Natural Refrigerant, Geothermal DX System Design … Refrigerant, Geothermal DX System Design &...

Natural Refrigerant, Geothermal

DX System Design & Performance

Lalit Chordia, PhD, Marc Portnoff

150 Gamma Drive

Pittsburgh, PA 15238

www.thargeo.com

http://www.igshpa.okstate.edu/membership/login.asp

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Thar Geothermal, LLC © 2014│ All Rights Reserved

Buildings accounted for

41% of the primary energy consumption &

40% of the carbon emissions

in the USA in 2010 (2011 Buildings Energy Data Book, buildingsdatabook.eren.doe.gov).

The Challenge:

The Built Environment’s Energy Consumption

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The Opportunity: Improve HVAC system performance!

Heat

Pumps

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What differentiates Thar Geothermal

from other commercial geothermal systems?

Safe & Natural Refrigerant Recycled Carbon Dioxide (R744)

• Enhanced Energy Efficiency

• Reduced Environmental Footprint

Less earth removed

Less waste

Less grout

Ground Heat

Exchanger (GHX)

Design Flexibility

Smaller Diameter

Ground Loops

Evaporator

Condenser

Expansion

Valve

Compressor

Geothermal

Well Field

R744

Refrigerant

Loop

CO2

WARMHOT

COLDCOOL

Cold AirHot Air

Heat Flow

Simpler Design

with Fewer

Components

Direct Exchange Geothermal

Geothermal

GHX

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Why Natural Refrigerants?

Man made refrigerant leaks, have a environmental impact

greater than transportation (auto, truck, air) www2.epa.gov/greenchill/August 16, 2012

Refrigerant Leaks are higher than transportation

Refrigerant Leaks

On Site Combustion

Transportation (e.g. Trucking, Autos, Air)

Purchased Electric

MT CO2

= 28100 lb

R-404A

One 100 pound cylinder of R-404A leaked

into the atmosphere equates to the tailpipe

emissions of 28 – 4x4 Chevy Suburban’s

traveling 12,000 miles each

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100 lb

One 100 pound cylinder of R-404A leaked into the atmosphere equates to the tailpipe

emissions of 28 – 4x4 Chevy Suburban’s traveling 12,000 miles each

Hybrid and Secondary Loop CO2 Refrigeration Systems

EPA GreenChill Partnership Webinar, August 16, 2012 www2.epa.gov/greenchill/hybrid-and-secondary-loop-co2-refrigeration-systems

R -

404

A

= 28

Each traveling 12,000 miles

Synthetic refrigerant leaks have a disproportionate and

negative environmental effect on global warming

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Environmental Impact of Synthetic Refrigerants

Total Equivalent Warming Impact

In food and retail application:

Direct Emission > Indirect Emissions

Direct

Refrigerant

Leakage (GWP)

Indirect System

Energy Consumption

(COP)

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Recycled Carbon Dioxide (co2)

R744 the Environmentally Exceptional Refrigerant

• Safe: Non toxic, Non flammable & Non corrosive

• Significantly less expensive

• Does not affect the ozone layer

• Orders of magnitude less impact

on global warming

• No phase-out potential, unaffected

by future legislation & taxation

• Beneficial Refrigerant Properties:

ECO2 Efficient for Geothermal Applications!

0

500

1000

1500

2000

2500

3000

3500

R22R134A R404A

R410AR744 (CO2)

GWP

R22

R134A

R404A

R410A

R744 (CO2)

Glo

ba

l W

arm

ing

Po

ten

tia

l

Refrigerant Type

R744

(CO2)

Brown, Christopher, Exploring CO2: The Natural Choice for Sustainable,

Efficient Refrigeration Systems, Danfoss, January 2013,

www.danfoss.com/co2

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How does R744 refrigerant expand opportunity?

• R744 is safe, low cost, and environmentally friendly & enables

Direct Exchange Geothermal design at the commercial scale.

• R744 has beneficial refrigerant properties:

Lower liquid & vapor viscosity means reduced refrigerant flow

energy requirements

Higher energy density means more efficient heat transfer

Higher cooling capacity means smaller heat

pump components and refrigerant lines

• R744 enables efficient compressor oil –

refrigerant separation so an effective oil

management system can keep the compressor

oil at the heat pump rack

Relative sizing of dry

suction line to give the same capacity

CO2R134a

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• Used Worldwide

Supermarket

Refrigeration

Installations

Over 5,000

Water Heaters

Over 4.0 million

Soda Pop

Machines

Over 2.5 million

R744, Recycled Carbon Dioxide (co2)

