High-Efficiency Natural Gas Emerging Technologies”€ Report @ ... Active Major RTU Manufacturers...
Transcript of High-Efficiency Natural Gas Emerging Technologies”€ Report @ ... Active Major RTU Manufacturers...
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High-Efficiency Natural Gas Emerging Technologies
Patricia Rowley
Senior Engineer
Gas Technology Institute
CenterPoint Energy
Energy Efficiency and Technology Conference
May 25, 2016
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> Not-for-profit (501c3) RD&D
organization with 70 year history
> Facilities
─ 18 acre campus near Chicago
─ 200,000 ft2,
28 specialized labs
─ Other sites in
California, D.C., Texas,
Alabama,Massachusetts
> Staff
─ Approximately 250
─ 170 engineers, scientists covering all
fields
Flex-Fuel
Test
Facility
GTI Overview
CHP and Renewable Energy Lab
Residential & Commercial Lab
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Residential/Commercial R&D
> GTI has a robust residential and commercial program focused on:
─ New appliance technology for hot water
and space conditioning
─ Commercial food service technology
─ Distributed generation/CHP
─ Building systems integration and
community planning
─ Solar thermal/natural gas hybrid systems
─ Carbon management solutions
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New Residential and Commercial Technologies and Products
Smart Energy Grid
Real-time
Energy Monitor
NGV Filling Station
Radiant TubingMicroCHP
Tankless/Solar
Hybrid Water Heater
Gas Heat Pump
Solar Thermal Panel
Venting Innovations
Plug n Play
Utility RoomInterior Piping
Smart Energy Grid
NGV Filling Station
Radiant Heating
Waste Heat Chiller/Heater
Solar Hybrid
Water Heating
CHP SystemsSolar Thermal Panel
High Efficiency Boilers
Commercial Food ServiceHumidity Control
Smart Energy Grid
Real-time
Energy Monitor
NGV Filling Station
Radiant TubingMicroCHP
Tankless/Solar
Hybrid Water Heater
Gas Heat Pump
Solar Thermal Panel
Venting Innovations
Plug n Play
Utility RoomInterior Piping
Various activities to address:
• Energy efficiency
• Renewables
• Smart Grid functionality
• New & expanded natural gas uses
cooling, onsite power, vehicles
Residential
Commercial
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Minimum Efficiency Standards for Natural Gas Furnaces
>Commercial furnaces: 80% Et
>Residential furnaces: ─ 78% AFUE (effective 1992)
─ 80% AFUE (effective 2015)
78-80%
Non-condensing furnaces
90-98%
Condensing furnaces
>100%
Gas Heat Pumps
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Minimum Efficiency Standards for Natural Gas Furnaces
>Commercial furnaces: 80% Et
>Residential furnaces: ─ 78% AFUE (effective 1992)
─ 80% AFUE (effective 2015)
─ 92% AFUE (proposed)
78-80%
Non-condensing furnaces
90-98%
Condensing furnaces
>100%
Gas Heat Pumps
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Condensing Furnaces for the Commercial Market
> Condensing furnaces are well established in
residential markets; only recently introduced in
commercial products
> RTUs are “last frontier” in adopting high efficiency
condensing technology
─ Significant market; used in nearly half U.S. commercial
floor space
─ Typically selected for low first costs instead of efficiency
> Condensing RTUs offer thermal efficiencies between
90% and 93%
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primary tubular heat exchanger
secondary (condensing) finned tube heat exchanger
Condensing Heating Module
> RTUs fundamentally scale up
residential condensing furnace
heat exchangers, but…
─ RTU supply fans may run
continuously so incremental
pressure drop can create
year-round fan energy penalty
─ Condensate management must
meet local codes and address
freezing rooftop environments
Source: Modine
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Condensate Code Review
> Regional codes vary regarding disposal and neutralization:
─ Location per mechanical codes (ICC IMC/IAPMO UMC)
> IMC/UMC: “discharged to an approved plumbing fixture or disposal area”
> IMC: “in accordance with the manufacturer’s installation instructions”
> approval is always subject to the local authority having jurisdiction
> interpreted as sanitary sewer, not storm sewer or ground discharge
─ Neutralization per plumbing codes (ICC IPC, not in IAPMO UPC)
> Per IPC, “acids … that … injure … sewer pipe, or interfere with sewage
treatment processes shall not be discharged into the plumbing system
without … passing through an approved dilution or neutralizing device …”
> Combustion condensate is acidic with pH ~3.5
> Some states/municipalities limiting acidity (discharge pH > 6)
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Icing at Flues is Typical in Operation
Residential Condensing
Furnace Flue in MNBig Box Retail Store Condensing
DOAS Flues in MN
Source: GTI
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Condensing Furnaces for the Commercial Market
> Increase heating efficiency to 90-93% Et
> Gas savings up to 16%
> Increase in fan energy due to added pressure drop
─ Can be reduced with staged or variable speed blowers
> Condensing RTUs need high heating loads and
long runtimes to generate energy savings needed
to offset higher equipment costs
