Development of Economical Gas- fired Ammonia …members.igu.org/old/IGU Events/igrc/igrc-2014...and...

WO1-3

Development of Economical Gas-

fired Ammonia-Water Absorption

Heat Pumps for Water Heating and

Space Heating Applications

> Paul Glanville

Senior Engineer, End Use Solutions,

Gas Technology Institute

> International Gas Union Research Conference

17 September 2014

IGRC 2014 2 IGRC 2014 2

ESTABLISHED 1941


> Independent, not-for-profit

company established by natural

gas industry

> Providing natural gas research,

development and technology

deployment services to industry

and government clients

> Facilities

─ 18 acre campus near Chicago

─ 200,000 ft2 with 28 labs

> Staff of 260

> Wellhead to the burner tip including

energy conversion technologies

Energy & Environmental Technology Center

CHP and Renewable Energy Lab Pilot-Scale Gasification Campus

Training

IGRC 2014 3 IGRC 2014 3

Outline

Can Gas Heat Pumps find their place in the U.S.?

> The U.S. market for residential space

and water heating

> Overview of residential gas heat

pump developments

> Performance comparisons

> Future RD&D Plans

IGRC 2014 4 IGRC 2014 4

Regional Space Heating by Fuel1

U.S. RESIDENTIAL SPACE HEATING

Space Heating Overview

> Largest residential use of

natural Gas in U.S.,

63% of the residential

load, 29.4 billion therms/yr

> Gas still preferred fuel

for space heating, but

declining from better

envelopes and competition

> Regional variation largely

climate driven, but also by

spark spread and state

regulations

> Cold climate focus

1. Map from “Guide to Determining Climate Region by County”, Prepared by PNNL and ORNL, Report No. PNNL-17211,

August 2010. Data from US DOE 2009 RECS (2013).

IGRC 2014 5 IGRC 2014 5

U.S. RESIDENTIAL SPACE HEATING

Trends

Traditional Gas Heating Losing Ground

> Gas is the most common heating fuel in U.S.

cold climate regions and some mild climates – 80% are central warm-air furnaces,

remainder is primarily steam/hydronic

system

> Furnace market share is dropping and with it

gas consumption, with an 18% drop in use of

natural gas as a heating fuel from 1997 to 2009

(incl. envelope improvements, migration, etc.)

> Higher efficiency heating technologies for

condensing combustion (~90-96% AFUE) an

old technology, represents over half of furnace

shipments – Stalled regional standards in U.S. seek to

require this, already the case in parts of

Canada

> Market needs cost-effective, high-efficiency

heat pump option for gas customers

0

20.000

40.000

60.000

80.000

100.000

120.000

140.000

-

500.000

1.000.000

1.500.000

2.000.000

2.500.000

3.000.000

3.500.000

4.000.000

1993 1995 1997 1999 2001 2003 2005 2007 2009 2011

GS

HP

Sh

ipm

en

ts (

EIA

)

An

nu

al

Sh

ipm

en

ts (

AH

RI)

EHPs Shipped

Furnaces Shipped

GSHPs Shipped

IGRC 2014 6 IGRC 2014 6

U.S. RESIDENTIAL WATER HEATING

Water Heating Overview

> Water heating is second largest

residential use of natural gas in U.S.,

26% of the residential load, 12.3

billion therms/yr

> Distribution of water heater types is

primarily influenced by spark spread,

not climate. Loads also not climate-

driven, but occupancy-driven

> Due to state efficiency codes and

water heating being the largest

residential load (2.5 billion

therms/yr), CA is major influence

with 10 million gas water heaters

> Nationwide, split is roughly 50/50

electric/gas

Water Heating by Fuel1

0,02,04,06,08,0

10,012,014,0

Millio

ns o

f H

om

es

U.S. Regional Price of Electricity

1. Map produced by NREL for the US DOE in 2013 (2010 prices).

Data from US DOE 2009 RECS (2013).

Electricity Gas

IGRC 2014 7 IGRC 2014 7


Trends

Low-Cost is Still King

> Lion’s share of

products sold are still

low-efficiency gas

and electric storage

residential water

heaters

> Growth in gas

condensing tankless

water heaters

> Electric heat pump

water heaters

growing as well,

however 2012

shipments were

on the order of

50,000/yr

0

2.000

4.000

6.000

8.000

10.000

12.000

2010 2011 2012 2013 2014 2015

Th

ou

san

ds o

f U

nit

s

VOLUME SALES OF WATER HEATERS

Heat Pump Water Heaters

Solar Thermal Storage tanks

Oil

Hybrid Water Heater

Gas Storage Non-Condensing Residential

Gas Storage Non-CondensingCommercialGas Storage Condensing Residential

Gas Storage Condensing Commercial

Gas Instantaneous Non-Condensing

Gas Instantaneous Condensing

Electric Storage Residential

Electric Storage Commercial

Electric Instantaneous

Indirect Cylinders

Combi Boilers

Data Source: Parker, M. “American Water Heating Dynamics: Present and Future”, ACEEE HWF (2011 ).

