Research Roadmap Air-Conditioning and Refrigeration Technology Institute, Inc .

Preface Heating, ventilation, air conditioning and refrigeration (HVAC&R) systems are widely recognized as essential for modern day life. This strategic level roadmap has been developed to focus policy makers and industry leaders upon fundamental research that is essential for the future of American enterprise and improving our way of life. The premise of this document is that the justification for performing basic HVAC&R research is well understood and therefore, this roadmap has been developed to provide a clear path forward to achieving essential goals.

Mark Menzer Senior Vice President, ARTI

Who is ARTI? The Air-Conditioning and Refrigeration Technology Institute, ARTI, is the HVAC&R industry’s fundamental research organization. For the past 15 years, ARTI has been successfully coordinating and sponsoring cooperative research in the HVAC&R and building sectors. Driven initially by the common challenge to develop non ozone-depleting refrigerants to help protect the ozone layer, ARTI’s research programs have expanded to address improving integration of HVAC&R technology into buildings to provide more energy efficient structures with improved indoor environments.

Strategic Focus The roadmap has identified a need to focus on basic and early stage research to develop the next generation of HVAC&R equipment and services. The American HVAC&R industry functions in a business and energy climate today that discourages investment in basic research leading to an increasing innovation gap with competitors abroad. The need for a strong research public/private partnership for this vital industry is clear, immediate and necessary. Commercialization (Market Conditioning)

Late Stage Product Development and Demonstration

Manufacturers (Governments Utilities)

Early Stage Product Research & Development

Manufacturers Governments Utilities Basic Research

ARTI US DOE Manufacturers

ARTI US DOE

Strategic Impact of this Research Significant Energy Efficiency Gains National Economic Growth Large Peak Electric Demand Reduction Indoor Air Quality Improvement Increased Food Safety Enhanced Homeland Security

Return on Investment Air conditioning has had an incredible impact on the way we live, giving us the option to work, play and relax in controlled environments. Refrigeration assures the freshness, health and safety of our food supply, helps develop modern medicines and is essential to thousands of chemical processes. Investing in research today means more than improving our way of life. Investment today assures jobs and exports for tomorrow, stabilizes our electric grid, conserves energy and provides for the health and welfare of our citizens. There are few other research investments that have a greater impact on our future.

The following entities have invested along with ARTI to meet their future energy goals

Basic Research is Important Fossil energy is finite, global climate change is significant, safeguarding against food borne bacteria requires more care and our indoor environments need improvement and indeed protection. Today’s HVAC&R marketplace does not value these important and inevitable forces that policy makers and scientists have identified. These “national interests” are being researched in a systematic fashion in Europe and Asia. America’s focus is near term incremental improvement of technology, which will naturally limit our future progress and success. There is a real danger of the American HVAC&R industry being rendered obsolete by foreign research. This roadmap and partnership will assure America’s rightful leadership role in this essential technology both in the near term and in the future.

Research Goals This roadmap provides the collective thought of hundreds of professional engineers, scientists, manufacturers, contractors, architects and policy makers all focusing on providing a strong scientific and economic foundation – through basic research – to provide answers that allow anyone to leverage the findings and quickly apply them to the next generation of goods and services. The ARTI Research Program is dedicated to the following goals:

Residential Buildings: Achieve a 50% reduction in HVAC&R annual energy consumption and peak electric energy demand in new buildings by 2020.

Commercial Buildings: Realize energy consumption and peak electric energy demand reductions of 25% in new buildings by 2020.

Refrigeration: Reduce refrigerant leakage in supermarket refrigeration systems by 90% and reduce energy consumption in supermarkets by 25% by 2020.

Emerging Technologies: Continually review and monitor research in the HVAC&R arena and elsewhere for breakthroughs that could contribute to achieving the roadmap’s goals.

HVAC&R is Important! Air conditioning and refrigeration transformed the 20th century. These defining technologies have altered the way we live, work, and play. From suburban tract houses to glass skyscrapers, indoor entertainment centers, supermarkets, restaurants, high-tech manufacturers’ clean rooms, and pressurized modules for space exploration, many of the nation’s modern structures and products would not exist without the invention of air conditioning and refrigeration. Air conditioning and refrigeration have changed our relationship with nature itself by creating indoor artificial climates, shifting seasonal patterns of work and play, and making America’s geographic differences environmentally insignificant.

