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DOE OSTI2020

Re-Envisioning RCx: Achieving Max Potential HVAC Controls Retrofits through Modernized BAS Hardware and Software

Most existing buildings have sub-optimal heating, ventilation, and air conditioning (HVAC) controls, resulting in wasted energy and occupant discomfort. Retro-commissioning (RCx) addresses many of these issues, but it is a lengthy and highly customized process. Limited capabilities of existing building automation system hardware restricts the scope of most RCx projects. Incentive programs consider building automation system (BAS) hardware retrofits to be high-capital investments and do not allow them in typical RCx programs. This paper describes work that the authors are leading to facilitate technical and market innovation in the BAS industry to unlock large savings in existing commercial buildings through deep retrofits of BAS hardware and software. California and New York research projects are demonstrating BAS retrofits leveraging the American Society of Heating, Refrigeration, and Air Conditioning Engineers’ (ASHRAE) new Guideline 36 high performance sequences of operation to achieve greater than 20 percent whole building energy savings, while saving costs and reducing risk through streamlined processes and standardization across BAS manufacturer product lines and across implementation practices. This paper describes market barriers that impede achieving deep savings from BAS retrofits in custom incentive and traditional RCx programs and presents a new maximum potential BAS retrofit model that addresses these barriers. The new model leverages the authors’ efforts in market enablement through open standards, BAS industry partnerships, and tools for cost-effective scaling that includes tools for project screening, savings calculations, and measurement and verification (M&V). This approach is widely applicable and will be ready for at-scale implementation within two years.

Paliaga, Gwelen↗
DOE OSTI2021

Cryogenic Carbon Capture™ (CCC) Status Report

The Cryogenic Carbon Capture™ (CCC) process separates CO2 from light gases in essentially any continuous process. CCC cools the gases to the frost or desublimation point of CO2 (-100 to -135 °C), separates and pressurizes the solids, and warms all streams to produce a CO2-depleted stream at ambient pressure and a pure (99+%) pressurized liquid CO2 stream typically to about 150 bar, both at ambient temperature. The process also recovers all gas moisture and most gas impurities less volatile than CO2 (NOx, SOx, Hg, PM, UHC, CCC, etc.) in separable streams. CCC nearly eliminates refrigeration energy for sensible temperature changes through heat integration. CCC does require energy to change the CO2 phase from a mixed vapor to a pressurized fluid, which represents the minimum energy required of any process for this separation. CCC uses additional energy for turbomachinery inefficiencies, heat losses, moisture removal and overall process pressure drop. Aside from these real-world energy demands, CCC operates near the minimum energy required to perform this gas separation by minimizing stream recycling. CCC compresses CO2 as a liquid, which is one of several reasons it costs about about half as much and consumes about half as much energy as an amine process when using flue gases with about 15% CO2. The process also has several major additional advantages, including (a) it is a bolt-on retrofit technology that does not need steam or any modification of existing equipment, (b) it recovers water and nearly all pollutants in addition to CO2 from the flue gas, (c) it enables highly efficient and cost effective energy storage at grid scale and on time scales of minutes, (d) it enables NG storage if the energy storage option is used, and (d) it has a small footprint and is minimally disruptive to existing plants, requiring only electrical power and a gas source to operate. Sustainable Energy Solutions (SES) has scaled this technology through several levels, the largest of which captures nominally 1 tonne of CO2/day and is called the skid system. Skid system field tests include utility-scale power plants, cement plants, heating plants, and other utility or industrial sites that burn natural gas, biomass, coal, shredded tires, municipal waste, and combinations of these fuels. These field tests produced 95-99% CO2 capture with CO2 purities of 99+% and initial CO2 contents that range from 4 to 28%. SES currently seeks to scale the system to merchant scale (10-80 tonnes of CO2 per day). In the process of doing so, SES has demonstrated the potential for CCC to contribute to energy storage and direct air capture in innovative and cost-effective ways. This presentation discusses the overall process and highlights results from field and in-house tests. These include (a) measured CO2 capture rates and operating conditions from in-house and field tests, and (b) predicted utility-scale costs and energy demands. This discussion also includes the application of the CCC technology to energy storage and direct air capture.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Recent Cryogenic Carbon Capture™ Field Test Results