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Past RTU Findings
> Very diverse heating runtimes for RTUs on a given
building, but patterns emerge
─ Perimeter zone RTUs see longer runtimes; interior core zone
RTUs see shorter runtimes
─ In general, excess core RTU
capacity increases w/area of
building
─ Entry, stock, & drive-thru RTUs
see high use pattern repeated
across “identical” stores;
opportunity for selective upgrades
Source: GTI
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Condensing RTU Early Market Entry Points
> Dedicated Outside Air Systems (DOAS)
or other high ventilation RTUs
─ Condition 100% OA for building ventilation
─ Highest heating and gas loads
─ Most promising early market entry point
> GTI pilot testing supports targeting DOAS;
however other technologies competing for OA roles
─ Direct fired vs. indirect fired condensing heating
─ Demand control ventilation (DCV)
─ Energy recovery ventilation (ERV)
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Condensing RTU Early Market Entry Points
>DOAS (ventilation air)─ retail stores
(“big box”)
─ schools
─ theaters
─ sports arenas
─ healthcare facilities
─ day care centers
>MUAS (make-up air)─ hotels, multifamily,
senior living facilities (corridors)
─ restaurants, commercial kitchens
─ gymnasiums, pools, health clubs
─ vehicle repair shops
─ laboratories
─ industrial facilities
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Condensing RTUs: Completed Work
> Nicor Gas ETP Pilot @ IL Walmart
─ Monitoring ended 5/31/2013
─ Therm savings: AHU1=1,983; AHU2=2,395
─ Report @ www.nicorgasrebates.com/resources/Emerging-technology
> NA ETP Pilot @ MN Target Store
─ 90%TE DOAS monitoring ended 8/15/2014
─ Annualized therm savings: 2197
Increased fan energy: 1542 kWh
─ Net annual cost savings: $1291
─ Funding from: CPE, DTE, & Union Gas
> Work Papers Facilitating EE Rebate Measures
─ Nicor Gas 100% OA Condensing RTU work paper submitted to IL-SAG in Oct
2015; adopted as new measure in IL-TRM v5.0 (2016), effective June 1, 2016
─ Prototype condensing work paper developed and applied with CenterPoint
Energy in MN, which can be replicated with other utilities/states/TRMs
Source: GTI
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Payback Economics
MN Target Big Box DOAS:
> Initial payback projections were 5.3 to 6.5 years
> Payback projections now 3.8 to 4.7 years, continuing to
trend downward
─ Competitive pricing of condensing heating modules (duct
furnaces)
─ Increased efficiency levels: 93%TE technology now available
at prices below original 90%TE technology.
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Condensing RTUs: Active/Pending Projects
> MN CARD Project Status (Active)─ Field testing of condensing makeup air units (MAU)
with 100%OA and condensing-RTU (0-30%OA)
w/CenterPoint Energy
─ Site 1: Kitchen make-up air unit with 100%OA
─ Site 2: 30% OA conventional RTU replacement
─ Baseline start Oct 2015; replacement Sept 2016
> NEEA Project Status (Active)
─ Four sites in Pacific NW, tests end June 2016; may be extended through next winter
1. assisted living center corridor MAU operating at 100% OA and 30% OA;
2. retail showroom and warehouse RTU operating at 100% OA and 30% OA;
3. restaurant kitchen MAU operating at 100% OA
4. restaurant kitchen MAU operating at 100% OA
> NYSERDA (Pending)─ Proposal awarded July 2015; still awaiting contract negotiations
─ Planned monitoring of 10 Munters condensing DOAS at 5 Walmart stores
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Condensing RTU Market
> Second-tier HVAC companies were first to introduce
condensing product lines
─ Engineered Air, Modine, Reznor, Munters
─ Only Reznor expanding condensing RTU product lines to full
spectrum (100 to 0%OA) including lower cost, “conventional”
condensing RTU
─ Trane & York tentatively entered market in 2015
─ 93% TE offerings now available from Trane, Modine, Reznor,
Munters (up from 90%)
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Active RTU Manufacturers
Source: GTI (information subject to change, check hot links for latest specifications)
Manufacturer Heating Module Specifications w/Hot Link (subject to change)
Trane (Creative
Solutions)
93% TE, 400 MBH input retrofitted to select 12.5 - 25 ton Voyager Light Commercial RTUs (furnace supplied by
others – Beckett and Heatco) Contact Trane directly for further details on this limited product offering
York
90% TE, 150 to 600 MBH input, 10:1 turndown, up to 9350 CFM
http://www.johnsoncontrols.com/content/us/en/products/building_efficiency/products-and-
systems/integrated_hvac_systems/Industrial___Commercial_HVAC_Equipment/dedicated-outside-air-
systems.html (100% OA – DOAS product line supplied by others)
Engineered Air90% TE, 100 – 1,400 MBH input, 15:1 turndown, 1,000 to 44,000 CFM
www.engineeredair.com/index.php/our_products/category/indirect-fired#djx-series (DJX Series products)
Modine93%TE, up to 500 MBH input, 7:1 turndown, up to 12,000 CFM
www.modinehvac.com/web/Commercial-HVAC/Commercial-Ventilation-1.htm (Atherion products)
Reznor (now part of
Nortek Global HVAC)
93% TE, up to 600 MBH package (400MBH split), up to 10:1 turndown, from 500 to 11,500 cfm package (6000
cfm split).