Residential Buildings GOAL: Achieve a 50% reduction in HVAC annual energy consumption and peak electric energy demand in new

SUCCESS STORY

Improved Equipment

20% Performance Improvement in Motor/ Compressors and Heat Exchangers

50% Reduction in Energy Consumption at a Price Assuring Widespread Use

Improved Systems

Improved Components

residential buildings by 2020.

25% Reduction in Building Envelope Energy Losses and a 50% Reduction in Duct Losses

Refrigerant Blends Operating Near and Above Critical Temperature This project addressed the cooling capacity and system performance drop-off of residential air conditioners at high ambient outdoor temperatures and updated two modeling tools that assist in the design of heat exchangers and air-conditioning systems. The updated modeling tools provide manufacturers with more accurate tools for developing residential systems with enhanced performance at high ambient temperature conditions.

Commercial Buildings GOAL: Realize energy consumption and peak electric energy demand reductions of 25% in new buildings by 2020. This would include reducing average annual ventilation and air conditioning use from 8,800 BTU/ft2 to

Space Constrained Products

System Optimization

Comfort and Noise

Distribution Systems

Affordable 13 EER Rooftop Air Conditioner

Chillers

Rooftop Air Conditioner

6,600 BTU/ft2.

Increase Energy Efficiency of Chillers by 25%

Improve Efficiency of Space Constrained Products by 25%

Decrease Energy Use by 10% Through Better Selection of Equipment and Components

Improve Comfort and Reduce Noise in Commercial HVAC&R Equipment

Reduce Energy Use by 15% Through Improved Distribution Systems

Refrigeration GOAL: Reduce refrigerant leakage in supermarket refrigeration systems by 90%, reduce refrigerant charge in

SUCCESS STORY

25% More Efficient Refrigerated Display Case

90% Reduction in Refrigerant Leakage in Supermarkets

Refrigerant Systems

Refrigeration Emissions

Display Cases

supermarkets systems by 60% and reduce energy consumption in supermarkets by 25% by 2020.

60% Smaller Refrigerant Charge

High Performance Heat Exchangers Small Tube, Noncircular and Flattened-Tube Heat Exchangers Several projects have addressed the potential enhancement in the performance of heat exchangers through the use of small tube, oval, and flattened-tube designs. In addition to taking advantage of reduced air-side pressure losses over the coil and its associated reduction in fan power consumption, these tube designs have the potential of providing the same cooling capacity with a much smaller refrigerant charge. Manufacturing cost, tube integrity and durability will play a key role in enhanced coil tube design and marketability.

Emerging Technologies GOAL: Continually review and monitor research in the HVAC&R arena and elsewhere for breakthroughs that

For Example: Novel Heat Exchangers (Microchannel, Plastic, Carbon Foam)

For Example: Magnetic Cooling and Other Advanced Cycles.

Novel Systems

Novel Equipment

Novel Components

could contribute to achieving the goals within the three application sectors.

For Example: Enhanced Carbon Dioxide Refrigeration, Heat Pump and Air Conditioners

The Path Forward Energy markets, environmental concerns and global competition are key issues facing America’s HVAC&R industry. Undertaking the basic research needed to achieve the HVAC&R industry goals is critical to addressing those issues . The only successful path forward for American HVAC&R manufacturing businesses is through innovation and product leadership. This can only be achieved through a strong public / private partnership focusing on basic and early stage research to provide the basic foundation for industry. For the HVAC&R the essential public / private partnership is ARTI Research Program. It is time to invest guidance, time and financial resources in American Technology.

Potential Projects for the Future Research: Air Conditioning and Refrigerant Technology Database – Web based database of various cooling, dehumidification, and air treatment technologies with an assessment of their current performance capabilities and commercialization potential. Smart Sensor Research – To support the development and integration of economical miniature wireless HVAC and IAQ sensors for fault detection and diagnostics, automatic and continuous commissioning, and monitoring and fine tuning HVAC and building performance. Advanced Heat Exchanger Research – To support the development and demonstration of new design concepts for higher efficiency, better performance during high temperature conditions, and greater moisture removal during part load conditions. Supermarket Refrigeration System Research – Support the development and demonstration of tighter supermarket systems to reduce refrigerant leakage and increase energy efficiency.