Projected

IGRC 2014 8 IGRC 2014 8


High-Efficiency Retrofit Options

> Non-condensing EnergyStar® water heater with 0.67-0.70 EF,

current models require electrical service

> Condensing gas storage water heaters (GSWH)/Hybrid, requiring

venting upgrade and electrical service

─ Most currently rated with thermal efficiency (TE), recent study has

found units with TE > 90% have EF of less than 0.80*

> Convert to non-condensing or condensing Gas Tankless Water

Heater (GTWH), with an EF 0.82 – 0.95 typically, requiring venting

upgrade, electrical service, and often larger gas piping

─ Delivered efficiency of TWHs is in dispute due to cyclic/startup losses

not covered by EF, some groups de-rate the EF of TWHs by 9%**

* Davis, R. “Laboratory Testing of Advanced Storage Water Heaters”, ACEEE HWF (2012).

** RESNET. Results of Electronic Ballot of RESNET Board of Directors on Adopting Proposed Standard

Amendment on Adjusting Instantaneous Water Heater Efficiency (2012).

Market is predominantly 0.59 – 0.62 EF residential GSWH

IGRC 2014 9 IGRC 2014 9


Why Now?

> After Energy Star (ES) for water heating was

enacted and with new Federal req’s, strong

incentives for high-efficiency

> While Electric Resistance Storage water heaters

are exempt, Electric Heat Pump water heaters

qualify for ES and financial incentives

─ Large potential in regional markets,

Pac NW, SE

> GTI Evaluated a series of EHPWHs in 2010

under standard and stressed conditions

> Interest in a gas-fired option, U.S. DOE and

utilities have supported developments of

GHPWHs with industry/OEM partners

IGRC 2014 10 IGRC 2014 10

RESIDENTIAL GAS HEAT PUMP

Opportunities for Water and Space

Heating in the U.S.

> Technical: Numerous heat pump cycles are technically feasible

─ Engine-driven vapor compression

─ Direct-fired absorption cycle: NH3-H2O, Strong Salt-H2O common

─ Solid sorption/adsorption: silica gel-H2O, zeolite-H2O

─ Stirling engine cycles and variants

─ Thermoacoustic cycles

> Economic: Problematic in prior commercialization efforts

─ Limited commercially available options, primarily EU/Japan

suppliers

─ Installed costs are high, sales volumes are low (1,000s), but

growing

─ GHPs are not often designed as dedicated water heating device

(e.g. residential absorption chiller).

> Critical for U.S. GHP products to be as low-cost as possible, as compared

to other “high-efficiency” options

IGRC 2014 11 IGRC 2014 11


Technology Development

> Gas Heat Pump Water Heater (GHPWH) and Gas Heat Pump (GHP)

for space heating both developed by startup company Stone

Mountain Technologies Inc. (SMTI), with OEM, GTI, and University

Support with government and utility sponsors

2010 2013 2014

GHPWH R&D Proof-of-Concept – Completed with 3 Packaged Lab.

Proof-of-Concept GHPWH Units, then refined controls and design.

GHPWH Field Testing – Currently at two residential sites,

five additional sites planned by end of 2014

GHP R&D Proof-of-Concept – Designing low-

cost GHP, in lab testing phase currently.

Field Testing

Planned

2015

IGRC 2014 12 IGRC 2014 12


System Specifications

> Based on low-cost single-

effect cycles, these are

intended as fully

retrofittable with

most common gas

storage water

heating and

hydronic heating

systems without

infrastructure

upgrade

GHPWH GHP

Heat Pump Output (kW) 2.9 23.4

Firing Rate (kW) 1.9 16.1

Efficiency 1.3 Energy Factor COP > 1.4

Storage Size (L) 265 N/A

Emissions (projected) 10 ng NOx/J 14 ng NOx/J

Commercial Introduction (projected) 2016 2017

Installation

Indoors/semi-

conditioned space

(garage), sealed NH3

charge < 25% max

allowed by ASHRAE

Std 15

Outdoors

Venting ½” – 1” PVC N/A

Gas Piping ½” ¾”

Estimated Consumer Cost <$1,800 <$4,500

IGRC 2014 13 IGRC 2014 13


How It Works

Very similar to vapor compression, except:

> Compressor is replaced with “thermal compressor”,

comprised of several HXs and addition of absorbent.