Sustainable Energy Solutions (SES) has been developing Cryogenic Carbon Capture™ (CCC) since 2008. In that time, two processes have been developed, the External Cooling Loop and Compressed Flue Gas CCC processes (CCC-ECL and CCC-CFG, respectively). The CCC-ECL process cools the flue gas with an external refrigerant loop. This process currently captures up to 1 tonne of CO2 per day (TPD). SES has tested CCC-ECL on real flue gas slip streams from subbituminous coal, bituminous coal, biomass, natural gas, shredded tires, and municipal waste fuels at field sites that include utility power stations, heating plants, cement kilns, and pilot-scale research reactors. The CO2 concentrations from these tests ranged from 5 to 22% on a dry basis. CO2 capture ranged from 95-99+% during these tests. Several other condensable species were also captured including NO2, SO2 and PMxx at 95+%. NO was also captured at a modest rate. The CCC-CFG process has been scaled up to a 0.25 ton per day system. This system has been tested on real flue gas streams including subbituminous coal, bituminous coal, and natural gas at field sites that include utility power stations, heating plants, and pilot-scale research reactors. CO2 concentrations for these tests ranged from 5 to 15% on a dry basis. CO2 capture ranged from 95-99+% during these tests. Several other condensable species were also captured including NO2, SO2, and PMxx at 95+%. NO was also captured at 90+%. Hg capture was also verified and the resulting effluent from CCC-CFG was below a 1ppt concentration. This paper will focus on discussion of the capabilities of CCC generally, the results of CCC-ECL field testing, and future steps surrounding the development of this technology. Test results that will be presented have been collected during 9 months of testing at a commercial power plant under funding from the US Department of Energy (DOE) and the host utility. Testing of one of the systems at a commercial cement plant in the United States will also be discussed. During this testing, the system captured CO2 from the cement plant and stored the CO2 in pressurized tanks. These tanks were provided to a partner company that later used the CO2 in a CO2 utilization demonstration. The CO2 was utilized to cure concrete manufactured using cement from the same plant where the CO2 was captured. This integrated capture and utilization demonstration was the first time that the cement industry has shown in the field that it can sequester its CO2 emissions in its main product stream. This represents a potential game changing solution for industrial CO2 emissions. Operational data and host-site feedback indicate that the CCC process is ideally suited for deployment into a variety of commercial environments. A few areas of de-risking remain to make sure the technology can meet very strict industrial reliability standards. These areas of de-risking are identified and discussed. The product CO2 is shown to meet specification for many uses including industrial and merchant applications. The technology is nearing readiness for deployment at commercial scale and several initial target markets have been identified.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Sizing Small-Scale Renewable Energy Systems for the Navajo Nation and Rural Communities

The Navajo Nation consists of about 55,000 residential homes spread across 27,000 square miles of trust land in the Southwest region of the United States. The Navajo Tribal Utility Authority (NTUA) reports that approximately 15,000 homes on the reservation do not have electricity due to the high costs of connecting rural homes located miles from utility distribution lines. In order to get these rural homeowners access electricity, NTUA and other Native owned companies are examining small-scale renewable energy systems to provide power for necessary usage such as lighting and refrigeration. The goal of this study is to evaluate the current renewable deployment efforts and provide additional considerations for photovoltaic (PV) systems that will optimize performance and improve efficiency to reduce costs. There are three case studies presented in different locations on the Navajo Nation with varying solar resource and energy load requirements. For each location, an assessment is completed that includes environmental parameters of the site- specific landscape and a system performance analysis of an off-grid residential PV system. The technical process, repeated for each location, demonstrates how the variance and uniqueness of each household can impact the system requirements after optimizations are applied. Therefore, the household variabilities and difference in locations must be considered. The differing results of each case study suggests additional analysis is needed for designing small-scale PV systems that takes a home-land-family specific approach to allow for better efficiency and more flexibility for future solar innovations to be considered for overall cost reductions.

