Appendix 1 Definition of baseline model
In this analysis, we assumed one 50-L and one 100-L single-door baseline refrigerator models to estimate cost-efficiency relationships for off- and micro/mini-grid uses. The key specifications of the baseline models are adjusted from those of two “category 1” basic technical models (42-L and 107-L refrigerators) described in a recent EU study (VHK and ARMINES 2016). Table 6 summarizes the key specifications.
Table 6 Characteristics of off-grid baseline refrigerator models Volume, envelope surface, and wall thickness
We assumed two baseline models (50-L and 100-L) with an average wall thickness of 3.8 cm (1.5 in.) and calculated the refrigerator envelope surface areas by adjusted size and wall thickness.
Compressor COP and cooling power
We assess the compressor efficiency (COP 1.7) of the EU basic technical models to be relatively high for small refrigerators. Commercially available single-speed compressors used in small refrigerators (e.g., with capacity less than 75 W, < 250 Btu/h) were assessed to be significantly less efficient than the typical compressors used in larger size refrigerators, e.g., COP 1.0 or less (VHK and ARMINES 2016; U.S. DOE 2011). However, in Europe, similar size compressors (R600a iso-butane) with COP 1.4 or above were available in 2015 (VHK and ARMINES 2016). VHK and ARMINES (2016) integrated category 1 and other relevant product categories into a new product category, “COLD 1,” and assumed the COP of the baseline COLD 1 product (which is approximately 250 L and uses an approximately 60-W compressor) to be about 1.6. In this analysis, we assumed the compressor COP of the baseline products is 1.4 based on the findings from VHK and ARMINES (2016). Accordingly, the cooling power of the baseline models increase compared with the cooling power of the models studies in VHK and ARMINES (2016).
Annual energy consumption
The annual energy consumption per refrigerated volume for the EU basic technical model is estimated to be 1.8 kWh/L for a 42-L unit and 0.8 kWh/L for a 107-L unit (VHK and ARMINES 2016). (Energy consumption per volume of small refrigerators is greater than energy consumption per volume of large refrigerators.) However, the 42-L technical model is assessed to be more efficient than both the EU label A+ threshold and a statistical regression result from data on commercially available products (VHK and ARMINES 2016). In this analysis, we used the curve expressed in Eq. (7) from VHK and ARMINES (2016), which is close to the EU label A+ threshold, resulting in 2.3 kWh/L and 1.2 kWh/L for our baseline 50-L and 100-L models, respectively. Note that EU label A+–qualified models, except for wine coolers, accounted for about 70% of the European market in 2014 (VHK and ARMINES 2016).
$$ \mathrm{Annual}\ \mathrm{Energy}\ \mathrm{Consumption}\ \left(\frac{\mathrm{kWh}}{\mathrm{L}}\right)=110\times {\mathrm{Volume}}^{-1}+0.1 $$
(7)
Equation (7) is based on the EU test standard with ambient temperature of 25 °C. We use an adjustment factor of 1.8 to scale energy use from a test standard based on IEC 62252:2007 (test ambient temperature 25 °C) to the US standard (test ambient temperature 32 °C), based on the findings from APEC (2016). As the result, the estimated annual electricity consumption based on the US test standard with an ambient temperature 32 °C is 207 kWh/year for the 50-L baseline model and 216 kWh/year for the 100-L baseline model. These are about 11–12% more efficient than the US MEPS for compact refrigerators with manual defrost (233 kWh/year for 50 L and 247 kWh/year for 100 L).
Appendix 2 Development of cost-efficiency relationship in refrigerators
Increasing insulation thickness
Increase in insulation thickness results in decreased interior volume, increased exterior cabinet dimensions, or a combination of both, which affects incremental cost and consumer utility (U.S. DOE 2011). Wall thickness cannot increase indefinitely. Limited spaces for refrigerators restrict how much exterior product size can increase, and reducing interior volume is considered undesirable because it affects consumer utility (U.S. DOE 2011). For these reasons, U.S. DOE (2011) did not consider a significant increase in insulation thickness (see Table 7). However, commercially available energy-efficient DC refrigerators use thick insulation, e.g., 11-cm polyurethane for SunDanzer’s DCR50 and DCF 50, which suggests that increased volume may not be as much of a constraint in the off-grid market as the on-grid market. Benefit from VIPs can also be obtained by increasing insulation thickness. We here assume that insulation can be increased up to 10 cm with concomitant increased exterior dimensions, based on practical limits estimated by previous studies (VHK and ARMINES 2016; U.S. DOE 2011).
