate the cooling process of a spilled salt pool as well as the thermal responses of heat structures, such as the stainless steel liner and the concrete below the salt. The model has been implemented as part of KP-SAM code, which is a branch of the systems code SAM specific to KP FHR. In conclusion, the simulation results of the model are compared with the data of the PELE2 and Argonne tests, and reasonable agreements are observed between the model and test data.

heat transfer model↗

DOE OSTI2022

LCLS-II helium cryoplant and cryo distribution system installation

The helium cryoplant and cryo distribution system (CDS) are key elements of the new superconducting Linac Coherent Light Source (LCLS-II) and will provide superfluid helium to the accelerator. The cryoplant consists of two helium refrigerators with an equivalent 4.5 K refrigeration capacity of 18 kW each. The 37 cryomodules of the LINAC will be operated at a temperature of 2.0 K to accelerate a 4 GeV electron beam that will generate extremely bright X-ray laser light. Two five-stage cold compressor cold boxes will be utilized to provide superfluid helium II for the superconducting cavity structures with a total cooling capacity of 8 kW at 2.0 K. This paper describes the installation of the LCLS-II cryoplant and CDS. The LCLS-II cryoplant was designed and contributed by Jefferson Lab. To expedite the project completion the reuse of proven design and technology from the Jefferson Lab CHL-2 cryoplant was the preferred strategy. The CDS consists of ~260 m thermally shielded and vacuum super insulated transfer lines, two distribution boxes and eight feed and end caps, and was designed and contributed by Fermilab. SLAC installed the cryoplant components into a newly erected building and the CDS components into the existing accelerator tunnel and klystron gallery with strong engineering support from both partner labs.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

Design and Fabrication of the Mu2e Cryogenic Distribution System

The muon-to-electron conversion (Mu2e) experiment at Fermilab will be used to search for the charged lepton flavor-violating conversion of muons to electrons in the field of an atomic nucleus. The Mu2e experiment is currently in the design and construction stage and is expected to begin operations in 2022. The Mu2e experiment uses four large superconducting solenoid magnets including a Production Solenoid (PS), an Upstream and Downstream Transport Solenoid (TSu and TSd) and a Detector Solenoid (DS). This paper will focus on the cryogenic distribution system for these four solenoid magnets. Liquid helium will be supplied from two re-purposed Tevatron satellite refrigerators. A large cryogenic distribution box (DB) is located in the Mu2e building to distribute the required cryogens to each of the four solenoid magnets. Each solenoid magnet will have a dedicated transfer line and cryogenic feed box (FB). The solenoid magnets each require two liquid helium circuits and two liquid nitrogen circuits. The most unique feature about this cryogenic system is that the assemblies for the start of the superconducting portion of the power leads are mounted in feed boxes that are in the range of 23 m to 31 m away from the solenoid magnets. The cryogenic feed boxes are located remotely to provide protection from radiation damage and high magnetic fields. The power leads are NbTi superconducting cable stabilized with high conductivity aluminum. The 6061-T6 aluminum grade was selected for the transfer line piping so that the piping would thermally contract at the same rate as the power lead. A major concern for this transfer line is that a small helium leak could create an electric discharge arc due to the Paschen effect. This paper includes a description of the design features and testing done to ensure that the power leads are protected from the Paschen effect while still being adequately cooled to liquid helium temperatures.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

A New Gold Mine? Achieving HVAC Energy Efficiency Through a System Metric

Washington State's Commercial Energy Code adopted a new energy metric called HVAC Total System Performance Ratio (TSPR) in 2019, a first in the codes world to regulate HVAC system efficiency. TSPR is a ratio of annual heating and cooling loads to the annual carbon emissions associated with the energy consumed by the HVAC system. TSPR provides a performance-based solution to evaluate and improve the overall HVAC design. The TSPR metric and its companion calculation tool were developed by Pacific Northwest National Laboratory (PNNL) with support from U.S. Department of Energy (DOE), Northwest Energy Efficiency Alliance (NEEA) and the City of Seattle. The new metric represents a significant shift in how HVAC design will meet code requirements. Utility programs can also leverage TSPR as a measure to determine energy savings and incentive amounts for HVAC retrofits. This paper describes the efforts by NEEA and its collaborators to prepare the market for TSPR adoption in code. This paper provides the pilot projects led by University of Washington Integrated Design Lab (IDL) to understand potential issues that could be faced by early adopters. This paper also covers how training and outreach provide engagement opportunities that can streamline code compliance, help address issues faced by early adopters and promote participation in utility programs. As Washington State works on the goals of 70% energy reduction and zero fossil-fuel greenhouse gas emission homes and buildings by the year 2031 , system level performance metrics will likely become increasingly more necessary and prevalent. This paper concludes that the HVAC TSPR requirement helps familiarize the HVAC industry with this approach and helps Washington achieve its long-term goals.

