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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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11 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

MaxTech HPWH Using Ultra-low GWP Refrigerant

Heat pump water heaters (HPWHs) are a proven technology for water heating that has been commercialized. The adoption of HPWHs for domestic and commercial water heating is growing rapidly because of superior performance compared with that of alternative water heating methods. Whereas most existing systems use R-134a as a working refrigerant, significant interest exists for deploying low global warming potential refrigerants to minimize environmental impacts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Performance Evaluation of Low-Cost Condensers Immersed in the Water Tank of a Heat Pump Water Heater

This paper reports the effect of low-cost immersed condensers on the performance of a heat pump water heater (HPWH) that does not require a water-circulating pump. The proposed design is based on the immersion of an L-style condenser coil through an opening in the top of the water tank. The novel design aims to eliminate the need for the water-circulating pumps, thereby substantially improving efficiency and reducing costs and maintenance of the HPWH system. Comprehensive computational fluid dynamics (CFD) simulations and experimental tests were performed, and the results showed that the CFD simulations were close to the experimental data. Further results confirm that the L-style condenser can introduce buoyancy-driven flow and eliminate temperature stratification in the studied HPWH water tank, thereby improving the heat transfer coefficient and coefficient of performance of the HPWH. The testing results further showed that the L-style condenser enabled more than 53% higher coefficient of performance and 400% higher heat transfer coefficient compared with the straight vertical condenser, and achieved much faster water heating. Furthermore, the effects of immersed condensers with different circuits on the HPWH performance were evaluated and compared. All results indicate that the current energy-saving and inexpensive HPWH technology is technically valid, and the benefits of performance improvement and low cost are attractive in future HPWH design.

Gao, Zhiming [ORNL] (ORCID:0000000271397995)↗
DOE OSTI2025

Enhancing heat pump water heater performance with embedded phase change materials thermal energy storage: First hour rating improvement and demand response operation

The increasing global emphasis on energy efficiency and sustainability has put heat pump water heaters (HPWHs) in the spotlight as an energy-efficient alternative to traditional water heating systems. However, their widespread adoption is limited by challenges such as insufficient First Hour Rating (FHR), suboptimal control mechanisms, and limited flexibility for demand response operations. Here, to address these limitations, this study proposes an innovative HPWH system integrated with embedded phase change material (PCM)-based thermal energy storage (TES). The research introduces a novel design and control strategy that leverages optimized PCM integration to enhance thermal storage capacity, improve hot water delivery during peak demand, and increase load-shifting potential. A combination of system modeling, performance simulation, and demand response control strategy evaluation was employed to quantify the benefits of PCM integration. Results demonstrate that the proposed PCM-TES HPWH system significantly enhances FHR, with an optimal 7.0 lb. of PCM increasing FHR by over 26 %—from 62 to 78 gal—for a standard 50-gal HPWH. Additionally, under advanced demand response operation using a preheat strategy, the system reduces the percentage of control temperature out-of-band time from 65 % (conventional HPWH) to just 11.6 %, enabling a more stable and efficient hot water supply. This research contributes a novel PCM-embedded HPWH design and control framework that addresses both performance and grid-interactivity challenges. The findings offer a viable pathway to enhancing the operational efficiency, flexibility, and grid responsiveness of residential water heating systems.

Demand response control↗
DOE OSTI2025

Charge Reduction and Performance Analysis of a Heat Pump Water Heater Using R290 as a Refrigerant—A Field Study

Heat pump water heaters (HPWHs) are a proven technology for water heating that has been commercialized. The adoption of HPWHs for domestic and commercial water heating is growing rapidly because of their superior performance compared with alternative water heating methods. Whereas most existing systems use R-134a as a working refrigerant, R290 has gained major attention owing to its superior thermodynamic properties. The goal of the current study is to assess the performance of residential HPWH with R290 as a direct refrigerant replacement for R134a. Two units of a 50 gal HPWH were used in this experimental study. A baseline unit contained R134a refrigerant, and a prototype unit contained R290 refrigerant. The prototype unit was developed through the modification of a commercially available HPWH unit to achieve a low charge of R290 refrigerant. Another major modification was the replacement of the baseline compressor with a compressor designed for R290. Tests were conducted in a field environment (a research and demonstration house) using programmed drawn profiles daily. The prototype that reduced the charge by 43–47% provided displayed performance comparable to the baseline unit regarding first-hour rating (FHR) and the uniform energy factor (UEF).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Design Considerations for Phase Change Material-Incorporated Heat Exchangers in Water Heating

In recent years, the buildings sector has seen major pushes towards decarbonization through innovations that promote deep electrification. 20% of an average household's energy use comes from water heating, and in the US, over half of all households still use gas water heaters. Of those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. However, HPWHs tend to have larger dimensions, preventing current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). This study outlines the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. To ensure optimal PCM utilization and tank storage capacity, this works seeks to co-maximize surface area and PCM volume; therefore, this research targets triply periodic minimal surface (TPMS) lattices, which boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives. Our current results indicate that tuning lattice properties can effectively produce geometries that provide enough energy storage to achieve a 50-gallon capacity out of a 40-gallon HPWH, even when placing the PCM heat exchanger inside the tank. Additionally, we demonstrate successful fabrication of lattices with these tuned properties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Making Small-Volume Heat Pump Water Heaters Larger: A Design Framework for Integrated Phase Change Material Heat Exchangers

Those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. One major barrier to wider HPWH adoption is the added equipment required, which prevents current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). PCMs have been studied extensively in building envelope and HVAC systems, but remain a nascent technology in residential water heating. While water itself has a uniquely high energy storage capacity, PCMs have an even higher energy storage density, thus providing the potential to elevate the performance of 40-gallon HPWHs to that of 50-gallon or larger tanks. This research is part of a larger project that seeks to utilize thermal energy storage to enable decarbonized water heating in low-income communities. In this study, we outline the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. In order to ensure optimal PCM utilization and tank storage capacity, we focus here on co-maximizing surface area and PCM volume in the heat exchangers; therefore, this research targets triply periodic minimal surface (TPMS) lattices. TPMS lattices boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries and offer highly tailorable designs; thus, they pair well with the growing field of additive manufacturing, or 3D printing. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives.

