1. Introduction
Due to the continuous development of heating and cooling installation techniques, as well as new construction and architectural challenges, innovative installation solutions are sought that will maintain the thermal comfort of building occupants while minimizing the visibility of the installations. Furthermore, due to climate change, despite the lack of legal requirements, many investors are choosing to additionally equip buildings with cooling systems to increase occupant comfort and thus the building’s importance. Broadly understood surface heating and cooling technologies [
1,
2] fit very well into this trend. These solutions use the surfaces of horizontal and vertical building partitions as heating/cooling elements by placing a heating or cooling element in the structure of a given partition, e.g., an electric heating cable, central heating, or chilled water pipes [
3,
4]. This type of solution has a number of advantages, such as covering the thermal needs of a given space without visible installation elements [
5], such as radiators, fan coil units, etc.; thermal storage; ensuring thermal comfort with lower installation parameters; and the possibility of cooperation with renewable energy sources. The main disadvantages of these solutions include limitations in the possibility of building partitions and relatively low energy efficiency, which in some cases requires additional supporting installations [
6,
7,
8]. Another important aspect is the radiation asymmetry, which can lead to unfavorable thermal comfort sensations (PMV), mainly in the case of wall and ceiling cooling/heating [
9,
10,
11].
In the case of surface heating/cooling, the most common is the water system, which uses water as a heat transfer medium through the even distribution of water installation pipes in the finishing layers of the building envelope, e.g., underfloor heating, or in ready-made plasterboards that can be used as a finishing element of walls or ceilings, as well as water systems placed directly in the building structure, i.e., ceilings/walls [
3,
4,
12]. Unfortunately, the considerable lengths of water pipes distributing heat along the modules increase the consumption of external energy due to the increased pumping costs.
In recent years, a number of publications have been published [
13,
14,
15,
16,
17] suggesting replacing the water medium in surface heating with another medium that does not require additional external energy for heat transfer. This solution involves the use of a heat pipe mechanism. A heat pipe is an enclosed space filled with a thermodynamic medium, which, thanks to phase changes, allows for heat transfer between its extreme points much more efficiently than by conduction. The structure of a classic heat pipe is divided into a heat uptake zone (due to liquid evaporation), adiabatic heat transfer, and heat release (during condensation) [
18,
19,
20]. In the structure of a heat pipe used for heating and cooling, there is no adiabatic heat transfer zone. The heat release zone occurs immediately after the heat uptake zone. Various compounds are used as thermodynamic mediums, such as freons, nitrogen, ammonia, helium, alcohols, water, etc. [
21,
22,
23]. Heat pipes, through the use of an appropriate thermodynamic medium, are characterized by high energy efficiency and allow for the transport of both heat and cold. These elements are widely used in the broader HVAC industry, e.g., in heat exchangers in air handling units and solar collectors [
24,
25,
26], but there are scarce data regarding their use directly in space heating and cooling [
27,
28].
A particularly interesting solution is the combination of multiple functions in one structural element, i.e., the use of building modules that would perform a structural function, heating and cooling the rooms, and at the same time would be a finishing element ensuring the interior aesthetics of the rooms. These modules can be manufactured outside the construction site as prefabricated elements for direct assembly on the site. This further reduces the costs and shortens the construction time of the building, and also improves the aesthetics of the workmanship and energy efficiency of the product. This is an important advantage of such a solution.
This article aims to analyze the potential use of prefabricated heating and cooling modules in buildings for various purposes in Poland’s climatic conditions. Climatic conditions in Poland included a fairly wide range of outdoor air temperature variations. The lowest winter temperatures recommended in heating equipment design standards start at −24 °C, while the highest summer temperatures recommended in cooling equipment design standards reach 32 °C. This article presents the characteristics of the heating and cooling module, and simulation studies of the heating and cooling demand of various building types in Poland’s climatic conditions. Comparing the demand with the module output allowed us to determine the possible scope of their application and the limiting conditions.