Liu, Bing↗

DOE OSTI2022

WBG-Enabled Current-Source Inverters for Integrated PM Motor Drives

This project takes advantage of the special capabilities of wide-bandgap (WBG) power semiconductor devices to develop innovative power electronics in the form of new current-source inverters (CSIs) that offer promising advantages over the dominant voltage-source inverter (VSI) topology. These CSIs, in turn, are extremely well-suited for integration into the housings of permanent magnet synchronous machines (PMSMs) to form integrated motor drives (IMDs). These new IMDs offer great promise for achieving major energy savings in a wide variety of applications that benefit from adjustable-speed control, including air conditioners, laundry appliances, industrial pumps/compressors, electric vehicles, and aerospace drives. WBG devices play a critical enabling role in these new IMDs because of their transformative features including much higher switching frequencies, lower losses, and compatibility with high operating temperatures. When incorporated into new CSI-based IMDs with PM machines, these WBG switches open the door to achieving major increases in power density, drive system efficiency, and fault tolerance, as well as substantial reductions in electromagnetic interference (EMI), manufacturing cost, and temperature-induced failures. The higher operating temperature capability of WBG devices compared to conventional silicon power devices is very appealing in IMD applications because the power electronics is mounted in close proximity to the motors which typically operate at temperatures well above the maximum limits of today’s silicon-based power electronics. This project has succeeded in designing, building, and testing multiple prototype versions of this CSI-IMD that have overcome many technical challenges in order to demonstrate the impressive performance improvements that can be achieved by the WBG-enabled CSI-IMD. The preliminary demo and bench-top versions of the current-source inverter developed during the first two years of the project were critical to laying the technical foundations for the 3 kW prototype CSI-IMD unit that was successfully built and tested during the third year. This prototype CSI-IMD unit was designed to fit within the housing envelope of the original permanent magnet (PM) synchronous machine in order to meet the demanding power density requirements that were set at the beginning of the project. All of the remaining performance objectives set for the prototype CSI-IMD unit including efficiency and electromagnetic interference (EMI) were also met. The last 18 months of the project were devoted to developing further enhancements of the WBG-enabled CSI-IMD technology that better prepare it for commercial production. More specifically, an upgraded version of the prototype CSI-IMD unit was developed that moved the power electronics into the same machine housing chamber as the motor, substantially raising the thermal demands on the power electronics. Tests with five different combinations of motor enclosure types and air cooling configurations were evaluated. Importantly, this work confirmed that the power electronics can deliver its full rated power and still operate well within its maximum temperature limits even for worst-case conditions when the housing is “totally-enclosed” without any openings for air to enter or exit the enclosure, and no blower/fan is provided to blow air over the outside surface of the enclosure. Reaching the full performance and energy-savings potential of this disruptive CSI-IMD motor drive technology is highly consistent with ARPA-E’s stated mission to “enhance the economic and energy security of the United States” while also supporting its commitment to “ensure that the U.S. maintains a technological lead in developing and deploying advanced energy technologies”. Follow-on projects are under way to explore the scalability of WBG-enabled CSI-IMD technology to 100 kW (peak) electric vehicle traction drives and fault-tolerant modular motor drives for future electrified aircraft propulsion applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Analysis of precooling optimization for residential buildings