14 SOLAR ENERGY↗
DOE OSTI2020

Improving AHU Performance by Minimizing Approach Temperature, Reducing Air Maldistribution, and Efficiently Handling Sensible and Latent Loads (Phase 1 Interim Final Technical Report)

Residential air handling units (AHUs) have stayed the same in form and efficiency for the past 30+ years, with incremental improvements made to address safety, functionality, and energy-efficiency. The purpose of this research in Phase I, Topic 9a: Next Generation Residential Air Handlers, was to improve AHU performance by minimizing heat exchanger (HX) approach temperature, reducing air maldistribution, and developing alternative system configurations which more efficiently handle sensible and latent loads. In this research Optimized Thermal Systems (OTS) developed, modeled, and evaluated multiple alternative system concepts. A dual vapor compression system separate sensible and latent cooling (SSLC) concept was studied to inform work on alternative concepts and to show best-case performance benefit. System concepts included ejector enhanced vapor compression cycles, desiccant assisted dehumidification, dual evaporator SSLC, and alternative AHU HX configurations. A dual vapor compression system showed COP improvement of 20%, however, required additional components, increased unit size, and increased cost. Two types of ejector enhanced vapor compression cycles with dual evaporators improved system COP by 9 to 11%, and reduced AHU losses by as much as 18%, with design changes limited to the AHU, no unit physical size increase, and a moderate increase to system first cost. Desiccant assisted air-conditioning required increased air flow rate resulting in higher fan power and the desiccant wheel increased sensible heat load leading to increased compressor power and reduced system COP. Dual evaporator cycles were found to degrade performance due to increased expansion losses. Optimized single slab HX designs used in place of the traditional A-coil HX led to 44–49% reduction in aluminum, 47–60% less refrigerant charge, and improved HX velocity distribution.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Update of ASHRAE Standard 140 Section 5.2 and Related Sections (BESTEST Building Thermal Fabric Test Cases)

This report documents new work intended to update the current building thermal fabric software-to-software comparative test specifications and example results of ANSI/ASHRAE Standard 140-2017, Sections 5.2.1, 5.2.2, 5.2.3, and related supporting sections. The Building Energy Simulation Test and Diagnostic Method (BESTEST) test specification and example results that provide the basis for these Standard 140 sections were originally published in 1995. The state of the art in building energy simulation modeling has advanced since then. Additionally, comments on the test specification over the years highlighted ambiguities, further necessitating the update to the original work. This new work was conducted for the U.S. Department of Energy (DOE) by Argonne National Laboratory (Argonne) and National Renewable Energy Laboratory (NREL), in collaboration with a working group of international experts associated with the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) Standing Standard Project Committee (SSPC) 140. SSPC 140 is responsible for ANSI/ASHRAE Standard 140. The new work, presented in this report, defined the test cases and specifications such that building energy simulation programs with time steps of one hour or less can perform the tests. Revisions to the test specification and update of example results follow the vetting process of iterative field trials established for previous BESTEST work that has been adapted for ASHRAE Standard 140.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Force Balance Model Assessment for Mechanistic Prediction of Sliding Bubble Velocity in Vertical Subcooled Boiling Flow

The bubble sliding after departing from nucleation site is frequently observed in flow boiling systems and, the crucial impact on wall heat transfer has been evidenced through many experiments. As a result, the heat transfer modeling associated with sliding bubble has become one of the subjects of great attention in CFD boiling heat transfer community. The modeling efforts are primarily aimed at improving the existing Heat Flux Partitioning (HFP) model via the implementation of sliding bubble-induced heat transfer. The performance of HFP model depends inherently on the fidelity of sub-models used to predict the fundamental bubble parameters (e.g., bubble departure/lift-off diameter). In the same context, the accurate prediction of sliding bubble parameters (e.g., sliding bubble growth, sliding bubble velocity) is essential to achieving the successful heat transfer modeling associated with sliding bubble. Of many sliding bubble parameters, this paper deals with the sliding bubble velocity. Specifically, the force balance model was assessed in view of the sliding bubble velocity prediction. The parametric effect of key sub-models (e.g., drag force, bubble growth models) used in the force balance equation was investigated. The experimental data from Maity (2000) and Yoo et al. (2016) were used for demonstrating the model predictive performance. It was found that the force balance model proposed in this study was able to predict well the bubble sliding velocity based on the accurate prediction of bubble growth during sliding. The predictive performance was proven with the experimental data measured under various subcooled boiling conditions of both water and refrigerant (NOVEC-7000) flowing upward in vertical channels.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