www.rezspec.com/en/me/all-products (YDMA, YDHA, & YDSA products)
AND
95% AFUE, 39 to 96 MBH input, 2 stage, up to 1,895 cfm.
http://www.reznorhvac.com/en/na/products/product-high-efficiency-packaged-air-conditioning-r8he (R8HE
products)
Munters
93%TE, up to 800 MBH input, 10:1 turndown, up to 16,000 CFM
https://www.munters.com/en/munters/products/combined-temperature--humidity-control/drycool-standard/
(DryCool product literature does not currently show condensing option, furnace supplied by others – Beckett)
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Active Major RTU Manufacturers
> Trane (circa later summer 2014)
─ Creative Solutions “job shop” will retrofit Trane Voyager RTUs with
condensing furnaces from others, such as Heatco and Beckett
> York (circa early spring 2015)
─ Following lead of non-major RTU mfr, York introduced DOAS with
up to 92% TE condensing upgrade from standard 80% TE non-
condensing furnace
http://www.johnsoncontrols.com/content/us/en/products/building_efficiency/products-and-systems/integrated_hvac_systems/Industrial___Commercial_HVAC_Equipment/dedicated-outside-air-systems.html
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…Expanding Condensing RTU Offerings
> Reznor providing condensing heating RTU product lines
for the full (100 to 0) %OA spectrum
─ YDMA (~100 to 60% nominally)
─ YDHA (~60 to 30% nominally)
─ YDSA (~30 to 0% nominally)
Source: Reznor
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…Introducing Lower First Cost “Conventional” Condensing RTU
> Stocked item w/significantly lower
cost point, approaching major
RTU manufacturer pricing on
$/ton, $/MBH, and $/cfm basis
─ Up to 1,895 cfm (up to 35% OA),
2 to 5 ton, 39 to 96 MBH, 95% AFUE
─ Slab or roof curb mount with
horizontal or downflow discharge
─ Aluminized steel primary and
stainless steel secondary HXs
> Part of NEEA & MN CARD demos
Source: Reznor
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Condensing RTU Summary
> High heating loads and high RTU runtimes are key to
generating net cost savings for favorable payback
> Early market development focus on facilities with high
OA needs (100% OA or high OA fraction)
─ Retail, schools, hotels, restaurants/commercial kitchen,
health clubs
> Market development will have challenging economics
in progression from 100 to 30% OA
─ Current high equipment cost premiums
─ Low natural gas prices in US/Canada
─ Below 30%OA products will need to be competitive with
low-cost, mass-produced, non-condensing RTUs
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What the Future Holds…
> Mainstream condensing RTU transition hinges on
─ Progressing incremental pressure drop below 0.15”WG
─ Broadening use of staged blowers
─ Achieving consensus on building heating loads
> In addition to EE evaluation, ongoing field testing and
market studies to include:
─ Target first costs for cost effective, mainstream (0-30% OA)
market economics
─ Installation contractor training, best practices, educational
materials
─ Combustion condensate codes & standards
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Condensing Heating Expanding into More Markets
> Plans date back to 5 years ago with higher gas
prices
> Despite lower gas prices, steady increase in heating
product categories with >90% AFUE/TE offerings
> In addition to RTUs, other commercial and multi-
family heating products are also going condensing
heating
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Latest Condensing Product Offerings
> Commercial furnaces
─ Stand-alone duct furnaces
─ Furnace for RTUs
> Unit heaters
─ Manufacturing, warehousing,
automotive, retail buildings
> Through-the-wall furnace/AC