To reduce peak demand and/or energy cost for residential buildings, optimal precooling strategies are becoming important as an alternative to rule-based precooling strategies that are intuitive but may not be optimal. Since precooling optimization is heavily dependent on a variety of factors such as the home thermal properties, HVAC system, weather, thermal comfort criteria, and utility rate structure, the individual and collective impact of these factors on precooling performance needs to be analyzed. In addition, since the indoor air temperature is affected by heat transfer to and from the interior wall surface, performance analysis in view of the interior wall surface temperature is also essential. Therefore, in this paper, an optimal precooling strategy that accounts for the aforementioned factors and utilizes a second-order thermal network model, is proposed. With this strategy, the HVAC on/off control signal that minimizes 24-hour energy cost while maintaining thermal comfort, is determined. Through extensive simulations, it is found that the proposed optimal precooling strategy is able to adapt to changing conditions and that having a sufficiently low interior wall surface temperature during precooling is critical for avoiding expensive on-peak operation. Here, the reason for the latter is that such a temperature indicates that enough “cooling energy” has been stored. It is also found that weather has the most dominant impact on the precooling performance, followed by home thermal condition, with the rated cooling capacity and utility rate structure having the least impact.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Land use-land cover gradient demonstrates the importance of perennial grasslands with intact soils for building soil carbon in the fertile Mollisols of the North Central US

The impact of land use change and agricultural management on the cycling of soil organic carbon (SOC) is not well understood, limiting our ability to manage for, and accurately model, soil carbon changes at both local and regional scales. To address this issue, here we combined long-term soil incubations with acid-hydrolysis and dry combustion to parse total SOC (C t ) into three operationally defined SOC pools (active, slow, and recalcitrant) from 9 long-term sites with varying land uses on current and former tallgrass prairie soil. Land uses represented a gradient of soil disturbance histories including remnant prairie, restored prairie, grazed pasture, annual crop rotations, and continuous maize. Dry combustion was used to estimate total carbon (C t , physical), while acid hydrolysis of both the active (C a ) and slow (C s ) pools was used to estimate a recalcitrant carbon pool (C r , chemical). Non-linear modeling of CO 2 efflux data from the long-term incubations was then used to estimate C a , and the decomposition rates of both C a and C s (k a and k r , biological). The size of the slow pools C s was then defined mathematically as C t- (C a + C r ). Remnant prairie had the highest C t , while cool-season pasture and a 35-y-old restored prairie had higher C t than the other agricultural systems. All agricultural systems, including pasture, had the highest fraction of C t as C r (~50%), whose mean residence time (MRT) in these soils is ≥500 years (Paul et al., 2001a) demonstrating that this fraction persists, while the more labile fractions were lost over the course of a few months (C a ) to a few decades (C s ) as a result of tillage-intensive agriculture. The two- to four-decade MRT time of C s indicated a pool likely to be more responsive to the 20 to 40 years of land-use practices used at some of the sites. The C s pool was largest in the remnant- and 35-y-old prairies indicating significant C accrual and stabilization compared to the agricultural ecosystems. Interestingly, the remnant prairie maintained the highest C a pool as well, demonstrating the strong connection between the quantity of fresh C inputs and the potential for long-term C stabilization and accrual. The accumulation of C in active (≈labile) pools as a first step toward long-term stabilization highlights the tenuous nature of early carbon gains, which can be quickly lost in response to climate change or poor management.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Developing a Control Strategy for Minimum Airflow Setting Considering CO2 Level and Energy Consumption in a Variable Air Volume System

In an office building equipped with a Variable Air Volume (VAV) system, this paper introduces a novel method for controlling the minimum supply airflow fraction in each zone’s VAV box, having a capability to consider indoor CO2 level and energy consumption. The EnergyPlus simulation using the medium office prototype model was employed, which evaluated the performance of the energy and CO2 concentration for five VAV box airflow control strategies. The paper focuses on CO2 concentration-based airflow control method and compares it with other four methods including conventional single-max, reduced minimum single-max, demand-controlled ventilation(DCV), and dualmax control methods according to guidelines and common practices. The newly proposed control strategy directly correlates the minimum airflow fraction to CO2 concentration. A general trend emerged when comparing CO2 concentrations—lower minimum airflow fractions were associated with higher concentrations. The proposed control method effectively maintained low CO2 concentrations and enabled a lower airflow fraction contributing to energy consumption reduction. It was confirmed that heating energy consumption in climate zone 4A, 5B, and 6A showed a maximum saving of approximately 30% compared to the conventional single-max and dual max control strategies. It was found that cooling energy consumption in climate zone 4A and 6A can achieve a maximum saving of approximately 10% compared to the conventional control strategies. The proposed CO2 concentration-based control logic is promising as it not only improves the indoor air quality lowering the CO2 concentration in the occupied spaces, but also contributes to HVAC energy savings.