─ Easier to compress liquid, solution pump requires appx.

1.0% of the compression energy of a standard vapor

compression heat pump

> Ammonia is the refrigerant, instead of more common

R-134a for EHPWHs, which is:

─ Very efficient thermodynamically, used almost exclusively

in industrial refrigeration

─ Has large affinity for water, stable over range of

temperature/pressure conditions

─ Non-ozone depleting

─ A natural chemical, with a global warming potential of 0

(R-134a is 1300)

─ An irritant and hazardous, requiring special care.

Helpfully, unlike most refrigerants, NH3 is lighter than air

[Source: MW CHP Center]

IGRC 2014 14 IGRC 2014 14

RESIDENTIAL GAS HEAT PUMP WATER HEATER

How It Works

> Heat pump absorbs heat from the

ambient air and recovers heat from the

absorption of NH3 to water (in absorber) ─ Heat transfer to potable water is

mediated by a closed hydronic loop

> In addition, useful heat from hot flue

gases exiting the heat pump is delivered

to storage tank by separate HX

> As the GHPWH only partially heats

water from the refrigeration cycle,

cooling effect at the evaporator is 1/3-1/2

that of equivalently sized EHPWHs

> GHPWH uses Single Effect absorption

cycle, more complex cycles were

considered by SMTI but were not cost-

effective

IGRC 2014 15 IGRC 2014 15


System Performance

> In environmental chamber, cold/dry to hot/humid conditions,

system operates close to theoretical maximum COP

> Performance in field has confirmed results, focus now on controls

and system cost

1

1,1

1,2

1,3

1,4

1,5

1,6

1,7

1,8

1,9

25 30 35 40 45 50 55 60 65

CO

P

Hot Water Supply Temperature [C]

Beta GHPWH Prototype: Steady State Performance Nominal 20°C Ambient

B1 Cycle B2 Cycle B3 Cycle

B1 HHV B2 HHV B3 HHV

IGRC 2014 16 IGRC 2014 16


Field Evaluation

> Team has developed methods to estimate installed energy savings

depending on usage, installation characteristics

─ Two-unit assessment active in TN, more planned for West Coast

─ Several improvements in controls, exp. valve implemented

DOE Test

Category

Daily Output

(L)

Delivered Efficiency

(Field Ambient – 19 C

avg.)

Medium Usage 208 1.20

High Usage 318 1.30

Extrapolating field “Delivered Efficiencies”, between

1.1 and 1.4 as measured, unit is showing

performance to 1.3 EF target. Tank standby loss can

be improved by 50%, using standard methods to

surpass this goal

y = 0,6493x + 1,6741 R² = 0,7406

0

2

4

6

8

10

12

14

16

0 5 10 15 20

Daily I

np

ut

(kW

h)

Daily Output (kWh)

IGRC 2014 17 IGRC 2014 17


Field Evaluation

> Unit has demonstrated

successful operation with

ambient temperatures

below 35 F, with a COP

> 1.0, unattainable by

EHPWHs that disable

HP at T < 45 F typically

> Under standard conditions,

unit shows COP near

theoretical maximum for

single effect cycle,

between 1.4 and 1.8

y = -0,0051x + 2,0521 R² = 0,7124

y = -27,736x + 10716 R² = 0,7091

-15000

-10000

-5000

0

5000

10000

15000

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

40 60 80 100 120 140

Cap

acit

y (

Btu

/hr)

Cycle

CO

P

Hydronic Return Temperature (F)

Data for GHPWH Cycling – Week of 4/6/14

Cycle COPCapacity

GTI data logging displays real-time cycle COP vs.

key metrics, ambient temperature, water

temperature, and hydronic return temperature

IGRC 2014 18 IGRC 2014 18


Combustion Design

> Firing into desorber at 1.9

kW, designed for efficiency,

cost, and size

> Boiler solution at chamber

walls has temperature of

120-170°C

> Beyond efficiency, NOx and

CO emission targets are

aggressive

5

10

15

20

25

30

25

50

75

100

125

20 25 30 35 40

NO

x E

mis

sio

ns

(p

pm

at

3%

O2)

CO

E

mis

sio

ns

[p

pm

air

fre

e)

Excess Air [%]

CO (No Restriction) CO (Restriction)

Nox (No Restriction) Nox (Restriction)

Reduce OD

Largely using radiant metal

mesh designs, several

geometries evaluated, results

mixed, refined with CFD to meet

targets, customized components

IGRC 2014 19 IGRC 2014 19


Technology Comparison

Is there a energy saving opportunity for GHPWHs?

