Frost, defrost, and refrost and its impact on the air-side thermal-hydraulic performance of louvered-fin, flat-tube heat exchangers

The thermal-hydraulic performance under conditions of an initial frost growth on the air-side surface, and for subsequent ‘refrosting’ after a defrost period is experimentally studied for folded-louvered-fin, microchannel heat exchangers. In total, five heat exchangers are considered; the thermal performances during one frost-growth cycle for four different fin geometries are compared in terms of overall heat transfer coefficient, pressure drop, and j and f factors; the defrost and refrost characteristics of two heat exchangers are compared to explore geometry effects. Typically, the performance under refrosting conditions becomes periodic and repeatable after the third or fourth refrosting cycle. The allowable frost growth period (before a defrost is required), the defrost requirement, and the thermal-hydraulic performance depend on heat exchanger geometry for the specimens used in this study.     

Development of a design tool for display case evaporators

A model for simulating a fin-and-tube display case evaporator has been developed to serve as a design tool for improving performance in frosting conditions. It is capable of simulating cross-counterflow evaporators with multiple modules having completely different geometries. Quasi-steady heat and mass transfer calculations provide local values of all relevant variables, including heat and mass transfer coefficients, air and refrigerant-side pressure drops and fin and tube frost thicknesses. A multi-lump method enables the model to simulate both tube and fin frost thicknesses and surface temperatures. The results presented in this paper reflect interactions with the display case and its air curtains and predict local and overall effects of frost accumulation, to facilitate optimization of the larger display case system.     

Modeling and performance analyses of evaporators in frozen-food supermarket display cabinets at low temperatures

This paper presents modeling and experimental analyses of evaporators in “in situ” frozen-food display cabinets at low temperatures in the supermarket industry. Extensive experiments were conducted to measure store and display cabinet relative humidities and temperatures, and pressures, temperatures and mass flow rates of the refrigerant. The mathematical model adopts various empirical correlations of heat transfer coefficients and frost properties in a fin-tube heat exchanger in order to investigate the influence of indoor conditions on the performance of the display cabinets. The model is validated with the experimental data of “in situ” cabinets. The model would be a good guide tool to the design engineers to evaluate the performance of supermarket display cabinet heat exchangers under various store conditions.     

Frost retardation of an air-source heat pump by the hot gas bypass method

This study is concerned with a hot gas (refrigerant) bypass method to retard the formation and propagation of frost in an air-source heat pump. The feasibility of the hot gas bypass method was investigated experimentally and the method's performance is compared with that of a normal, 1.12 kW capacity air-source heat pump system with no defrost equipment such as an electric resistance heater. Results indicate that the hot gas bypass method is useful for retarding the formation and growth of frost at the outdoor coil. The best performance is shown under a bypass refrigerant flow rate of 0.2 kg/min (20% of the whole system refrigerant flow rate). During 210 min of heat pump operation, the hot gas bypass method improved COP and heating capacity at an average of 8.5% and 5.7%, respectively, relative to the normal system.     

The application of photo-coupler for frost detecting in an air-source heat pump

This experimental study is carried out to investigate reliability and effectiveness of a new method of using photo-coupler for detecting frost formation in an air source heat pump, and further to determine the most efficient initiation point of the defrost cycle. This new method of using photo-coupler as a frost sensing device is evaluated by comparing its performance with conventional time control defrost system in which defrost cycle is set to start at predetermined interval, e.g. about at every 1–1.5 h. Results indicate that overall heating capacity of photo-coupler detection method (case IV) is 5.5% higher than that of time control method. It is also shown that for maximum efficiency the defrost cycle must be initiated before the frost build-up area exceeds 45% of total front surface of the outdoor coil.     

Modeling of frosting behavior on a cold plate

This paper proposes a mathematical model to predict the frost properties and heat and mass transfer within the frost layer formed on a cold plate. Laminar flow equations for moist air and empirical correlations for local frost properties are employed to predict the frost layer growth. Correlations for local frost density and effective thermal conductivity of the frost layer, derived from various experimental data, are expressed as a function of the various frosting parameters: the Reynolds number, frost surface temperature, absolute humidity and temperature of the moist air, cooling plate temperature, and frost density. The numerical results are compared with experimental data to validate the proposed model, and those agree well with the experimental data within a maximum error of 10%. Heat and mass transfer coefficients obtained from the numerical analyses are also presented. The results show that the model for the frost growth using the correlation of the heat transfer coefficient without considering the air flow has a limitation in its application.     

Fan supplied heat exchanger fin performance under frosting conditions

In this paper, a validated numerical model for frost growth on heat exchange fins is modified to simulate a fan-supplied finned heat exchanger under refrigeration frosting conditions. It is found that frost growth on refrigeration heat exchangers causes a dramatic drop in the fin heat rate, airflow rate, and fin efficiency while the pressure drop increases. A sensitivity study shows the effects of changing several design parameters including the type of fan.     

