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.     

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.     

Performance of finned-tube heat exchangers under frosting conditions: I. Simulation model

This paper describes an analytical model that was developed to predict the performance of finned-tube heat exchangers under frosting conditions. The method models the frost growth mechanism and heat exchanger performance in a comprehensive manner. The results include frost accumulation and its effect on energy transfer in relation to varying humidities, fin densities and ambient conditions.     

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.     

A study on airside performance of geometry combination fins using large scale model

This study investigated the pressure drop and heat transfer characteristics of heat exchanger according to the arrangement of fins as well as fin configuration by the similitude experiments with the finned-tube geometry scaled as large as four times. Colburn j factor, Fanning friction factor, f, and goodness factors are compared to each other to estimate performance of each case for four different kinds of fins, which are louver, double side slit, single side slit and plain fin. Results show that heat transfer would be altered by fin arrangement and that friction loss is more affected by fin configurations than by the fin arrangements. In particular, heat transfer depends more on the shape of front row than that of rear row. The heat transfer rate of combined fin arrangement increases a lot more under the same pressure drop than that of conventional fin arrangement. This indicates that the heat exchanger of higher efficiency would be designed by the proper combination of fins of different shapes.     

Assessment of condensation heat transfer correlations in the modelling of fin and tube heat exchangers

This is the second paper of a series that assesses the performance of a refrigeration system model by means of cycle parameters. In this case, the condensation temperature is the parameter to study and it is focused on fin and tube condensers. It also studies the influence of the heat transfer models on the estimation of this refrigeration cycle parameter and different correlations for the heat transfer coefficients have been implemented in order to characterise the heat transfer in the heat exchangers. The flow inside the heat exchangers is considered one-dimensional as in previous works. In the cycle definition, other submodels for all the cycle component have been taken into account to complete the system of equations that characterises the behaviour of the refrigeration cycle. This global system is solved by means of a Newton–Raphson algorithm and a known technique called SEWTLE is used to model the heat exchangers. Some experimental results are employed to compare the condensation temperatures provided by the numerical procedure and to evaluate the performance of each heat transfer coefficient. These experimental results correspond to an air-to-water heat pump and are obtained by using R-22 and R-290 as refrigerants.     

Heat transfer enhancement by winglet-type vortex generator arrays in compact plain-fin-and-tube heat exchangers

The potential of winglet type vortex generator (VG) arrays for air-side heat transfer enhancement is experimentally evaluated by full-scale wind-tunnel testing of a compact plain-fin-and-tube heat exchanger. The effectiveness of a 3VG alternate-tube inline array of vortex generators is compared to a single-row vortex generator design and the baseline configuration. The winglets are placed in a common-flow-up orientation for improved tube wake management. The overall heat transfer and pressure drop performance are assessed under dry-surface conditions over a Reynolds number range based on hydraulic diameter of 220 ≤ Re ≤ 960. It is found that the air-side heat transfer coefficient increases from 16.5% to 44% for the single-row winglet arrangement with an increase in pressure drop of less than 12%. For the three-row vortex generator array, the enhancement in heat transfer coefficient increases with Reynolds number from 29.9% to 68.8% with a pressure drop penalty from 26% at Re = 960 to 87.5% at Re = 220. The results indicate that vortex generator arrays can significantly enhance the performance of fin-tube heat exchangers with flow depths and fin densities typical to those used in air-cooling and refrigeration applications.     

Air-side thermal hydraulic performance of multi-louvered fin aluminum heat exchangers

An experimental study on the air-side heat transfer and pressure drop characteristics for multi-louvered fin and flat tube heat exchangers has been performed. For 45 heat exchangers with different louver angles (15–29°), fin pitches (1.0, 1.2, 1.4 mm) and flow depths (16, 20, 24 mm), a series of tests were conducted for the air-side Reynolds numbers of 100–600, at a constant tube-side water flow rate of 0.32 m³/h. The inlet temperatures of the air and water for heat exchangers were 21 and 45°C, respectively. The air-side thermal performance data were analyzed using effectiveness-NTU method for cross-flow heat exchanger with both fluid unmixed conditions. The heat transfer coefficient and pressure drop data for heat exchangers with different geometrical configurations were reported in terms of Colburn j-factor and Fanning friction factor f, as functions of Reynolds number based on louver pitch. The general correlations for j and f factors are developed and compared to other correlations. The f correlation indicates that the flow depth is one of the important parameters for the pressure drop.     

Experimental investigation of adverse effect of frost formation on microchannel evaporators,part 1: Effect of fin geometry and environmental effects

This study experimentally investigated the frost growth on louvered folded fins in microchannel heat exchangers when used in outdoor air-source heat pump systems. The effects of surface temperature, fin geometries, and air environmental conditions were studied. The overall aim was to isolate and quantify the effect of geometry from surface temperature effects. Experimental data of frost weight, local frost thickness, air pressure drop across the coils, time of frost–defrost cycles and heat transfer rates were recorded. Data showed that the frosting time and the frost growth rates depended mainly on the local fin surface temperature. Lower fin density was beneficial because it delayed the blockage of the air flow. The fin length and fin depth had minor effects on frosting performance. The air humidity had a fairly significant effect on rate of frost formation while air velocity seemed to have a small effect on the frost growth rate.     

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.     