Lira, T., ATMOsphere America 2014 – Summary

Report, June 2014, San Francisco, CA,

http://publications.shecco.com/publications/view/70

Integrated Hardware

• Established Supply Chains

http://www.r744.com/companies/view/panasonic

http://www.r744.com/companies/view/johnson_controls

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Thar Geothermal, LLC © 2014│ All Rights Reserved Masson, N., Mainstreaming Natural Refrigerants, The Business Case for

North America, Shecco, ATMOsphere America: June 2013, Washington DC

U.S.A. Supermarkets using R744 (CO2) Refrigerants

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Initial Experiences with Transcritical CO2 Systems in U.S. Supermarkets

EPA GreenChill Partnership Webinar, January 14, 2014 www2.epa.gov/greenchill/hybrid-and-secondary-loop-co2-refrigeration-systems

• 100% HFC‐free store (56,000 sq ft) CO2 Transcritical Refrigeration systems

HVAC systems

Vending and self contained systems

• Refrigeration contributed to whole building design

• Energy savings greater than 60% above the ASHRAE 90.1‐2007 baseline

• Expected to save ~2.5 million kW-hrs/year

http://www.r744.com/articles/whole_foods_opens_co2_transcritical_store_in_brooklyn

Whole Foods Opens CO2 Transcritical Store in Brooklyn, NY

R744 in the News

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Evanston, Illinois, USA

Walgreens CO2 showcase at 2013 FMI Energy & Store Development Conference

24 September 2013

Walgreens presented its net zero energy

retail store …… features carbon dioxide

refrigeration for heating, cooling and

refrigeration equipment.

http://www.r744.com/articles/walgreens_co_sub_2_sub_showcase

_at_2013_fmi_energy_store_development_conference

CO2 transcritical refrigeration coupled

with geothermal energy yielded 2.5

times the cooling efficiency

R744 in the News (continued)

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Comparison: Indirect & Direct Exchange Geothermal

COOLING MODE

Water Indirect Exchange

Evaporator

Condenser

Expansion

Valve

Compressor

Geothermal

Well Field

R744

Refrigerant

Loop

CO2

WARMHOT

COLDCOOL

Cold AirHot Air

Heat Flow

R744 Direct Exchange

DX - Simpler Design

with Fewer

Components Geothermal

GHX

Geothermal

Well Field

Warmer Water

Cooler

Water

Water

Pump

Water

Loop

Heat Flow

Expansion

Valve

Cold Air

Evaporator

Hot Air

Low Pres Liquid

Condenser

Compressor

R410a

Refrigerant

Loop

High Pres Liquid

Low

Pres

Vapor

High Pres Vapor

WARMHOT

COOL COLD

R410a to

Water HXGeothermal

GHX

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Thar All 744 DIRECT EXCHANGE

Ground Source Geothermal - COOLING MODE

Evaporator

Low Pres Liquid

Condenser

Expansion

Valve

Compressor

Geothermal

GHX

R744

Refrigerant

Loop

High Pres Liquid

Low Pres

Vapor High Pres Vapor

CO2

WARM HOT

COLD COOL

Cold Air Hot Air

Heat Flow

Pre

ssu

re (

psi

g)

Enthalpy (Btu/lbm)

Well Field

Evaporator HX

Pres

sure

(psig

)

Enthalpy (Btu/lbm)

Well Field

Evaporator HX

GHX

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Thar Geo R744 DIRECT EXCHANGE

Ground Source Geothermal – HEATING MODE

Evaporator

Low Pres Liquid

Condenser

Expansion

Valve

Compressor

Geothermal

GHX

R744

Refrigerant

Loop

High Pres Liquid

Low Pres

Vapor High Pres Vapor

CO2

WARM HOT

COLD COOL

Cold Air Hot Air

Heat Flow

Pre

ssu

re (

psi

g)

Enthalpy (Btu/lbm)

Condenser HX

Well Field

Pres

sure

(psi

g)

Enthalpy (Btu/lbm)

Condenser HX

Well FieldGHX

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0

5

10

15

20

25

30

35

40

30 40 50 60 70 80

He

atin

g o

r C

oo

ling

CO

P

GHX Ground Temperature (deg F)

Heating Cycle COP Cooling Cycle COP

GHX heating & cooling load management

is important to enhance energy efficiency

EES Results (25%) - 10 HP R744 Compressor

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Cost and difficulty of evaluating the

suitability of individual installation

sites

High cost of ground loop

installation; ~50-75% of total system

Degree of disruption associated

with ground loop installation

Thar Geothermal solutions are

focused on lowering these barrier!