For analysis, we selected the building module tested in the Air Conditioning and Heating Department of the Warsaw University of Technology, as part of the project No. RPMA.01.02.00-14-9558/17 “Innovative and ecological heating and cooling system with composite prefabricated wall elements”, supported by the Regional Operational Program of the Mazowieckie Voivodeship, and the research grant no. 2/ILGiT/2023 of the Warsaw University of Technology, supporting the scientific activity in the discipline of Civil Engineering, Geodesy, and Transport.
2. Description of the Analyzed Module
The heating and cooling module is a wall module with a thickness of 0.2 m—on the front side a 0.05 m thick reinforced concrete slab, inside 0.15m of polystyrene. The module is 2.7 m in height and 0.5 m in width. In front of reinforced concrete, a steel heat pipe filled with a phase-change thermodynamic medium is located vertically. Heat pipes are connected to the two feed water collectors (hot and cold), which are embedded horizontally in the front part—hot water at the bottom and chilled water at the top.
Figure 1 shows a cross-section of the tested module, indicating the dimensions of the module and the location of the water collector and the heat pipe. The heat pipe embedded in the module is shaped approximately in the form of a sinusoid running between the collectors. The horizontal parts of the tube were arranged in the module at a distance of 10 cm from each other and 10 cm from the side edge. The horizontal parts of the heat pipe with a length of 4 × 10 cm are placed in the special design of the collector (
Figure 1c). The heat pipes are made of stainless steel, with a smooth surface on the inside and outside. The heat pipes are filled with a thermodynamic medium, the composition of which is covered by a patent.
The main function of the tested building module is heating and cooling of the internal space—supplying the room with heat or cold as required to maintain thermal comfort (as a single source or as a supporting element of installation). Large heat exchange surfaces allow for the use of low-temperature heat sources. Module can be also used as an element which is filling the load-bearing structure of the building (as an external, internal partition) and for additional insulation, limiting heat loss from the room to the external environment (on the external side, the module has additional insulation—a 15 cm thick layer of polystyrene).
The possibility of performing different functions simultaneously is the main advantage of the analyzed module. It is achieved by placing two collectors in one module, which allows it to operate both in heating mode (after supplying the lower collector of the module with hot water) and in cooling mode (after supplying the upper collector of the module with cold water).
The research conducted within the project No. RPMA.01.02.00-14-9558/17 “Innovative and ecological heating and cooling system with composite prefabricated wall elements”, supported by the Regional Operational Program of the Mazowieckie Voivodeship, aimed to experimentally determine the thermal parameters of the module (its thermal and cooling power), as well as the value and range of changes in its control parameters as a control object (while maintaining thermal comfort in the room). In order to perform tests and measurements, a measuring station was built on which a wall module was mounted and connected to the heat and cooling source by means of a hydraulic installation. A detailed description of the research, the measuring devices used and their accuracy, and the methodology for obtaining the results, is provided in [
13].
Based on the results of the conducted research, the following can be stated:
- 1.
Relatively low thermal efficiency of the module is observed, both in cooling and heating mode [
13,
29]. The most important factors that limit the power of the module in the tested design are as follows:
- -
The high thermal resistance in the heat exchange process between the supply water from the heating/cooling system and the thermodynamic medium in the heat pipe;
- -
The wrong proportion of the mixture used as the thermodynamic medium;
- -
Improperly placed reinforcement in the reinforced concrete material of the module.
The current design can only be used in selected cases. This article examines the types of buildings and spaces in which the tested model can be used in its current form (structure). Ultimately, a change to the module’s design is required to improve its efficiency and expand its application area.
- 2.
Large changes in the module control parameters, including large values of time constants and a strong dependence of the gain coefficient on the direction of the change in the supply water temperature, require complex control algorithms. Standard control algorithms, or a cascade structure of the control system, may prove insufficient. It will be necessary to use predictive algorithms, with the prediction of the required thermal power of the module with a time horizon of at least 1–2 h. Of course, in this case, the simplest 2-state on–off control algorithm can also be used. However, such an algorithm is not used when maintaining thermal comfort in rooms due to the low quality of control.