Lee, Jong Man↗

DOE OSTI2026

Deep learning–based digital twins for heat pumps

Heat pumps are effective cooling and heating appliances to save energy in buildings. However, traditional heat pump models are challenging to integrate with building demands in a co-simulation environment because of the nonlinear thermodynamics of refrigerants. Developing digital twin representatives for heat pumps capable of faster calculations with good accuracy is desirable. This study aimed to establish a generic deep learning–based digital twin for heat pumps with a large amount of high-fidelity data. Two refrigerants for two different heat pumps were considered: an air source heat pump with refrigerant R-410A, an air source heat pump with refrigerant CO 2 , a water source heat pump with refrigerant R-410A, and a water source heat pump with refrigerant CO 2 . Furthermore, results showed that the deep learning (long short-term memory) models effectively represented these four heat pumps as a digital twin: (a) accuracy for training and testing showed smaller than 0.02 for heating electricity and heating demands, and (b) the digital twins showed good consistency with original data for heating electricity and heating demands (root mean square errors of less than 0.12 W and 0.19 W, respectively). Therefore, deep learning–based heat pump models can be used in the co-simulation of building mechanical systems.

Air source heat pump↗

DOE OSTI2024

A Generalized Nuclear Code of Accounts for Cost Estimation Standardization

This is a joint INL-EPRI study. Link to corresponding page at the Electric Power Research Institute (EPRI): https://www.epri.com/research/products/000000003002028937 Recent Advanced Reactor (AR) designs typically offer features and attributes that depart from traditional water-cooled reactors in terms of fuel forms, coolants, structural materials, size, safety margins, and other important design and operational aspects. These departures, relative to the industry experience, will likely present a challenge for potential owner-operators when evaluating one or more AR designs for commercial deployment on a like-for-like basis. This is further exacerbated with new classes of reactors gaining prominence (e.g., microreactors) and new emerging applications (e.g., floating barge reactors or space propulsion reactors). The differences in design-specific technologies are compounded by the differences in approach to cost estimation. The lack of consistency in build up toward cost estimates creates a challenge when comparing competing concepts and evaluating their associated cost drivers. The outcome of a 2019 Scoping Study conducted by the Electric Power Research Institute (EPRI) indicated the need for a cost modeling guide (CMG), which would be underpinned by a technology-neutral and inclusive Generalized Nuclear Code of Accounts (GN-COA). A code of accounts (COA) is a tool by which costs are identified in even more specific categories, providing clarity on what specific costs are included in an estimate. A parallel independent effort was meanwhile taking place at Idaho National Laboratory via funding by the Systems Analysis Integration (SA&I) campaign of the Office of Nuclear Energy under the U.S. Department of Energy (U.S. DOE-NE) to also update the COA structure to enable more flexibility and encompass a wider variety of reactor technologies. After being made aware of these synergistic efforts, the two parties decided to combine efforts and develop a joint new standard format for nuclear cost estimation that builds on previous structures. This document describes the development of this joint GN-COA and provides guidance on the implementation of the tool, which is provided as the associated GN-COA Excel document. The main attributes of this novel COA format are that all items are functionally defined (in order to be technology and application agnostic) and grouped into logical arrangements that facilitate the tabulation of costs for reactor constructions under consideration. The intent is for the GN-COA to form a standard that is endorsed by future vendors and customers.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Performance assessment of a real water source heat pump within a hardware-in-the-loop (HIL) testing environment

