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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
22
> 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
33
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
4
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
55
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
66
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
77
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%
88
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
99
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)
1010
Icing at Flues is Typical in Operation
Residential Condensing
Furnace Flue in MNBig Box Retail Store Condensing
DOAS Flues in MN
Source: GTI
1111
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
1212
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
13
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)
14
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
1515
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
1616
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.
1717
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
18
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%)
19
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)
20
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
21
…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
22
…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
23
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
24
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
25
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
26
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
27
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
2828
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
2929
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
3030
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?
3131
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
3232
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?
3333
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
34
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
35
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
3636
> 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
3737
> 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
38
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
39
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
4040
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.
4141
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
42
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
