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At least 19 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 OSTI2024

Grid-connected heat pump water heater benefits for low-income households in the Southeastern United States

Energy efficient heat pump water heaters (HPWHs) reduce customer energy costs; grid-connected controls further increase HPWH value by enabling energy storage and shifting demand to cheaper, off-peak periods. However, a HPWH’s first cost premium can put it out of reach for low-income customers. This paper will present results of an ongoing study exploring the benefits of load shifting HPWHs for 24 low-income households, aiming to support increased product deployment in this demographic. The study uses EcoPort modules to shift HPWH load for a study sample consisting primarily of low-income adults and seniors in North Carolina. Building upon prior studies, the study’s HPWH operating schedules are designed to maximize shifted energy and minimize participant electricity costs based on local time-of-use rates. The study documents load profiles of grid-connected HPWHs in a less-studied demographic group and explores how certain groups may have particularly flexible loads due to their unique usage profiles. The results are relevant for HPWH product performance in the Southeast. The study will quantify HPWH load shifting performance during North Carolina’s hot summer, temperate shoulder, and occasionally sub-freezing winter seasons, and the study includes installations in conditioned, semi-conditioned, and unconditioned spaces. Finally, study results will also explore how controlled HPWHs can provide value to the regional grid by reducing seasonal peaks via demand response. Lessons learned include HPWH acceptance for low-income and senior users, best practices for maintaining HPWH connectivity among users without prior product experience, and strategies to leverage remote monitoring to ensure optimal operation and enhance HPWH reliability.

Urigwe, Daniela↗
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 OSTI2024

Field Study of 120-volt Heat Pump Water Heaters in the Big Easy

To meet long-term goals for reducing carbon emissions and lessen the impacts of climate change, the U.S. plans to decarbonize its building stock, which includes the replacement of fossil fuel-burning end uses with energy efficient electric alternatives. As part of this strategy, the replacement of fossil fuel water heaters with heat pump water heaters (HPWH) has the potential to avoid substantial carbon emissions. An estimated 10-15 million single-family homes with fossil fuel water heaters do not have the electrical panel capacity to install a 240-volt, 30-amp HPWH. For these homes, a technology recently introduced to the market, the 120-volt plug-in HPWH, can provide energy efficient electrification of water heating without an expensive panel and wiring retrofit. This paper presents the results of an ongoing 120-volt HPWH field study conducted in 17 homes in New Orleans, LA. Key installation scenarios are profiled for retrofitting from gas-fired water heaters to 120-volt HPWHs, accounting for space, air volume, air temperature, condensate drainage, and electrical. Each HPWH had its surrounding air temperature, relative humidity, inlet and outlet water temperature, flow, and energy consumption monitored. Using these data, hot water delivery and energy efficiency performance were analyzed based on home characteristics. Hot water run outs were investigated to understand how hot water usage, inlet water temperature, and surrounding air temperature impact the HPWH’s ability to meet load. From these results, best practices for 120-volt HPWH siting, sizing, and installation were developed. In addition, results are explored further to add insight for electrification policies and product development.

heat pump water heater, 120-volt, Residential buil↗
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 OSTI2024

“Max-tech FHR”: What is the maximum technically achievable water delivery capacity from a single 120 V plug?

