Buildings account for a significant portion of global energy use and consumption. Buildings have substantial energy consumption due to the use of heating, ventilation, and cooling systems. It is evident that the use of insulation materials and phase change materials (PCMs) in the design of buildings can effectively reduce the cost of air conditioning by reducing external heat gains and losses. Additionally, the use of environmentally friendly, cost-effective, and natural materials can be beneficial from an environmental standpoint. This paper aims to evaluate the potential for cost savings in the air conditioning of various PCMs and insulation-stuffed building roof configurations. In that respect, four types of phase change materials (HS29, HS36, FS42, and FS30) and four insulation materials (Therma cork, sawdust, aerogel, and sheep wool) were selected. The thermophysical properties of PCMs (solid and liquid state), insulation materials, and building elements were determined experimentally as per ASTM D 5334 standards. Ten various building roof models (contemporary roof pattern) are studied with four various PCMs and four various insulations. In addition, novel building roof design integrated with PCM/insulation were analysed numerically, related to environmental conditions that refer to two different scenarios in India (hot dry and composite climates). It further analyses the reduction in greenhouse gas emissions associated with different roof configurations. The aforementioned PCM/insulation materials were stuffed in the void spaces of the contemporary roof pattern. Thermo-economic analysis of novel roof design with PCM/insulation materials on air-conditioning costs, carbon dioxide emissions and payback time are compared with conventional roofs (CR) and contemporary roof patterns (CRP). The thermo-economic analysis was carried out based on the number of degree-hours of heating and cooling to determine the building's annual energy usage. HS29 PCM stuffed roof pattern (HS29RP) saved the highest total energy cost savings of 11.89/14.71 $/m2/year when compared with conventional roof and 11.35/13.89 $/m2/year compared with contemporary roof pattern for Jabalpur/Kota climatic conditions. HS29 PCM stuffed roof pattern (HS29RP) exhibits the maximum carbon emission mitigation of 215.32/275.37 kg/kWh when compared with conventional roof and 204.95/259.57 kg/kWh for climatic conditions of Jabalpur/Kota. While considering shortest payback span, sawdust stuffed roof pattern shows the minimum payback period of 0.69 and 2.15 years when compared with conventional roof and contemporary roof pattern. The findings of this research offer significant contributions to the development of energy-efficient building envelopes applicable to a wider range of buildings, including those with and without air conditioning systems.
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