IEA/HPT Annex 53 Advanced Cooling/Refrigeration Technologies Development – Task 1 Report

Air conditioning (AC) and refrigeration systems account for a large share of today’s global energy consumption, and this demand is expected to increase sharply over the next 50 years unless actions are taken to ameliorate the increase. The adoption of AC in developed countries increased rapidly in the twentieth century, and the twenty-first century is expected to see increased adoption in developing countries—especially those with hotter climates and large, growing populations, such as India, China, Brazil, and Middle Eastern and African nations. The International Energy Agency (IEA) projects that by 2050, AC energy consumption levels will increase by 4.3 times over the 2010 levels for non-Organization of Economic Coordination and Development (OECD) countries vs. only 1.5 times for OECD countries (Figure 1).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Critical Material Supply Chain Analysis: Magnetocalorics

Understanding manufacturing cost and supply chain implications of technologies is critical to aid adoption of next-generation energy solutions, such as advanced heating ventilation and air conditioning (HVAC) equipment for building energy efficiency. This report provides insights into the market, regulatory, technology, and cost drivers most impacting the adoption of magnetocaloric refrigeration (MCR) systems in the U.S., with a focus on the rare earth materials requirements, manufacturing costs of key components, and detail on the supply chain of critical materials.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Continuous Monitoring and Partial Water Softening for Cooling Tower Water Treatment

Cooling towers are an integral component of many refrigeration systems, providing comfort or process cooling across a broad range of applications. They are the point in the system where heat is dissipated to the atmosphere through the evaporative cooling process. Cooling towers are commonly found in industrial applications and are also often used in water-cooled chilled water plants in medium to large commercial buildings. Continuous monitoring and partial water softening for cooling towers used in medium to large commercial buildings are the focus of this paper. Cooling towers consume large amounts of water. Cooling tower-related water consumption is one of largest potable water loads within buildings in the United States, with substantial building water use associated with heating and cooling. Regional water shortages have highlighted a need to reduce water consumption; the U.S. General Services Administration (GSA) and Executive Order 13834 place priority on reducing water consumption. This priority has fueled interest in the identification, investigation, and potential broad deployment of cost-effective opportunities to reduce water use, such as alternative water treatment (AWT) technologies for cooling towers. Traditional water treatment approaches use chemicals to extend the ability of the water to hold scaling minerals in suspension, minimize corrosion, and prevent biological growth. This treatment protects the chillers and cooling tower equipment; however, even when chemicals are used regularly, a certain percentage of condenser water must be drained and made up with fresh water to maintain system water quality parameters. In addition, the use of chemicals sometimes creates a waste disposal issue and can cause building owners to incur additional fees, such as disposal or wastewater charges. To manage cooling tower water treatment, GSA typically contracts with a company specializing in conventional chemical maintenance for a fixed fee. While there are many types and vendors of AWT systems, this project assesses the effectiveness of one technology provided by Aqualogix. This system is a chilled water plant monitoring and control system aimed at optimizing system performance by reducing the blowdown occurrences used to remove mineral build-up. The technology consists of two components – continuous programmable logic control (PLC) monitoring and side-stream filtration with partial water softening. PLC monitoring calculates cycles of concentration (CoC) and determines the optimum amount of blowdown water required to satisfy all water chemistry requirements. Side-stream filtration removes suspended matter and improves biocide efficacy while precisely dispensing softened water to achieve optimal makeup water hardness. Unlike other AWT systems evaluated by GSA to date, this system does not replace the legacy treatment system but is used in addition to chemical water treatment. The vendor claims their technology will reduce water consumption, water discharge, and maintenance costs. The AWT system evaluated in this demonstration is a commercialized technology. Given its commercialized state, the system evaluated in this report is at a Technology Readiness Level 9 according to National Aeronautics and Space Administration (NASA) definitions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