Table 7 Energy savings and incremental costs resulting from increasing insulation thickness To estimate the costs of increasing insulation thickness (resulting in increased exterior product dimensions) and corresponding reduction in energy consumption, we adjust estimates from other studies. According to U.S. DOE (2011), the materials cost for a 2-cm increase in insulation thickness is $2.6–3.4 (for products of 50 to 110 L), and the largest share of the total incremental cost of $16 comes from depreciation ($10), which would require redesign of the entire refrigerator platform, likely requiring that a new production plant be built. VHK and ARMINES (2016) also assumed that an increase in insulation thickness results in increased exterior cabinet dimensions. The study estimated increasing insulation up to 10 cm to reduce energy consumption up to 29–41% by product type and specifications (VHK and ARMINES 2016).
Although the baseline compact refrigerator models defined in U.S. DOE (2011) have similar sizes and specifications to those of our baseline models, the depreciation cost for potentially building a new production facility is not appropriate to use in this analysis. The estimated envelope surface areas of the 50-L and 100-L baseline models are about 36% and 53% of that of the 247-L model in VHK and ARMINES (2016). According to VHK and ARMINES (2016), the incremental cost required to increase insulation thickness by 1 cm is about $13–$15. Based on this relationship, we assume that the efficiency rates of our 50-L and 100-L baseline refrigerators improve by 18% and 25%, respectively, from increasing insulation thickness by 2 cm (see Table 7 for details). The incremental cost associated with this is calculated by $14 × 2 cm × 36% = $10.1 for the 50-L model and $14 × 2 cm × 53% = $14.8 for the 100-L model.
Vacuum insulation panels
Typically, 2-cm-thick VIPs are used to replace standard insulation. VIPs are estimated to reduce energy consumption collectively by 23% for the 247-L base-case model in VHK and ARMINES (2016). This improvement can be achieved without increasing insulation thickness. U.S. DOE (2011) estimated an efficiency improvement potential from adding VIPs to increase refrigerator insulation, but U.S. DOE’s estimated incremental costs appear outdated compared with those in VHK and ARMINES (2016).
The baseline compact refrigerator models defined in U.S. DOE (2011) are similar in size and specifications to our baseline models, so we assume that adding VIPs of similar size to those applied in U.S. DOE (2011) can reduce the energy consumption by 10–20%. We estimate the size of VIPs used in VHK and ARMINES (2016) to be 5481 cm2 (70% of 7830 cm2) and the manufacturing cost to be $0.004/cm2. We assume that adding 4000 cm2 (~ 70% of door covered) of VIPs in the cabinet and 1850 cm2 (~ 50% of lateral and back sides covered) of VIPs to the door would cost about $24 for our 50-L baseline model and that adding 6100 cm2 (~ 70% of door covered) of VIPs in the cabinet and 2850 cm2 (~ 50% of lateral and back sides covered) of VIPs in the door would cost about $36 for our 100-L baseline model.
Table 8 Energy savings and incremental costs by using vacuum insulation panels
Efficient compressors
As discussed earlier, we assumed the compressor COP of our baseline products to be 1.4 based on findings from VHK and ARMINES (2016). According to VHK and ARMINES (2016), compressors with COP 1.7 are available for all cooling capacities. The incremental costs for efficient compressors are estimated to be about $4–$5 for 0.1 improvement in nominal COP (W/W) based on VHK and ARMINES (2016) and U.S. DOE (2011). We assume that the compressor efficiency improvement (COP 1.4 to 1.7 W/W) can reduce the energy consumption by 20% at an incremental cost of $15.