Over the last decade, the global fight against climate change through electrification has led to an increase in research on building heating, ventilation, and air conditioning (HVAC) systems that utilize intelligent control algorithms to provide demand-side grid service while also maintaining the thermal comfort of building occupants. As the pivotal point between building electricity consumption and indoor thermal comfort, high-efficiency electrical vapor-compression heat pumps are at the center of these emerging studies, and various grid-interactive and occupant-comfort control algorithms have been developed for them. The impact of these algorithms on heat pump operation and performance when subjected to different weather conditions, building loads, and grid requests calls for investigation and verification via experimental testing with actual heat pumps integrated with real-time building and grid responses. This study introduces a Water-Source Heat Pump (WSHP) Hardware-in-The-Loop (HIL) Test Facility that is the first of its kind. This testbed utilizes a 2-ton variable speed water-to-air heat pump that is capable of interacting with a virtual environment currently comprised of an EnergyPlus (E+) building simulation, an agent-based occupant behavioral model, and a single U-tube ground-loop heat exchanger (GLHE) model. Detailed descriptions of the testbed’s physical design and operation, virtual environment, as well as their mutual communication is provided. An uncertainty analysis is also performed under manufacturer specified heating and cooling design conditions. This analysis shows that the total load across the WSHP’s demand side heat exchanger, i.e., the sum of its latent and sensible components, can be measured with a relative uncertainty of ± 10.4% and ± 3.6% in cooling and heating mode respectively. The WSHP’s coefficient of performance (COP) can be measured with relative uncertainties of ± 10.4% in cooling mode, and ± 3.7% in heating mode. A preliminary 24-h experimental demonstration is then performed utilizing the DOE prototype small commercial office building model in E+. The simulation takes place in Atlanta, GA on the date of 08/26/15 from 12:00 AM to 11:59 PM using TMY3 weather data. Here, the results from this demonstration show that over the course of this experiment the simulated outputs of zone dry-bulb temperature, zone humidity ratio, and WSHP inlet water temperature can be tracked by testbed emulators up to a root mean squared error (RMSE) of ± 0.27 °C, ± 0.376 g/kg, and ± 0.85 °C respectively. The WSHP’s dynamic behavioral characteristics and performance are also captured, and correspond well with the authors’ previous understanding of heat pump efficiency as a function of evaporator and condenser fluid inlet conditions respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Innovative Advanced Hydrogen Mobile Fueler (Final Technical Report)

The US Department of Energy (DOE) funded a project to design, develop, deploy and analyze the economic viability of an innovative Advanced Hydrogen Mobile Fueler (AHMF). As part of the design activity the project team defined specifications based upon vehicle requirements and compliance with specific fueling performance criteria. The AHMF was originally designed to fuel 10-20 fuel cell vehicles (FCV) per day, consistent with the requirements of the H70 fueling category. The AHMF is able to operate without remote power connections, is modular for easy transport and deployment, and can provide expanded daily capacity and multi-day operations using delivered gaseous hydrogen. Toward the end of the project, due to request from the hydrogen industry and some necessary modifications of the AHMF, the system is now modified to fuel heavy duty vehicles. The project was conducted over two primary phases, each including several key tasks, subtasks, and project milestones. Phase 1 involved the design, development, and construction of the AHMF, moving from a conceptual design through to completion of assembly and testing. In addition to reviewing several different approaches, the team chose to take a conventional station design and modify it for mobile fueling. There were several innovative components included in the design. The high pressure storage was the first to achieve a US Department of Energy (DOE) Special Permit (SP 20391) to transport high pressure hydrogen (95 MPa) in a composite cylinder. The second novel system was a liquid nitrogen (LIN) cooling system with a compact heat exchanger. Without this change, the cooling system would not be able to fit into the AHMF. Phase 2 demonstrated the AHMF by fueling fuel cell buses at a fleet in Pomona, CA. The site was chosen because a temporary fueling solution was required while a fixed station was being installed. The existing permits for the fixed station and non-public access also was a determining factor. Over two months, the buses were fueled 320 times with over 5000 kg of hydrogen from tube trailers. Existing shore power was used, and the average electrical efficiency was 0.13 kWh/kg. The average liquid nitrogen (LIN) consumption was 90.68 scf/kg. The fueling and consumption data was provided to the National Renewable Energy Laboratory (NREL) for analysis. An economic analysis was performed and will be provided in a separate report. The project was successful, but not without challenges and lessons learned. The DOT special permit led the way for the use of high pressure, composite cylinders and is being by multiple other systems and applications. The pandemic along with time for the DOT special permit approval delayed the project for years. The team also believes that hydrogen mobile fueling has a use for the industry, especially during this upcoming phase of expansion. However, it does have its limitations due to high cost to build and operate, and the same permitting challenges as a fixed station. A fully capable system at the speeds and pressures of the AHMF may not be necessary for most applications and would help reduce the cost and increase storage capacity. The on-board generator can be easily replaced with shore power or the wide range of power generation solutions in the marketplace. One of the major results of the project was the development of new code language in National Fire Protection Agency (NFPA) 2 and the International Fire Code (IFC) for on-demand mobile fueling. This will provide guidance for Authorities Having Jurisdiction (AHJ) and user on how to permit temporary fueling sites across the nation.

08 HYDROGEN↗