U.S. Industrial and Commercial Motor System Market Assessment Report Volume 1: Characteristics of the Installed Base

Motor systems are an integral part of our industrial and commercial facilities. They provide the motive force behind the fans, pumps, compressors, chillers, and conveyors in these facilities. Given their centrality to any facility’s operations, they are a critical energy end use to understand, particularly when developing technologies and policies to meet sustainability goals, improve productivity, and enhance resilience. In the late 1990s, the U.S. Department of Energy (DOE) conducted two seminal studies to better understand the installed stock and energy savings opportunities of industrial and commercial motor systems. In the industrial sector, The United States Industrial Electric Motor Systems Market Opportunities Assessment used primary data collected through onsite assessments and led to a greater understanding of the installed base of motor systems, their characteristics, and the opportunities for energy savings (U.S. Department of Energy, 2002). Notable findings included the following: Industrial motor systems consumed 679 billion kilowatt-hours (kWh) in 1994, representing 23 percent of U.S. electricity consumption. Cost-effective energy efficiency measures could result in 62-104 billion kWh of energy savings annually. Sixty-two percent of the energy savings potential was from fan, pump, and compressor end use equipment. Nearly half of motor system electricity consumption was attributable to approximately 3,500 facilities, or 1.5 percent of U.S. manufacturing facilities. Opportunities for Energy Savings in the Residential and Commercial Sectors with High Efficiency Electric Motors provided an evaluation of the installed stock of motor driven equipment in U.S. commercial and residential buildings and opportunities for utilization of high efficiency motors and variable speed technologies (Arthur D. Little, 1999). Notable findings included the following: Commercial motor systems consumed 343 billion kWh in 1995, with refrigeration and space conditioning constituting 93 percent of the total. Cost-effective energy efficiency measures could result in 51 billion kWh of energy savings annually. Due in no small part to these seminal studies, motor system technologies and usage characteristics have changed drastically since the late 1990s. Greater awareness of cost-effective strategies for reducing motor system electricity consumption have been developed and deployed. This includes several software tools, literature, and utility and government programs promoting energy efficiency improvements in motor driven systems. Additionally, several rounds of energy efficiency standards have been enacted, resulting in improved installed motor efficiency. The cost of variable speed drives has dropped substantially, and combined with utility rebate programs, has led to their greater adoption. Further, since these results were published, the U.S. manufacturing sector has undergone a massive transformation. Due to global competition, some sectors have relocated operations overseas. Others have brought operations onshore to avail low cost and abundant natural gas. Additionally, automation and robotics have pervaded the entire sector. Consequently, these two reports likely do not represent the current state of motor driven systems in U.S. industrial and commercial facilities. As cited in recent studies, the lack of current information on motor system electricity consumption and use characteristics limits the ability to conduct analysis on energy savings potential, develop technologies to address energy and productivity gaps, and develop programs to promote energy efficiency practices and technologies for motor systems (International Energy Agency, 2007; UNIDO, 2010; McKane and Hasanbeigi, 2011; Waide and Brunner, 2011). Specifically, the lack of information affects a range of stakeholders: Governments must rely on outdated information when setting research agendas, developing policies, and designing energy efficiency programs and offerings. Utilities and energy efficiency programs cannot identify the current market needs or potential impact when designing rebate and energy efficiency programs. Electric grid planners cannot identify motor system usage characteristics when developing plans to support the resilience of the electric grid. Manufacturers of motors, motor driven equipment, and drives are hampered when developing technologies to meet the needs of their market. Motor system end users are limited in their ability to identify energy saving opportunities within their own facilities because they do not have reliable benchmark information. In response to the lack of current information and analysis on industrial and commercial motor systems, the DOE initiated an update to these two studies. Launched in 2016 and led by Lawrence Berkeley National Laboratory (LBNL), the Motor System Market Assessment (MSMA) provides an updated, more comprehensive assessment of the installed stock of motor systems in both the industrial and commercial sectors, a review of the supply chains supporting motor and drives in the U.S., and the performance improvement opportunity available from using best available technologies and maintenance and operation practices. The outcomes of the MSMA are documented in three U.S. Industrial and Commercial Motor System Market Assessment reports, with this report being the first listed: 1. Volume 1: Characteristics of the Installed Base (this report) documents the findings on the installed base of motor systems in the U.S. industrial and commercial sectors. Quantification of energy savings potential is not documented in this report but in Volume 3. 2. Volume 2: Motors and Drives Supply Chain Review reviews the state of supply chains for motors and drives installed in U.S. industrial and commercial facilities, focusing on advanced motor and drive technologies and their constituent materials. 3. Volume 3: Energy Savings Opportunity analyzes the energy performance improvement opportunity for the installed base of U.S. industrial and commercial motor systems. This report has been prepared as a reference for motor system stakeholders. It provides factual information as could be best determined by the assessment results and avoids speculating on any findings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Open Building Control