A detailed description of the results of the research is provided in [
13].
4. Analysis of Results
The comparison of the cooling/heating demand of the analyzed rooms with the maximum power that can be obtained from the installed heating and cooling modules is presented in
Table 6 (for cooling) and
Table 7 (for heating).
4.1. Analysis of a Hotel Room
Analyzing the results obtained for a hotel room, it can be concluded that the decisive parameter for the use of modules is the number and size of windows in the room, as they determine the amount of heat gain and loss.
In the case of a room with a single external window, which constitutes 25% of the external walls area, the heating and cooling panels are able to meet the cooling and heating needs of the room with a safe surplus, regardless of orientation and location. With this surplus, the number and location of panels can even be optimized, for example, by maintaining only the ceiling cooling or reducing the number of wall panels.
In the case of a room with two windows, which, in the analyzed example, constitute approximately 50% of the external walls’ area, the panels are only able to meet the cooling needs of the room with a north-facing window. For other exposures and locations, the panels are unable to provide the required cooling and heating power. However, in such facilities, mechanical supply and exhaust ventilation is used, which, in winter, can supply air at a temperature higher than the room temperature, providing additional heating capacity. In the case of the analyzed double room, the supply air temperature would need to be increased by approximately 10 K above the room temperature. Due to the possible Coanda effect, the range of the supply air stream should be checked. Unfortunately, even using ventilation air at a temperature reduced by 10 K will not cover the maximum heat gains for the south façade. Therefore, additional simulations were performed to determine the limiting window area for which the panels would be able to cover the heat gains. Calculations showed that the limiting value is a window area of approximately 35% of the external wall area, at which the cooling capacity of the installed modules will be able to assimilate the heat gains for the hotel room, regardless of the window façade. Another solution to limit heat gain is the use of appropriate shading screens to reduce the inflow of low solar radiation (increasing the shading coefficient fC).
4.2. Analysis of a Multi-Family Residential Building
In the case of north-facing living spaces (and bedrooms), the panels are sufficient to meet the cooling needs of these rooms. For south-facing bedrooms, the panels are also sufficient to meet the cooling needs, but without excess heat. Therefore, the stated share of windows in the building envelope area (30%) should be assumed as the maximum. For all other exposures and locations of living spaces, the panels are unable to provide the required cooling and heating capacity. In these types of rooms, besides windows, the main source of heat gain is external infiltration air. In Poland, mechanical exhaust ventilation systems from kitchens and bathrooms are common for living spaces. This causes an inflow of external air into the remaining rooms of the apartment at an uncontrolled flow rate and uncontrolled infiltration air temperature, which typically increases heat gains in summer and heat losses in winter. The analysis of the impact of changing the window area on the thermal balance of the rooms did not yield any measurable results. To achieve thermal balance in this type of room, it is necessary to change the mechanical supply and exhaust ventilation system or use an additional (in addition to the modules) heating and cooling installation.
4.3. Analysis of a Classroom
For a classroom, regardless of its exposure or location, panels cannot provide the required cooling and heating capacity. In such facilities, the decisive parameter shaping heat gains is the number of occupants and the heat gains they generate. As with hotels, mechanical supply and exhaust ventilation should be installed in these facilities to maintain carbon dioxide concentrations below acceptable limits. This system, with the supply of warm or cold air, can balance the room’s thermal balance in both summer and winter. For heating, increasing the supply air temperature by a maximum of 5K above the required room temperature would be sufficient. For cooling, it can be assumed that for a 15-person classroom, the cooling capacity supplied by ventilation air is approximately 1206 W, which will balance cooling for a north-facing room. However, for a south-facing room, there will still be an approximately 20% deficit, which can be eliminated by increasing the ventilation airflow. However, it should be noted that the calculations for all analyzed rooms were made for maximum heat gain values throughout the year, while most school buildings are not used during the holiday months when maximum outside temperatures occur.