─ Multifamily (condos),
Senior living facilities
> Wall furnaces/hearths
─ Multifamily (rentals),
Home additions
Source: Heatco
Source: Modine
Source: Empire
Source: Suburban
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Through-The-Wall (Vertical) Condensing Furnace/AC Package Offerings
> Over last 18 months,
4 of 5 top manufacturers
introduced condensing!1. Allied (Lennox)
2. National
3. Suburban
4. Aerosys
5. NapoleonCompany “Thru-the-Wall” HVAC Product Line Condensing OfferingAllied Air Enterprises (owned by Lennox)
Magic-Pakwww.magic-pak.com/
up to 95% TE with V-Series HWC Single Packaged Vertical Unit www.magic-pak.com/products/v-series/hwc.asp
National Comfort Products Comfort Packwww.nationalcomfortproducts.com/
none
Suburban Manufacturing DynaPackhttp://www.suburbanmanufacturing.com/
up to 92% AFUE with H-Serieswww.suburbanmanufacturing.com/lit/DYP4pg-8-5-2014_72ppi.pdf
AeroSys Inc. AeroPakhttp://www.aerosysinc.com
up to 95% AFUE with G-Serieswww.aerosysinc.com/pdf/AeroPak-AP-Series.pdf
Napoleon Heating & Cooling CondoPakhttp://www.aerosysinc.com
up to 93% AFUE with PSC-Serieswww.napoleonheatingandcooling.com/products/condo-pack/
Source: Allied
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More Detailed Specifications
Product Line Heating Efficiency Heating Input (kBtu/hr) Cooling Efficiency Cooling Input (ton)
Magic-Pak - HWC Series 93-95% TE 22, 33, 44, or 55 9.2-11 EER 1, 1.5, 2, or 2.5
DynaPack - H Series 91-92% AFUE 39 or 52 10.2-10.7 SEER 1, 1.5, 2, 2.5, or 3
AeroPak - AP Series 94-95% AFUE 30, 40, or 51 9 EER 1, 1.5, 2, or 2.5
Condo Pak - P Series 90.6-93% AFUE 30, 40, or 50 9-10.8 EER 1, 1.4, 1.6, or 2
> Modest cooling efficiencies up to ~11 EER within
constrained, existing dimensions while heating
efficiencies range 90-95%
> Non-condensing products have similar specs but with
~ 80% heating efficiency
> BUT codes, standards, and voluntary EE initiatives can
raise issues and present market challenges
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Potential Issues/ChallengesEnergy Savings and EEP
>Through-the-wall equipment rated under varying
standards (i.e. AFUE and/or TE; SEER or EER)
─ How do rating methods impact selection, actual
performance, EEP implementation?
─ Are companion cooling efficiencies adequate for
current and near term standards and codes?
> 9.0 EER (current federal minimum)
> 11.0 EER (effective Sept. 2019)
> ASHRAE Standard 90.1-2013 specifies
minimum 10.0 EER
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Potential Issues/ChallengesEnergy Savings and EEP
>Do field measured energy savings compare to
savings estimates based on the rated
efficiencies?
>What are the net energy savings and resulting
payback?
─ Do the economics warrant inclusion in utility EEPs?
─ What magnitude of rebates are needed for attractive
paybacks?
─ Are resulting total resource cost (TRC) >1?
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Potential Technical Challenges
>Impacts on multifamily retrofit and new construction, and inclusion in EE programs of..
─ Condensate management:
> Disposal access to sanitary sewer
> Neutralization of acidic content
> Condensing flue icing at external grilles on outside wall during winter
─ Is ductwork and air tightness in multifamily buildings acceptable for building program requirements? (ENERGY STAR Quality Installation duct loss/ft2)
Source: GTI
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Potential Technical Challenges (cont’d)
>Early generation condensing furnaces had issues with air flow rates, static pressures, and temperatures
─ Will these issues be present in multifamily
buildings?
─ Will it impact market acceptance and energy
performance?