Best practice control sequences are often not implemented correctly, or are not implemented at all, in large commercial buildings. This typically leads to 10-30 percent energy waste, along with reduced occupant productivity and unnecessary equipment wear. The current process of designing and implementing such control sequences is a manual process that starts with designers who often don’t have adequate training, then requires controls programmers to interpret and program a verbose written sequence. This process has been shown to fail to deliver high performance control sequences at scale. The Open Building Control project digitizes the current control delivery process. The project is developing tools for system designers to select control sequences, assess their energy performance and load flexibility potential using whole building simulation, specify the sequence for implementation using machine-to-machine translation by a control provider and formally testing the as-installed sequences by a commissioning agent. The project developed tools for each stage of this delivery process. The key innovation of the project is the development of the Control Description Language, a language that allows such a digitized control delivery process with end-to-end verification. Libraries of control sequences have been implemented using the Control Description Language, and their performance has been demonstrated using whole building energy simulation. An automated translation of such sequences to a commercial control product line has been conducted using a prototype translator. Tools for formal verification of as-installed control sequences relative to their specification have been developed and demonstrated. The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) started the process of forming a committee to make this language an ASHRAE/ANSI Standard. This new standard will complement existing and emerging ASHRAE standards for building communication and semantic modeling by providing a standard for expressing the control logic - the actual brain of the building. We expect this language and the process it enables to be an important contribution to the deployment of high performance building control sequences at scale because it allows taming the complexity of the control delivery process, which is continually increasing due to the need for higher performance and increased load flexibility to meet goals for net zero energy and increased renewable integration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Benefit FOA FY2015 - Solid State Magnetocaloric Air Conditioner (Final Report)

The active magnetic refrigeration (AMR) cycle holds great promise to reduce energy consumption of space cooling and heating. It is estimated that it could achieve up to 25% improvement in energy efficiency over conventional vapor compression systems. Prototypes have been built and demonstrated the working principles and energy benefits of the technology. These prototypes however were of low specific cooling power, defined as cooling power obtainable from unit mass of magnetocaloric materials (MCM). Specific cooling power is inversely proportional to the cost of the system. Therefore, for the magnetocaloric technology to be commercially viable, the specific cooling power must be increased. To increase the specific cooling power, for any MCM, the frequency of operation must increase. However, the maximum frequency that an AMR can operate at is limited by the residence time that is required to transfer heat in and out of the regenerator during the cold and got blows. This time length is dependent on the thermal conductivity of the heat transfer medium. The higher the thermal conductivity of the heat transfer medium, the faster heat can be transferred between the medium and the MCM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Advanced Energy Design Guide for K-12 School Buildings (AEDG) Training: Cooperative Research and Development Final Report, CRADA Number CRD-18-00761