Table 9 Energy savings and incremental costs by compressor efficiency improvement
Variable-speed drives
U.S. DOE (2011) estimated a VSD compressor alone to improve energy efficiency by 35% at an incremental cost of $44. According to VHK and ARMINES (2016), COP and minimum capacity that can be achieved with VSD compressors vary with size of refrigerator. The study estimated that adding a VSD to base-case models reduced energy consumption by 11–28% by product category, e.g., 11% for a 247-L model. VSD compressors typically use a permanent-magnet DC motor instead of the induction motor used in a single-speed AC compressor. DC motors for VSD compressors require additional electronics compared with AC motors. Although it is difficult to precisely estimate the cost difference between DC motors and AC motors, the controls for a DC motor require additional electronics costing an additional $10–$20 (Shah et al. 2014a, b). According to comments from an industrial expert, a VSD alone can improve energy efficiency by 10–12%. While DC compressors are still very expensive in market price, a $10–$20 inverter package that converts DC into AC makes it possible to use an AC compressor with the inverter combined. This cheaper solution is already commercially available. Here, we assume that a VSD compressor with BLDC motor improves efficiency, compared with an equivalent efficient AC compressor, by an average of 23% at an average incremental cost of $27. Based on VHK and ARMINES (2016), Shah et al. (2014a, b), and U.S. DOE (2011), efficiency improvements range from 10 to 35%, and incremental costs range from $10 to $44.
Table 10 Energy savings and incremental costs for variable-speed drives
Appendix 3 Analysis results for 50-L refrigerators
Table 11 Estimated incremental cost vs. efficiency improvement compared with 50-L baseline
Appendix 4 Sensitivity of our findings to key assumptions
Our key finding is that the cost of refrigeration service can be reduced significantly by improving refrigerator efficiency. This is because the cost of the efficiency improvement is less than the savings from lowered electricity bills or smaller SHSs needed to power-efficient refrigerators compared with the costs and SHS size associated with less efficient refrigerators. There is some uncertainty about the cost of several efficiency options we discuss as well as the consumption reductions from these efficiency options. Therefore, we assess the sensitivity of our results to higher incremental efficiency improvement costs and smaller energy savings than we assume in our analysis.
Specifically, we assess whether the cost of refrigeration service can be reduced even if the efficiency improvements realized were 25% less than our assumptions (e.g., if the energy savings potential of a VSD compressor were 17%, which is 25% lower than the 23% that we assumed), and if the incremental cost of energy efficiency improvement is 25% higher than our estimates (e.g., if the incremental cost of a VSD compressor were $34, which is 25% higher than the $27 assumed in our analysis). Further, we assess whether our findings still hold true if the cost of SHSs is 25% lower than we assumed, (e.g., if PV cost was $0.38/W, which is 25% lower than the $0.50/W assumed in our analysis).
Figures 12 and 13 show annualized costs at discount rate 11.5% of refrigeration service under these alternative assumptions about costs and efficiency improvement. If the efficiency improvements realized were 25% less than our assumptions, the annualized cost of SHSs would increase by 5–24% for 50-L units and 6–21% for 100-L units, depending on design options, compared with the case analyzed in “Potential to reduce the cost of refrigeration service” section (see green dotted lines in Figs. 12 and 13). If the cost of SHSs were 25% lower than we assumed, the annualized cost of SHSs would decrease by 15–22% for 50-L units and 12–20% for 100-L units, depending on design options, compared with the case analyzed in Section 3.2 (see purple dotted lines in Figs. 12 and 13). The more efficient SHS with MPPT efficiency 95% and other efficiency 95% and the 25% higher incremental cost of energy efficiency improvements do not significantly change the annualized cost of SHSs (see blue and red dotted lines in Figs. 12 and 13). Figures 14, 15, 16, and 17 show annualized costs of refrigeration service under the same assumptions at discount rate of 8% and 15%.
Appendix 5 Estimated purchase price of solar home systems with refrigerators
Figures 18 and 19 illustrate the results of estimated SHS prices in 2017 by scenario. The total cost of SHS with a 50-L super-efficient refrigerator is expected to decrease by 13% (for lead-acid battery) and 40% (for Li-ion battery) with 63% smaller PV and battery capacities required, compared with the same energy system with a standard refrigerator. The total cost of SHS with a 100-L super-efficient refrigerator is expected to decrease by 11% (for lead-acid battery) and 42% (for Li-ion battery) with 70% smaller PV and battery capacities required, compared with the same energy system with a standard refrigerator. Although energy-efficient refrigerators cost more than less efficient models, their adoption contributes to the decline in overall solar home system cost. Similar results would also apply over a range of system sizes, appliance types, and applications.