25 ENERGY STORAGE↗
DOE OSTI2025

Low-Power, Load-Balancing Whole Home Electrification Solution: Cooperative Research and Development (Final Report)

Testing was conducted at the Systems Performance Laboratory in NREL’s Energy Systems Integration Facility to test the performance of 120V wall-mounted heat pumps, 120V heat pump water heaters (HPWH), Electric Vehicle Supply Equipment (EVSE), and other plug-in loads, using NeoCharge Smart Splitters and whole home energy software as appropriate. Four different simulated occupancy scenarios were used to evaluate the package of technology and controls.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Thermoelectric heat pump water heater priced for mass market deployment with 30% energy savings

This project, a Cooperative Research and Development Agreement (CRADA) partnership between A. O. Smith and Oak Ridge National Laboratory (ORNL), was initiated to develop a heat pump water heater (HPWH) based on thermoelectric (TE) heat pump technology capable of seeing widespread market adoption by having a one-year payback versus electric resistance options.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Next Generation Refrigerants for Domestic Heat Pump Water Heaters

To select next generation refrigerants and phase out R-134a, we conducted extensive drop-in tests of multiple new refrigerants. For laboratory investigations, we performed drop-in UEF (uniform energy factor) and FHR (first hour rating) tests on two heat pump water heaters (HPWHs), one uses a 220V compressor and 40-gallon water tank, and the other uses a 120V compressor and 50-gallon tank. The alternative refrigerants/blends include R-1234yf, R-1234ze, R-515B, R-513A, and R-516A, among which R-513A is A1, non-flammable and the others are in A2L category. All the alternative refrigerants required similar optimum system charges as the baseline R-134a. They resulted in similar or better UEFs than R-134a. R-516A led to best UEFs in both the HPWHs. The resultant discharge temperatures of the new refrigerants/blends are lower than R-134a, indicating good lubricant compatibility. The 120V HPWH delivered > 60 gallons first-hour rating using R-134a. The alternatives led to reduced FHRs due to their smaller volumetric vaporization capacities using the same compressor. Except R-515B, the other refrigerants/blends delivered FHRs > 60 gallons. R-516A produced better UEFs and FHRs in both the units than the other replacements. If considering flammability, R-513A would be the best option, which has similar UEF and FHR as R-134a.

Shen, Bo [ORNL] (ORCID:0000000336600393)↗
DOE OSTI2025

Demand Response in Residential Energy Code: Technical Brief

As buildings account for over 75% of U.S. electricity use, effectively managing their loads can greatly facilitate the transition towards a clean, reliable grid. Grid-interactive efficient buildings (GEBs) combine efficiency and demand flexibility with smart technologies and communication to provide occupant comfort and productivity while serving the grid as a distributed energy resource (DER). In turn, GEBs can play a key role in ensuring access to an affordable, reliable, sustainable, and modern U.S. electric power system. Their national adoption could provide $\$$100-200 billion in U.S. electric power system cost savings over the next two decades. The associated reduction in CO 2 emissions is estimated at 6% per year by 2030 (DOE 2021). Building codes represent standard design practice in the construction industry and continually evolve to include advanced technologies and innovative practices. Historically, national model energy codes establish minimum efficiency requirements for new construction (ICC 2020). Expanding codes to support GEB capabilities is a pivotal step towards realizing demand flexibility in support of a clean grid by addressing capabilities to improve interoperability between smart building systems, the grid, and renewable energy resources. Realizing GEBs requires buildings with automated demand response (DR) capabilities that enable standardized communication with or control of, subject to explicit consumer consent, energy smart appliances or home energy management systems. This is achieved through direct or indirect (i.e., via an aggregator) communication between appliances and the electric grid. Energy codes can also support DR communication standardization and advance the deployment of building-integrated DERs such as energy storage, generation, and electric vehicles (EVs). Incorporating automated DR capabilities in energy codes provides many benefits to the consumers. Specifically, it aligns building electric load demand with intermittent renewable energy source availability, decreases peak load on the electric grid, allows buildings to respond to utility price signals, supports electrical network reliability and market growth of products and processes aligned with clean economic growth. The incorporation of DR into the model residential energy codes was considered for both the 2021 and 2024 International Energy Conservation Code (IECC) code development cycles. The approved DR measures in the 2021 cycle were removed in response to appeals (ICC 2020). Updated language was presented for consideration again for the 2024 IECC, where it was negotiated and again approved, and again removed in response to appeals (ICC 2024). This resulted in many sections, including sections on demand responsive controls, being moved to the credits options or an appendix as a voluntary application. This technical brief updates the proposed DR components such that they can be considered by states and local governments for direct incorporation into their codes, as well as for future IECC energy code development. The proposal refinements are intended to support consistency in approach and provide a degree of certainty for building owners, designers, contractors, manufacturers, and building and fire safety professionals. The scope of this technical brief includes three strategies for DR in residential buildings: 1) smart thermostats with demand-responsive control, 2) electric water heating incorporating demand-responsive controls and communication and 3) grid Integrated solar and energy storage systems.

2021 IECC↗