Electrifying water heating will require affordable, direct drop-in replacements for existing gas water heaters that meet consumer expectations for hot water delivery. For many replacement scenarios, affordability requires a replacement option with like-for-like physical product dimensions, and existing consumer expectations presume a large delivery capacity from a small water heater. This work explores the technical potential for hot water delivery capacity for a heat pump water heater (HPWH) powered from a common 120 V plug. Delivery capability in this work is quantified by two metrics: the First Hour Rating (FHR) defined in the Code of Federal Regulations, and a real-world draw profile that resulted in hot water runout during field studies of 120 V HPWHs. The work focuses on the common “tall-and-slim” gas water heater product category, with external product dimensions of 20 inch diameter and 60 inch height. Using a simulation model in DOE/ORNL Heat Pump Design Model, validated by experimental baseline testing of a commercially available 120 V HPWH model, several measures were evaluated to maximize the delivery capacity of a 120 V HPWH. The 120 V HPWH was constrained by 1) external product dimensions of 20 in diameter and 60 inch height, 2) electrical power of 1.5 kW (85% of the available power from a dedicated 120 V, 15 A circuit), and 3) commercially-available components. The measures implemented included a large compressor, a pumped loop with plate heat exchanger to maximize tank stratification, enlarged heat exchangers, and relatively thin insulation to maximize the water storage volume.

Gluesenkamp, Kyle↗
DOE OSTI2024

Factors Influencing Grid-connected Heat Pump Water Heater Performance in the Southeast U.S.

Grid-connected heat pump water heaters (HPWH) can shift electrical load while minimizing impacts to hot water availability for occupants. This capability provides a flexible grid resource to utilities seeking to manage peak loads Such load control also can feasibly improve renewable utilization within the utility electric production mix, for instance using off-peak generation during periods with high renewable energy generation. It also offers lower electric bills to customers through increased energy efficiency of HPWH and cuts greenhouse gas emissions. In particular, the Southeast U.S. due to its high penetration of electric water heating presents a promising opportunity for grid-connected HPWHs. This paper builds upon the results of an extensive HPWH load shifting field study conducted in 51 occupied homes in Florida using EcoPort technology (Butzbaugh et al, 2022). In 2022, only an initial evaluation was available. Here, long term load results are available as well as examination of various control strategies and influences. Analysis is conducted for HPWH energy use and load shifting performance based on home occupancy (i.e., low and high) and water heater location (i.e., conditioned and unconditioned) across different temperature profiles. An unexpected outcome of this analysis was the poor performance of HPWHs located in conditioned spaces, possibly because of inadequate air volume from improper installation. We did find higher demand reductions from 2-hour load ups and slightly improved for critical peak signals in the afternoon control periods. As expected, higher occupancy households showed great load reductions.

Fenaughty, Karen↗
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 OSTI2024

Late-Stage Research Development and Demonstration Sub-activities Updates – FY24 Q3

Oak Ridge National Laboratory (ORNL), in collaboration with the Pacific Northwest National Laboratory (PNNL), the National Renewable Energy Laboratory (NREL), the Lawrence Berkeley National Laboratory (LBNL), and the Hummingbird Firm (a specialized consulting firm focused on promoting diversity, equity, and inclusion considerations), has initiated a national initiative known as the Heat Pump (HP) and Heat Pump Water Heater (HPWH) Field Validation Partnership. This effort involves active participation from numerous critical entities involved in research and market transformation within the field. The ORNL team is responsible for leading Late-Stage Research Development and Demonstration (LSRDD) among the four different topics. The overall outcomes of this project will be: (1) A structured Field Validation Partnership between DOE, the national labs, research, implementation, and market transformation organizations. This will result in unique way to coordinate field validation plans and collect relevant data from around the country into the HP and HPWH Field Validation Database. (2) The Field Validation Partnership will result in a continuous stream of information between DOE and the major industry players in the space of HPs and HPWHs. If desired, DOE could use this information to inform roadmaps related to HP and HPWH market adoption and research going forward. (3) The structure of this Partnership provides a mechanism for sharing lessons learned directly between Late-Stage RD&D, Building Integration Barriers, Regional Market and Policy and Workforce Development efforts. The result will be training content that is well-reviewed by the Partnership which will lead to a workforce that meets the industry’s quality and workforce supply demands. (4) The structure of this Partnership also provides an opportunity for regions to share lessons learned on policy and market transformation with each other through the Market and Policy core Committee. This report includes an update in Late-Stage Research Development and Demonstration.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

Electrification Options for Multi-Family Water Heating in Cold Climates - Final Report