Modeling of frost growth and frost properties with airflow over a flat plate

A physical model of frost layer growth and frost properties with airflow over a flat plate at subfreezing temperature was developed. Frost roughness was measured, and an empirical correlation for the average frost roughness was suggested. Heat and mass transfer coefficients were calculated using the modified Prandtl mixing-length scheme containing the effects of both frost roughness and turbulent boundary layer thickness. Frost thermal conductivity was theoretically analyzed by solving the combined equations of air equivalent conductivity and thermal conductivity of the frost inner layer. Based on the present model, heat and mass transfer coefficient, frost thermal conductivity, frost thickness, frost mass concentration and frost density with time and space were estimated. The model showed good agreement with the basic trends of the test data taken from other literature. Spatial and temporal changes of heat flux and frost surface temperature were also investigated.     

Experimental investigation of the performance of industrial evaporator coils operating under frosting conditions

This paper describes a field experimental investigation of the effects of frost formation on the performance of a low-temperature large-scale evaporator coil used in industrial refrigeration systems. A series of experiments were conducted to determine the in situ coil cooling capacity of the evaporator over time as frost builds on its surfaces. Field-measured quantities include inlet and outlet air temperatures, inlet and outlet air relative humidity, and air volume flow rate. These measurements provide a baseline set of experimental data that can be used to validate numerical models of industrial evaporators operating under frosting conditions.     

An experimental study on frosting of laminar air flow on a cold surface with local cooling

This paper presents the heat and mass transfer characteristics of the humid airflow in frosting conditions. A flat plate of aluminum with cooling modules at the central region was used for the simulation of flat surface part of the fin of the heat exchanger. The local surface temperature of the plate and the local thickness and total mass of the frost on the plate were measured to analyze the heat and mass transfer characteristics. In order to analyze the frosting characteristics, an analysis algorithm was developed, which can provide the local air temperature, the frost surface temperature, the sensible and the latent heat flux distributions at the test plate. Also, by integrating the local heat flux distribution, the average heat flux characteristics were analyzed. The present experiment and analysis found that the characteristic of the upstream airflow was very different from that of the downstream airflow.     

Refrigerant flow instability as a means to predict the need for defrosting the evaporator in a retail display freezer cabinet

For refrigerated display cabinets to perform their function of keeping food cold, there must be free movement of air through the evaporator. The moisture in the ambient air entrained in the cabinet forms frost on the evaporator. It is traditional for heat to be applied to the evaporator at regular intervals to melt this frost. The frequency, typically 3–4 times per day, is enough to avoid the frost becoming excessive even in extreme conditions. For much of the time defrosting is not always necessary. A large portion of the energy used during a defrost is an overhead – heating and then cooling the metal and the food rather than melting the frost. The effect of this is examined in the paper along with the results from testing an algorithm that detects the need for a defrost from the pattern of refrigerant flow (or evaporator exit superheat). The algorithm allows the number of defrosts to be reduced without excessively raising the temperature of food stored in the cabinet. The reduction in energy and carbon dioxide emission were examined and were shown to be substantial.     

Frost formation and heat transfer on a cold surface in ice fog

In this paper a semi-empirical model describing heat and mass transfer on a cold surface in humid air under supersaturated frosting conditions is presented. The lack of psychrometric data in the supersaturated zone of the psychrometric chart has historically impeded the ability of researchers to accurately predict heat and mass transfer in supersaturated air. The work described in this paper has been partially made possible by developing a systematic procedure to compute the properties of supersaturated air, especially in the low temperature zone of the psychrometric chart. Development of such a capability will allow us to predict the amount of frost collected, the frost deposition and heat transfer rates, frost thickness and surface temperature, and other important parameters.     

An analysis of the feasibility and characteristics of photoelectric technique applied in defrost-control

An innovative photoelectric technology is presented in this paper for detecting frost in the field of defrost-control of refrigerator or freezer applications. Experiments were conducted with a small-scale laboratory test section under natural convection conditions. Two agreeable properties of the new technology, “on–off” and “linear”, have been demonstrated by the experiments. The first property provides an effective judgment of the defrost-control strategy while the second one is suitable for developing an accurate measurement of the frost height. The characteristics (electric current, environment temperature, metal surface temperature, light intensity and sensor location) that affect the properties were investigated for the development of this technology.     

Air-side heat transfer enhancement of a refrigerator evaporator using vortex generation

In most domestic and commercial refrigeration systems, frost forms on the air-side surface of the air-to-refrigerant heat exchanger. Frost-tolerant designs typically employ a large fin spacing in order to delay the need for a defrost cycle. Unfortunately, this approach does not allow for a very high air-side heat transfer coefficient, and the performance of these heat exchangers is often air-side limited. Longitudinal vortex generation is a proven and effective technique for thinning the thermal boundary layer and enhancing heat transfer, but its efficacy in a frosting environment is essentially unknown. In this study, an array of delta-wing vortex generators is applied to a plain-fin-and-tube heat exchanger with a fin spacing of 8.5 mm. Heat transfer and pressure drop performance are measured to determine the effectiveness of the vortex generator under frosting conditions. For air-side Reynolds numbers between 500 and 1300, the air-side thermal resistance is reduced by 35–42% when vortex generation is used. Correspondingly, the heat transfer coefficient is observed to range from 33 to 53 W m⁻² K⁻¹ for the enhanced heat exchanger and from 18 to 26 W m⁻² K⁻¹ for the baseline heat exchanger.     