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Gas Heat Pumps
>Gas Engine-driven Heat Pumps:
─ Vapor-compression cycle driven by natural
gas engine in place of electric motor
─ Rated performance:
0.95-1.2 COP cooling at 95°F
1.2-1.5 COP heating at 47°F
78-80%
Non-condensing furnaces
90-98%
Condensing furnaces
>100%
Gas Heat Pumps
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Natural Gas Heat Pump:Technology Status
> Developed in Japan to reduce peak electric demand
> GHP uses advanced natural gas engine to drive two
scroll compressors
─ Variable-speed engine to improve part-load performance
─ Engines have proven reliability and demonstrated
long life (30,000 hrs)
─ Engine heat recovery supplements heating
Source: IntelliChoice Energy
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Natural Gas Heat Pump:Technology Status
> GHPs provide heating and cooling with reduced
electricity use and peak electric demand
> Available in variable refrigerant flow (VRF) for zoned
systems; multiple units can be combined
> Environmentally friendly refrigerant R410A
Source: IntelliChoice Energy
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> IntelliChoice Energy (ICE) NextAire ™ was first gas engine heat pump
commercially available in U.S. for HVAC
─ 8-ton and 15-ton Multi-Zone VRF units,
11-ton packaged rooftop
─ Aisin/Toyota engine has proven reliability,
demonstrated long life (30,000 hrs),
Maintenance interval of 6,000 to 10,000 hrs
─ Variable refrigerant flow (VRF) provides
heating and cooling for up to 33 zones
─ GTI currently monitoring sites in Idaho, Georgia, and Illinois
> Propane NextAire certified for U.S and in production
> ICE/SWG/ Marathon residential GHP (3 to 5-ton) certified in 2016
Idaho Demo Site
Natural Gas Heat Pump:IntelliChoice Energy
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> Yanmar introduced GHP product line to the
U.S. market in 2016
─ 13-ton and 16-ton 2-pipe VRF system
─ 16-ton 3-pipe VRF system for simultaneous
heating/cooling
─ Initial market focus in Southeast U.S. to
leverage existing service network
─ Demonstration units installed:
─ Adairsville, GA
─ Union Gas, Ontario
Natural Gas Engine Heat Pump:Yanmar
Source: Yanmar
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Natural Gas Heat Pump:Benefits
> Demonstrated savings in energy and operating costs
compared to conventional chiller/boiler equipment and
electric heat pumps
─ Significant reduction in peak electric
demand
─ 80% less electric power consumption
─ Up to 30% reduction in operating costs,
not including savings in water use
─ Efficiency varies with ambient temperatures and part-load;
energy and economic benefits vary with climate and application
Source: IntelliChoice Energy
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Natural Gas Heat Pump:Current Market
> Initial product introduction in 2009 only for warm climates; NextAire™ Model E certified in 2014 for all U.S. climates
> Over 400 units installed in schools, government, commercial buildings
> First costs are a significant barrier; higher sales volumes needed
> Utility installations expand service networks; introduce technology to new consulting firms and contractors
─ CenterPoint Energy, Golden Valley, MN:
one 15-ton unit
─ Elizabethtown (AGLR): one 8-ton,
nine 15-ton units; completed Nov 2014
─ Nicor, Bellwood, IL: two 15-ton units
applied for LEED certification
Source: GTI
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Natural Gas Heat Pump: Current Projects
> UTD Laboratory Testing:
─ Measured efficiencies of 15-ton Model E across a range of loads and cold climate
conditions (1.2-1.3 COP )
─ At low ambient temperatures (5°F), heating capacity maintained
─ Efficiency reduced at low temperatures and low part load
─ VRF configuration is a critical to system performance.
> U.S. DOD ESTCP Side-by-side Demonstration of GHP and
Electric Cold Climate HP:
─ Great Lakes Naval Station in North Chicago, IL.
─ Compare electric vs gas heat pump performance in cold climate; determine relative
savings in energy, lifecycle costs, and environmental benefits.
─ Baseline monitoring to begin June 2015.
> UTD and NYSERDA GHP Modeling and Feasibility Assessment:
─ Modeling of GHP, electric heat pump, and RTU in multiple building applications in
New York and five other climates.
─ Economic and market potential for GHP in New York.
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Sponsor Acknowledgements
> Utilization Technology Development (UTD)
www.utd-co.org
> Nicor Gas Emerging Technology Program
www.nicorgasrebates.com/emerging
> GTI North American Emerging Technology Program
Collaborative
http://www.gastechnology.org/Expertise/Pages/Emerging-Technology-
Program.aspx
and CenterPoint Energy, Union Gas, DTE Energy for their support
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Thanks for your attention!
PATRICIA ROWLEY
Senior Engineer, Building Energy Efficiency
Gas Technology Institute
1700 S. Mount Prospect Road
Des Plaines, IL 60018-1804
847/768-0555
gastechnology.org | @gastechnology