Barriers limiting Geothermal Systems to 1-2% Market Share

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Smaller Boreholes Less earth removed

Less waste – lower disposal $

Less grout

Smaller equipment

Lower mobilization cost

R744 Smaller Geo-loops can reduce

Environmental Footprint & Cost

0

10

20

30

40

50

60

6.03.0

1.5

300 ft Well vol (ft3)Volume of 300 ft Borehole

Conventional

1.25” Pipe (1.66” O.D.)

HDPE

Thar Geothermal

Stainless

Steel

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How does R744 refrigerant expand opportunity?

• R744 enables the design of smaller diameter ground loops providing

for ground heat exchanger design flexibility and innovation

Vertical

Closed-

loop

System tcsgroup.eu.com

Horizontal

Closed-loop

System

hydroheat.com

Radial

System

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Thar R744 Geothermal Facility, Pittsburgh, PA

Ground Heat Exchanger Development

Vertical

GHX

#1

Horizontal

GHX

#2 Vertical

GHX

#3

Radiant Patio

GHX

Mud Rotary

Down Hole Hammer

Sonic

Horizontal Directional

Horizontal Directional

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~290’

10’

25’

Ground Level 3-4’

Two Tier Horizontal GHX

15’ spacing 1 2 3 4 5 6 7

Minimizes Surface Disruption

Horizontal Direction Drilling

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Comparison of Radial vs. Vertical Ground Heat Exchanger

Example: 30,150 ft ground loops

15 ft dia. cylinders of earths

surrounding ground loops

Vertical on 15 ft centers; ~6,750 ft2

More sub-surface space efficient

Radial 60 deg, 10 loop design; ~530 ft2 (8%)

Significantly reduces surface disturbance

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R744 DX Geothermal enables accessing the earth beneath

parking lots with minimal disruption

300’ x 300’

Horizontal Radial GHX

2 Layer Design

30-80 ton of GHX capacity

depending on earth properties

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Thar Geothermal systems are versatile and can

integrate with all types of standard HVAC systems

• Central or Distributed

• Air or Water Heat Exchangers

• Active Radiant (Chilled Beam)

• Passive Radiant

• Cassette

• Wall Mount

• Mini Air Handling Unit

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tcsgroup.eu.com

Comfort Controls

Conventional HVAC

Delivery Systems

Temperature

Relative Humidity

Indoor Air Quality

R744

Above Ground

Mechanical Room

DX

Geothermal

GHX

Below Ground

Geology- Drilling- Geo-Loop Installation-Grouting

R744

The Approach

R744

Hybrid Design

Options Available

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Thar R744 Geothermal Facility, Pittsburgh, PA

System Integration & Development

Radiant P

ati

o

Manufacturing &

Warehouse Space Cooling & Heating

Air Handling Units

Shipping & Receiving Cooling & Heating

Air Handling Units

Front Offices

Radiant Floor

CompressorPumps

Toll Process Space Cooling & Heating

Air Handling Units

Geothermal

Lab & Workshop

Thermal Image

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Thar Geothermal Development Facility

Air Handling

Units

• Validate R744 DX heat pump cycle

• Component Testing and Evaluation

Microchannel Heat Exchanger Designs

Auto Expansion Control Valves

Oil Management System

Control Software/Hardware

• Demonstration at commercial scale geothermal system (15-20 ton)

Air Side Heat Exchanger (heating and cooling)

Radiant Floor (heating and cooling)

50

55

60

65

70

75

80

100 200 300 400

Tem

p (d

eg

F)

AHU_2_TE1 AHU_2_TE2

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Café

Patio

March 6, 2013 Thermal Image

R744 Radiant Patio – Snow Melt

February 18, 2014

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

0 1,440 2,880 4,320

CO

P

2/16 2/17 2/18 2/19

CO

P

R744 Radiant Floor Heat Pump COP

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• Thar Geothermal Solutions are the next evolution in

Ground Source Heat Pump Systems providing

Enhanced Economic & Environmental Value

• All Natural, Safe & Non-toxic R744 (CO2) Refrigerant

Less expensive, Promotes ease of maintenance

• Direct Exchange Design More Efficient

• Improved Return on Investment Reduced Operating Costs

Reduced Maintenance Costs

Same or Lower Capital Costs

• Reduced Environmental Impact

Conclusions

CO2MFORT

ADVANTAGE

Nature’s

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Contact: [email protected]

Marc Portnoff General Manager

Thar Geothermal

150 Gamma Drive, Pittsburgh, PA 15238

412-963-6500 ext. 246

[email protected]

www.thargeo.com

Thank you for your kind attention!

Natural Refrigerant, Geothermal DX System Design … Refrigerant, Geothermal DX System Design &...

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