Development of a slug flow absorber working with ammonia–water mixture: part II—data reduction model for local heat and mass transfer characterization

This study deals with a data reduction model for clarifying experimental results of a counter-current slug flow absorber, working with ammonia–water mixture, for significantly low solution flow rate conditions. The data reduction model to obtain the local heat and mass transfer coefficient on the liquid side is proposed by using the drift flux model to analyze the flow characteristics. The control volume method and heat and mass transfer analogy are employed to solve the combined heat and mass transfer problem. As a result, it is found that the local heat and mass transfer coefficient on the liquid side of the absorber is greatly influenced by the flow pattern. The heat and mass transfer coefficient at the frost flow region is higher than that at the slug flow region due to flow disturbance and random fluctuation. The solution flow rate and gas flow rate have influence on the local heat and mass transfer coefficient at the frost flow region. However, it is insignificant at the slug flow region.     

Energy-efficient flat-tube heat exchangers for indirectly cooled display cabinets

Different designs of flat-tube heat exchangers with plain fins have been evaluated theoretically in a parameter study in order to evaluate their performance potential in indirectly cooled display cabinets. Two different types of flat-tube heat exchangers were considered; one with serpentine fins and one with continuous plate fins. Both flat-tube heat exchanger types were adapted to the laminar flow regime on the liquid as well as on the air side. The performance of the two heat exchanger types had previously been verified experimentally under dehumidifying conditions. The results from this parameter study show that considerable savings in the required electric drive power to compressors, pumps and fans can be obtained in comparison with the traditional cooling coil. The savings may be up to 15%. In addition, the required temperature difference for the flat-tube heat exchangers is so small that frost-free operation is possible, which would result in even larger savings.     

A design method of thermoelectric coolerConception d'un refroidisseur thermoélectrique

A system design method of thermoelectric cooler is developed in the present study. The design calculation utilizes the performance curve of the thermoelectric module that is determined experimentally. An automatic test apparatus was designed and built to illustrate the testing. The performance test results of the module are used to determine the physical properties and derive an empirical relation for the performance of thermoelectric module. These results are then used in the system analysis of a thermoelectric cooler using a thermal network model. The thermal resistance of heat sink is chosen as one of the key parameters in the design of a thermoelectric cooler. The system simulation shows that there exists a cheapest heat sink for the design of a thermoelectric cooler. It is also shown that the system simulation coincides with experimental data of a thermoelectric cooler using an air-cooled heat sink with thermal resistance 0.2515°C/W. An optimal design of thermoelectric cooler at the conditions of optimal COP is also studied. The optimal design can be made either on the basis of the maximum value of the optimal cooling capacity, or on the basis of the best heat sink technology available.     

Irreversible refrigerators with isothermal heat exchanges: Réfrigérateurs irréversibles avecéchanges thermiques isotherms

A maximum for the coefficient of performance (COP_f) is verified for a temperature difference between reservoirs and the hot isotherm of a closed irreversible cyclical refrigerator working at steady-state conditions. A maximum also exists when the COP_f is considered as a function only of a parameter depending on the thermal characteristics of the heat exchangers. The influence of the parameter and entropy generation on the COP_f maxima is described.     

Experimental study of warm-air defrosting of heat-pump evaporators

The defrosting of a heat-pump evaporator with warm air has been investigated experimentally under controlled conditions in an air-conditioned wind tunnel. The work was initiated to explore the possibility of defrosting an evaporator under conditions where a heat pump continues to perform heating duty. A four-row straight-fin heat exchanger was used, supported from below by a load transducer to measure its weight variation during both frost accumulation and removal. The rate of melting was determined as a function of air temperature, relative humidity and velocity. The removal from the evaporator surfaces of water produced by defrosting was found to be dependent on air velocity. Proposals are advanced for further experimental studies.     

An elemental NTU- model for vapour-compression liquid chillers

This paper presents a steady-state model for predicting the performance of vapour-compression liquid chillers over a wide range of operating conditions. The model overcomes the idealisations of previous models with regard to modelling the heat exchangers. In particular, it employs an elemental NTU- methodology to model both the shell-and-tube condenser and evaporator. The approach allows the change in heat transfer coefficients throughout the heat exchangers to be accounted for, thereby improving both physical realism and the accuracy of the simulation model. The model requires only those inputs that are readily available to the user (e.g. condenser inlet water temperature and evaporator water outlet temperature). The outputs of the model include system performance variables such as the compressor electrical work input and the coefficient of performance (COP) as well as states of the refrigerant throughout the refrigeration cycle. The methodology employed within the model also allows the performance of chillers using refrigerant mixtures to be modelled. The model is validated with data from one single screw chiller and one twin-screw chiller where the agreement is found to be within ±10%.