1999 present

2004 Twenty-first Century Research (21CR) Program

1992 1997

2003 R-22 Alternative Refrigerant Evaluation Program (AREP) An international program to test and to report on the performance of R-22 alternatives.

1991 2001

• Evaluation of the Performance Potential of CO2 as a Refrigerant in Air-to-Air Air Conditioners and Heat Pumps: System Modeling and Analysis (610-10030) • Critical Literature Review of Lubricant Influences on Refrigerant Heat Transfer and Pressure Drop (611-20080) • Variable Primary Flow Chilled Water Systems: Potential Benefits and Application Issues (61120070) • Using Acid Number as a Leading Indicator of Refrigerant and Air Conditioning System Performance (611-50060) • Evaluation of the Performance Potential of CO2 as a Refrigerant in Air-to-Air Air Conditioners and Heat Pumps: System Modeling and Analysis (610-10030) • CO2 Compressor-Expander Analysis (611-10060) • Application of High-Temperature Mold Materials to Die Cast Copper Motor Rotor for Improved Efficiency (605-20030) • Critical Literature Review on Lubricant Influence in Refrigerant Heat Transfer and Pressure Drop (611-20080) • Methods for Automated and Continuous Commissioning of Building Systems (610-30040) • Automated Integration of Real-Time Information into Building Management Systems (611-30050)

2002

Materials Compatibility & Lubricant Research (MCLR) Program – Fundamental research to assist U.S. manufacturers in phasing out of CFC refrigerants and to assist in the transition to HFC refrigerants.

ARI INDUSTRY RESEARCH TIMELINE

• Measurement of Performance of Carbon Dioxide Compressors (611-10070) • Potential Benefits of Smart Refrigerant Distributors (605-20050) • State-of-the-Art Review, Whole Buildings and Building Envelope Simulation and Design Tools (605-30010) • State-of-the-Art Review, HVAC Component and System Simulation and Design Tools (605-30020) • Energy Savings Potential of Flexible and Adaptive HVAC Distribution Systems for Office Buildings - Phase I (605-30030) • Investigation of the Causes of “Black Soot” Phenomena (605-40010) • Defining the Effectiveness of UV Lamps Installed in Circulating Air Ductwork (610-40030) • Investigation of Building Exhaust Air Re-Entrainment Into Outdoor Air Intakes of Packaged Outdoor HVAC Equipment - Phase I (610-40040) • Properties and Cycle Performance of Refrigerant Blends Operating Near and Above the Refrigerant Critical Point (610-50010) • Add-on Effort to ASHRAE 1073-RP: Determination of Refrigerant Lower Flammability Limits in Compliance with Proposal Addendum 34p to ANSI/ASHRAE Standard 34 (605-50020)

2000

2001

• • • •

ARTI Refrigerant Database (605-00010/610-00010) Microchannel Heat Exchangers with Carbon Dioxide (605-10020) Evaluating the Performance of Thermoacoustic Cooling (610-10040) Evaluating the Ability of Unitary Equipment to Maintain Adequate Space Humidity Levels (605-20010) • An Assessment of the State-of-the-Art, and Potential Design Improvements, for FlatTube Heat Exchangers in Air Conditioning and Refrigeration Applications – Phase I (605-20020) • Assessment of the Commercial Implications of ASHRAE A3 Flammable Refrigerants Used in Air Conditioning and Refrigeration Systems (610-50025) • Study of the Effects of Water in Synthetic Lubricant Systems and Clathrate Formation (610-50035) • The Efficiency Limits of Water Vapor Compressors (605-10010)

Air-Conditioning & Refrigeration Technology Institute 4100 North Fairfax Drive, Suite 200 Arlington, Virginia 22203 phone: (+1) 703-524-8800 fax: (+1) 703-522-2349 November 2004