Experimental investigation of the surface temperature and water retention effects on the frosting performance of a compact microchannel heat exchanger for heat pump systems

Frost formation on a louvered fin microchannel heat exchanger was experimentally investigated in this paper with the aim of determining the dominant factors affecting the time of frosting and frost growth rate. A novel methodology was developed to measure frost thickness and frost weight at intervals during the frosting period. Frost mass and thickness growth rates, corresponding coil heat transfer, capacity degradations and air pressure drop are measured and discussed. The experimental data showed that at a given air dry bulb temperature, the fin surface temperature and air humidity are the primary parameters that influence the frost growth rates. Water retention and air velocity had a secondary impact on the frosting performance. From digital images of the frost growth it was observed that frost does not nucleate from the water droplets retained in between fins but it developed from the leading edges of the fins.     

Heat transfer characteristics of flat plate finned-tube heat exchangers with large fin pitch

The objective of this study is to provide experimental data that can be used in the optimal design of flat plate finned-tube heat exchangers with large fin pitch. In this study, 22 heat exchangers were tested with a variation of fin pitch, number of tube row, and tube alignment. The air-side heat transfer coefficient decreased with a reduction of the fin pitch and an increase of the number of tube row. The reduction in the heat transfer coefficient of the four-row heat exchanger coil was approximately 10% as the fin pitch decreased from 15.0 to 7.5 mm over the Reynolds number range of 500–900 that was calculated based on the tube diameter. For all fin pitches, the heat transfer coefficient decreased as the number of tube row increased from 1 to 4. The staggered tube alignment improved heat transfer performance more than 10% compared to the inline tube alignment. A heat transfer correlation was developed from the measured data for flat plate finned-tubes with large fin pitch. The correlation yielded good predictions of the measured data with mean deviations of 3.8 and 6.2% for the inline and staggered tube alignment, respectively.     

Effects of fin shape on condensation in herringbone microfin tubes

Effects of fin height and helix angle on condensation inside a herringbone microfin tube have been experimentally investigated with five types of herringbone microfin tubes. Heat transfer coefficients are about 2–4 times higher than that of the helical microfin tube under high mass velocity conditions. In the low mass velocity, they are equal to that of the helical microfin tube. The heat transfer enhancement increases with fin height up to 0.18 mm; higher fin heights show enhancement values similar to the 0.18 mm results. Pressure drop increases with the fin height. Larger helix angle yields higher heat transfer and higher pressure drop. For the lowest fin and/or smallest helix angle, the pressure drop is comparable with that of the helical microfin tube, while the heat transfer enhancement is higher. The enhancement mechanism is discussed from flow pattern observations. Effect of mass transfer resistance for R410A is estimated and negligible effects have been proved.     

Assessment of boiling heat transfer correlations in the modelling of fin and tube heat exchangers

A new way to assess the performance of refrigeration system models is presented in this paper, based on the estimation of cycle parameters, such as the evaporation temperature which will determine the validity of the method. This paper is the first of a series which will also study the influence of the heat transfer coefficient models on the estimation of the refrigeration cycle parameters. It focuses on fin and tube evaporators and includes the dehumidification process of humid air. The flow through the heat exchanger is considered to be steady and the refrigerant flow inside the tubes is considered one-dimensional. The evaporator model is discretised in cells where 1D mass, momentum and energy conservation equations are solved by using an iterative procedure called SEWTLE. This procedure is based on decoupling the calculation of the fluid flows from each other assuming that the tube temperature field is known at each fluid iteration. Special attention is paid to the correlations utilised for the evaluation of heat transfer coefficients as well as the friction factor on the air and on the refrigerant side. A comparison between calculated values and measured results is made on the basis of the evaporation temperature. The experimental results used in this work correspond to an air-to-water heat pump and have been obtained by using R-22 and R-290 as refrigerants.     

Experimental investigation of thermal contact resistance in plain-fin-and-tube evaporators with collarless fins

The thermal contact resistance between fins and tubes in a plain-fin heat exchanger has been studied. The test coils have aluminum fins and tubes with no fin-collars. The heat-exchanger configuration under investigation was selected because this fin–tube joint is commonly used in refrigeration applications. Two coils were examined: one in the as-manufactured condition, and the other with brazed fin–tube joints—providing an intimate, metallurgical, bond between fins and tubes. Both heat exchangers were examined under dry and frosting conditions. The results show significant contact resistance in the production heat exchanger when operating under dry conditions. When frost is formed on the surface, the contact resistance is dramatically reduced to an insignificant value.     

翅片结构对换热器结霜特性影响的实验研究

本文对空气源热泵的翅片管换热器表面霜层生长特性进行实验研究,通过红外热像仪对霜层表面温度进行测量,并用热电偶直接测量装置进行校核.分析了平片、波纹片、条缝片3种翅片类型及翅片节距对霜层厚度、结霜量、换热量的影响,并用霜层-湿空气界面条件等作为传热及传质驱动力分析了霜层生长规律.实验结果表明,波纹片及条缝片翅片换热器界面...     

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.     

Dynamic behavior of a direct expansion evaporator under frosting condition. Part II. Field investigation on a shipping container

A field investigation is performed on the frost formation at an evaporator of a commercial full-scale refrigerated container that uses R-12 as the working refrigerant. Results when compared with those from a numerical model presented earlier show that the model is capable of predicting the dynamic behavior of a direct expansion evaporator under both non-frosting and frosting conditions. The air outlet and energy transferred compare well between experiment and model, and within 20% for the air pressure drop. The frost occurrence and propagation agree well generally, with the frost formation first occurring at the first row where the refrigerant enters the evaporator.     

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.