In multi-family buildings, large water storage tanks in centralized domestic hot water (DHW) systems can serve as thermal energy storage (TES) batteries to mitigate grid impact. These systems offer demand shift and efficiency benefits, significantly reducing peak power consumption, particularly in cold climates. This study evaluates the load-shifting benefits of a centralized heat pump water heater (HPWH) system equipped with a CO2 heat pump in multi-family buildings through simulation. The heat pump system and water storage tank are sized using design-day sizing. A finite-element-based stratified tank model and CO2 heat pump performance map from a commercial DHW product are used. Annual simulations are conducted to assess the benefits of the centralized DHW system for energy efficiency improvements, load shifting, and emission reductions. These simulations incorporate utility tariffs and marginal grid emission data from Los Angeles and Chicago. In Los Angeles, using a water tank as a thermal battery achieves 7.4% utility cost savings and 10.2% emission reduction. In Chicago, compared to HPWH conventional operation without preheating, TES-enabled central HPWH provides 15% utility cost savings and 13% emission reduction. The case study demonstrates that the demand reduction potential of central CO2 HPWHs is significant in cold climate regions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

A Simulation Study of 120V Heat Pump Water Heaters

A 120 V heat pump water heater (HPWH) is a direct plug-in option to replace gas water heater (WH) without needing expensive electric panel upgrade to 220 V. To enable the smooth transition, the HPWH should provide comparable water heating capacity as the gas WH. WH capacities are rated in the form of first hour rating (FHR). Typical home gas WHs have FHRs > 65 gallon with a 40-gallon water tank. It imposes a major challenge on 120V HPWHs. Most 120V circuits in US can provide 1,800 to 2,400W, not adequate to drive electric resistance heat to boost FHRs. Thus, all the heat needs to come from the heat pump with its top power below 1500 Watts, which is constraint by the installation footprint. This study uses a hardware based, HPWH design model, i.e. the DOE/ORNL Heat Pump Design Model to design a 120V unit with a brazed plate condenser, fin-and-tube evaporator and an adequately sized compressor. To maximize the FHR, multiple strategies were simulated, including use of a mixing valve, overheating the tank temperature to 140F, a new sensing method for quicker response, and an innovative water circulation path. We also simulated 24-hour unform energy factors (UEF) to show the tradeoff between the capacity and operation efficiency. Additionally, we evaluated the impact of insulation thickness on FHR and UEF, to seek further footprint reduction or stretch the tank volume.

Shen, Bo↗
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 OSTI2024

Realizing the Residential Electrification Opportunity: One Heat Pump at a Time

Space and water heating in residential buildings is a major contributor of greenhouse gas (GHG) emissions in the United States. Advanced electric heat pumps (HP) and heat pump water heaters (HPWH) are poised to provide a low carbon alternative to traditional fossil-based space and water heating. Widespread deployment of heat pumps could help address the significant portion of building emissions and primary energy used in American households, however much work needs to be done to close the knowledge gap between like-for-like fossil equipment replacement and switching to HPs for the average contractor. The Pacific Northwest National Laboratory (PNNL) has been working on closing this knowledge gap through the development of decision tools and resources targeted towards contractors and installers. Developed in coordination with stakeholders and experienced contractors from a variety of geographic regions, these tools help streamline the process of sizing and selecting residential HPs and HPWHs for key use cases. Along with the complementary Retrofit Decision Tool developed by PNNL, the decision tools will help contractors understand the importance of whole building considerations when choosing HPs including envelope upgrades, duct assessments, and electrical assessments to ensure optimal selection and performance of the HP or HPWH. They also provide direct links to resources and best practices developed by PNNL as well as external entities to further help contractor education and training. This paper describes the development of these tools, and their role in moving the existing space and water heating market towards HPs to help realize the country’s decarbonization goals.

heat pump, heat pump water heater, Residential bui↗
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)↗