Case study: reducing heating energy consumption in a high tunnel greenhouse with renewable energy and microclimate control by bench-top root-zone heating, bench covers, and under-bench insulation

Abstract

Appalachian State University's Nexus project designed an efficient greenhouse heating system that integrated renewable energy and root zone heating technology to reduce the greenhouse heating energy burden on local farmers and installed it at local cooperative farms. This study analyzed 5 years of data from 2018 to 2022 to investigate the energy savings and microclimate control effectiveness of the Nexus heating system installed at Springhouse Farm in North Carolina, USA. By varying bench cover materials, bottom insulation, and the number of loops of root zone tubing, the different soil temperatures required for plant types and growth stages were achieved with a single temperature controller. A root zone heating fluid of 32.2 ℃ satisfactorily maintained the germination soil between 20 and 25 ℃ in March 2019 with an average outside temperature of 4.8 ℃ and an average low temperature of − 0.4 ℃. Growing soil maintained an average temperature of 15 ℃ with bottom insulation and an average of 11–12 ℃ without bottom insulation. Compared to the conventional heating system (a forced-air propane unit heater alone), weather-adjusted propane consumption (propane usage divided by heating degree days) was reduced by 65% with the Nexus system alone and 45% with the Nexus system and unit heater together. It shows that the Nexus system has significantly reduced greenhouse heating energy consumption and maintained productive conditions. The renewable energy fraction ranged only 9–13% of the total thermal energy used due to the high inlet temperature entering the solar thermal collector. This can be improved by separating the heat storage and backup heat source.