U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Building Technologies Office (BTO), Commercial Buildings Integration (CBI) Program supports the adoption of zero energy ready buildings design practices through targeted Science, Technology, Engineering, and Mathematics (STEM) workforce development. The National Renewable Energy Laboratory (NREL) identified the opportunity to provided targeted training to those professionals that have the greatest potential to impact adoption and successful design outcomes of zero energy ready buildings projects. In January 2018, ASHRAE released Achieving Zero Energy: Advanced Energy Design Guide for K-12 School Buildings (AEDG). The AEDG was developed in collaboration with NREL, American Institute of Architects (AIA), American Society of Heating, Refrigeration and Air-conditioning Engineers (ASHRAE), U.S. Green Building Council (USGBC), and Illuminating Engineers Society (IES). The purpose of this CRADA was to create a partnership between NREL, AIA, ASHRAE, USGBC, and IES to create and host on-demand, web-based training based on the AEDG.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Development of an Advanced Hydrogen Energy Storage System using Aerogel in a Cryogenic Flux Capacitor (CFC)

The Cryogenic Flux Capacitor (CFC) is a cold, dense fluid storage core with integrated design features that afford the designer flexibility and provide new possibilities for the storage and discharge of energy. The stored energy, in this case, is represented by hydrogen physically bonded within the nanoscale pores within the aerogel composite blanket material, and the process of bonding or debonding is governed by principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m2/g) allows for storage densities close to, or in some cases exceeding, that of normal boiling point liquids. Its performance easily exceeds what can be achieved via ambient temperature, high-pressure gas storage for an equivalent volume. CFC storage is predicted to be easily scalable, is constructed from readily available commercial materials, lends itself to a range of pressure applications, and is geometry insensitive. They can also be used in modular designs, affording even more flexibility for potential deployment. In addition to the aerogel adsorbent within the blanket material, a CFC includes thermally-conductive membrane layered with the aerogel, which acts as a large-area, quick-response thermal management system. The system conducts heat throughout the volume to discharge the unit quickly. This same thermal management system can also be connected to a refrigeration system, or cold fluid such as liquid nitrogen (LN2), to facilitate the charging up of the CFC. The charging and discharging can be performed as fast or as slow as desired by controlling the cooling or heating supplied to the CFC.

08 HYDROGEN↗
DOE OSTI2021

Cost-Optimized Cold Climate Heat Pump Development and Field Test

Cold climate heat pumps (CCHPs) expand the heat pump market to climates where heating demand is dominant. They can achieve more than 70% energy savings compared with electric resistance heating and operate at lower cost than using tank-stored propane to fuel a furnace. A high-efficiency heat pump with a heating seasonal performance factor (HSPF)—as defined by the Air-Conditioning, Heating, and Refrigeration Institute (AHRI 2008)—greater than 10.0 would be more efficient than gas heating in terms of source energy. However, developing a cost-effective CCHP involves some challenges. A typical single-speed, air-source heat pump (ASHP) with an HSPF of 7.7 Btu/Wh does not work well under cold outdoor temperature conditions typical of cold climate locations for four major reasons: 1. Discharge temperature is too high—The low suction pressure and high compression pressure ratio at low ambient temperatures causes high compressor discharge temperatures in excess of the maximum limit for many of the compressors on the market. Furthermore, system charge of a heat pump is usually optimized in the cooling mode, which leads to overcharge conditions in the heating mode, further increasing the discharge temperature. 2. Heating capacity is insufficient if sized to meet the building design cooling load— Heating capacity of a single-speed heat pump decreases with ambient temperature. The heating capacity at -13°F (-25°C) typically decreases to 20%–40% of the rated heating capacity at 47°F (8.3°C) (~equivalent to the rated cooling capacity at 95°F [35°C]). Therefore, a single-speed heat pump, typically sized to match the building design cooling load, cannot provide adequate heating capacity to match the building heating load at low ambient temperatures. The capacity deficit is filled by inefficient resistance heat, thus lowering the system efficiency and significantly increasing power demand. 3. Cyclic loss is significant if sized to meet the building design heating load—If a single-speed heat pump is sized to meet the heating load, it will be significantly oversized relative to the cooling load in many cold climates. This will cause excessive on/off cyclic loss during the cooling and heating operations at moderately low ambient temperatures. Thus, capacity modulation capability (e.g., using a variable-speed or multi-stage compressor) is necessary for a CCHP, which uses its full capacity to meet the peak heating load and partial capacity to meet the cooling and part-load heating loads. 4. Coefficient of performance (COP) is low—Heating COP degrades significantly at low ambient temperatures owing to the large temperature difference between the heat source and sink. A target CCHP should be sized to meet the building design heating load while minimizing the cyclic loss for the cooling and heating operations at moderate ambient temperatures.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