> Comparative Analysis–Assembling laboratory test data

with daily electricity & natural gas consumption:

─ CEC Residential Gas Water Heating Program, GTI and

PG&E performing laboratory testing on residential gas

tankless and gas storage water heaters respectively*

─ Laboratory Characterization of Electric HPWHs, GTI

testing three of the major 2009-10 EHPWH products.

Results for analysis are for EF of 2.4 – 2.6**

─ Laboratory Testing of Prototype Gas-Fired Residential

Absorption HPWH, GTI testing of prototype absorption

GHPWH under standard and field conditions. Results for

first generation. prototype correspond to EF 1.1 – 1.2***

* Kosar, D. et al. “Residential Water Heating Program - Facilitating the Market Transformation to Higher Efficiency Gas-Fired Water Heating -

Final Project Report”. CEC Contract CEC-500-2013-060. (2013)

Link: http://www.energy.ca.gov/publications/displayOneReport.php?pubNum=CEC-500-2013-060

** Glanville, P. et al. “Parametric Laboratory Evaluation of Residential Heat Pump Water Heaters”, Trans. of ASHRAE v. 118 pt. 1, Chicago, IL.

(2012).

Link: http://aceee.org/files/pdf/conferences/hwf/2011/1B%20-%20Paul%20Glanville.pdf

*** Garrabrant, M. et al. “Development and Validation of a Gas-Fired Residential Heat Pump Water Heater - Final Report “. DOE Contract

EE0003985 (2012).

Link: http://www.osti.gov/scitech/biblio/1060285

http://www.energy.ca.gov/publications/displayOneReport.php?pubNum=CEC-500-2013-060








http://aceee.org/files/pdf/conferences/hwf/2011/1B - Paul Glanville.pdf





http://www.osti.gov/scitech/biblio/1060285

http://www.osti.gov/scitech/biblio/1060285

IGRC 2014 20 IGRC 2014 20



When introduced

into the market,

GHPWHs will have

the only Source

Energy Factor >

1.0. Success in

large gas WH

markets is critical

(CA/NY)

NY – Dark Shade; CA – Light Shade; Energy prices are statewide averages for gas/electricity

$0

$50

$100

$150

$200

$250

$300

$350

$400

An

nu

al

Op

era

tin

g C

os

t

Gas Storage WH Tankless WH Gas Heat Pump WH AOS Electric Heat Pump WH GE Electric Heat Pump WH

IGRC 2014 21 IGRC 2014 21



$0,00

$500,00

$1.000,00

$1.500,00

$2.000,00

$2.500,00

$3.000,00

To

tal In

sta

lled

Co

st

Equipment Cost Installation Cost

$2.500,00

$3.000,00

$3.500,00

$4.000,00

$4.500,00

$5.000,00

$5.500,00

$6.000,00

10 Y

ear

Co

st

of

Ow

ne

rsh

ip

California New York

> With low firing

rate required,

GHPWH

installation costs

are low

> GHPWH has total

cost of ownership

close to baseline

water heaters,

cost-engineering

will result in the

lowest cost of

ownership

IGRC 2014 22 IGRC 2014 22

RESIDENTIAL GAS HEAT PUMPS

Technology Performance

GHP Space Heater Development:

> Using lessons learned, team is

scaling up low-cost, single-effect

system to GHP for space heating

> Unit will be equivalent to a 80,000

Btu/hr output hydronic boiler, with

3:1 turndown and outdoor install

> Planned GTI psychrometric

chamber testing down to -13°F

(-25°C) during coming winter

IGRC 2014 23 IGRC 2014 23

RESIDENTIAL GAS HEAT PUMPS

Future Plans

> Water Heating

─ GHPWH on target for near term market introduction, field demonstration in five states underway. OEM and utility support has been critical.

─ U.S. DOE recognized GHPWHs through recent rule change. Parallel development efforts underway led by ORNL.

> Space Heating

─ GHP prototype demonstration completed early 2015, field evaluation shortly thereafter

─ Exploring dynamics of combined water/space heating

IGRC 2014 24 IGRC 2014 24

Connect With Us


1700 S Mount Prospect Rd, Des Plaines, IL 60018, USA

www.gastechnology.org

Contact:

Paul Glanville

Senior Engineer,

End Use Solutions

847-768-0782

[email protected]

@gastechnology

Development of Economical Gas- fired Ammonia …members.igu.org/old/IGU Events/igrc/igrc-2014...and...

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