LightMAT - Continuous fiber malleable thermoset composites with sub-1-minute dwell times; validation of impact performance and evaluation of the efficacy of the compression forming process (CRADA 409 Final Report)

In spite of carbon fiber composite materials’ significant impact on light-weighting, performance, and efficiency in the aerospace industry, adoption of these materials has been slow in high-volume industries such as automotive. Two major barriers to adoption are cost and cycle-time. Current approaches to thermoset composite part production are dependent on in-mold curing of thermosets which are not optimal for high volume, high throughput production due to limitations and inefficiencies associated with the in-mold cure itself. In addition, ancillary activities, such as transport and storage of shelf-life-limited uncured, or B-staged prepreg materials typically necessitate refrigerated transport and storage which significantly impacts the economic and energy costs associated with manufacturing. Furthermore, limited out-life means that trimmings cannot typically be used as they partially cure during initial production leading to high scrap rates (+20% is common). Finally, the need to cure in-mold drives cycle times to multiple minutes in the best cases, and 10’s of minutes to hours in most cases. Mallinda is developing polyimine malleable thermoset prepreg composite materials which have excellent mechanical properties (100 GPa tensile modulus, 2 GPA tensile strength, 2.4% elongation at break) and high operating temperatures (Tg>200°C). At scale, polyimine resins are commensurate in price with commodity epoxy resins. What distinguishes malleable thermoset prepreg from traditional thermoset prepreg materials, is that they are fully cured during Mallinda’s roll-to-roll production of prepreg laminate. This results in 5 key value-differentiating benefits. First, it simplifies manufacturing logistics by enabling ambient transportation and storage, and by significantly extending out-life and shelf-life almost indefinitely. Second, elimination of autoclave curing reduces the economic and energy costs to the customer. Third, scrap rates can be reduced as malleable thermoset prepreg materials are directly reusable. Fourth, the manufacturing consolidation step can be roughly 10x faster than traditional thermosets, because the resin is already cured. Parts can be made via compression forming by the application of heat and pressure to quickly vitrify and consolidate a multilayer part – easily leading to sub 3-minute cycle times (at lab scale we have demonstrated a 20 second dwell time, with room for further optimization). Finally, the closed-loop cradle-to-cradle solution-based recyclability of malleable thermoset composites can also contribute significantly to the future of sustainable lightweight materials. The focus of this project was the development, optimization and validation of malleable thermoset composite materials which exhibit manufacturing cycle times of 3-minute or less, high speed impact performance on par with incumbent technologies, and defect-free consolidation of 3 dimensional parts. Government funding is required on this project because Mallinda is a start-up company whose focus is the development and scale-up of the described technology for introduction to the transportation segment. Unlike incumbent industry players, Mallinda is bringing a completely new and highly relevant malleable thermoset technology to bear on the problem of high throughput composites. As a small business, Mallinda relies on a combination of government R&D funding and private capital to perform development work.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Model Evaluation Protocol for Fire Models Involving Fuels at Liquefied Natural Gas Facilities.

This document provides a description of the model evaluation protocol (MEP) for pool fires, jet fires, and fireballs involving liquefied natural gas (LNG), refrigerant fluids, and byproducts at LNG facilities. The purpose of the MEP is to provide procedures regarding the assessment of a model's suitability to predict heat flux from fires. Three components, namely, a scientific assessment, model verification, and model validation comprise the MEP. The evaluation of a model satisfying these three components is to be documented in the form of a model evaluation report (MER). Discussion of models for the prediction of fire, detailed information on each of the three MEP components, the MEP procedure regarding new versions of previously approved models, and the format of the model evaluation report (MER) are provided.

03 NATURAL GAS↗