The use of CFD to improve the performance of a chilled multi-deck retail display cabinet

Maintaining food temperatures below critical values is the key to maximising the high quality display life of chilled foods. Studies were carried out to see if computational fluid dynamic (CFD) modelling could be used to rapidly identify the changes that would be required to an existing multi-deck display cabinet so that it would meet a higher test specification. Implementing the changes on a Pastorfrigor MV 200TP display cabinet reduced the average power consumption from 1.37 to 1.29 kW as well as significantly reducing the number of test packs which spent any time above 4 °C, from 12 to 1.     

CFD simulation of refrigerated display cabinets

The finite element method is employed for the analysis of velocity and temperature distributions in refrigerated open display cabinets. The CFD code is based on the streamfunction-vorticity formulation, and incorporates a LES turbulence model. As an example of application, a vertical multi-deck cabinet is investigated under different operating conditions. The numerical results have been validated by comparison with experimental tests performed in accordance with the EN441 Standard. The influence of various design parameters has been investigated.     

Modified two-fluid model for air curtains in open vertical display cabinets

A modified two-fluid turbulence model is established to simulate the flow and heat transfer characteristics of air curtains in an open vertical display cabinet. The air exiting the back panel (AEBP), the inner air curtain and the outer air curtain are taken as the first fluid and described with the standard k− turbulence model (KE). The air outside the display cabinet is considered as the second fluid and calculated by the laminar model. Different from the existing two-fluid model, the mass transfer rate equation between the turbulent and the non-turbulent fluids is modified, and the face coefficient of honeycomb (the ratio of the effective area to the total area of honeycomb) is fetched with the volume fraction of air curtain in order to conveniently depict the blow characteristics of the honeycomb. The comparisons between the simulated temperatures and the experimental ones indicate that the modified two-fluid model (MTF) can give better agreement with the measurements than KE and two original two-fluid models (TF1 and TF2).     

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.     

Comparison of CFD analysis to empirical data in a commercial vortex tube

This paper presents a comparison between the performance predicted by a computational fluid dynamic (CFD) model and experimental measurements taken using a commercially available vortex tube. Specifically, the measured exit temperatures into and out of the vortex tube are compared with the CFD model. The data and the model are both verified using global mass and energy balances. The CFD model is a two-dimensional (2D) steady axisymmetric model (with swirl) that utilizes both the standard and renormalization group (RNG) k-epsilon turbulence models. While CFD has been used previously to understand the fluid behavior internal to the vortex tube, it has not been applied as a predictive model of the vortex tube in order to develop a design tool that can be used with confidence over a range of operating conditions and geometries. The objective of this paper is the demonstration of the successful use of CFD in this regard, thereby providing a powerful tool that can be used to optimize vortex tube design as well as assess its utility in the context of new applications.     

CFD simulation of coupled heat and mass transfer through porous foods during vacuum cooling process

A numerical simulation by using a computational fluid dynamics (CFD) code is carried out to predict heat and mass transfer during vacuum cooling of porous foods on the basis of mathematical models of unsteady heat and mass transfer. The simulations allow the simultaneous prediction of temperature distribution, weight loss and moisture content of the meats at low saturation pressure throughout the chilling process. The simulations are also capable of accounting for the effects of the dependent variables such as pressure, temperature, density and water content, thermal shrinkage, and anisotropy of the food. The model is verified by vacuum cooling of cooked meats with cylindrical shape within an experimental vacuum cooler. A data file for pressure history was created from the experimental pressure values, which were applied in the simulations as the boundary condition of the surface temperature.     

Effect of the airflow rate of a ceiling type air-conditioner on ventilation effectiveness in a lecture room

We performed a study on the effect of the discharge airflow rate of the ceiling type air-conditioner on ventilation performance in the lecture room with the mixing ventilation. The experiments and CFD were conducted for analyzing ventilation performance. The concepts of mean air age and indoor CO₂ concentration were used for evaluating ventilation performance. We made the CO₂ generation model in the simulation and calculated a lot of cases with respect to the airflow rate of air-conditioner and the mechanical ventilation rate. And the selected experimental measurements were performed in the lecture room of the same layout as the numerical one for verifying simulation results. Mean air age is gradually increased, but CO₂ concentration is oppositely decreased in the occupied zone with the increment of the discharge airflow rate of the ceiling type air-conditioner. This result shows that both mean air age and residual life time must be considered for evaluating ventilation performance when the contaminants are generated indoors. And the increment of discharge airflow of the ceiling type air-conditioner can induce the piston effect and push the contaminants out of the occupied zone. From this result, it is found out that ventilation performance can be increased when the momentum source like an air-conditioner is used in the room with the mixing ventilation.     

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.     

CFD analysis of ejector in a combined ejector cooling system

One-dimensional ejector analyses often use coefficients derived from experimental data for a set of operating conditions with limited functionality. In this study, several ejector designs were modelled using finite volume CFD techniques to resolve the flow dynamics in the ejectors. The CFD results were validated with available experimental data. Flow field analyses and predictions of ejector performance outside the experimental range were also carried out. During validation, data from CFD predicted the entrainment ratios with greater accuracy on definite area ratios, although no shock was recorded in the ejector. Predictions outside the experimental range—at operating conditions in a combined ejector–vapour compression system—and flow conditions resulting from ejector geometry variations are discussed. It is found that the maximum entrainment ratio happens in the ejector just before a shock occurs and that the position of the nozzle is an important ejector design parameter.     

Effect of deflecting ring on noise generated by outdoor set of a split-unit air conditioner

In order to analyze the influence of the deflecting ring on the noise generated by the outdoor set of a split-unit air conditioner, the flow field in the outdoor set is simulated with the CFD software STAR-CD, the relative turbulent intensities are computed and the influence of the width and contoured duct of the deflecting ring on the noise generated by the outdoor set is analyzed. The results of computation and experiment show that there is an optimal width of the deflecting ring, corresponding to the minimum noise generated by the outdoor set. In addition, the influence of the contoured duct of the deflecting ring on the noise generated by the outdoor set is analyzed and a double contoured duct is designed. The results of computation and experiment verify that the deflecting ring with double contoured duct can improve the aerodynamic performance and reduce the noise generated by the outdoor set.     

Improvement of air distribution in refrigerated vertical open front remote supermarket display cases

This paper presents some of the results derived from extensive experimentation on display cases for supermarkets and derives some possible improvements to augment temperature uniformity and energy performance. The effect of the perforation pattern of the rear duct on the distribution of airflow between these and the front curtain is brought out. The critical component is air infiltration across the curtain, which is governed by internal air distribution and curtain characteristics. It is observed that a 70–30 distribution of flow between the curtain and the rear duct perforations yields a performance that satisfies the standards. Further, a judicious distribution of perforations on the rear duct at various levels and across is necessary. Correlations available in the literature are useful in making a qualitative assessment of the results.     

Temperature and energy performance of refrigerated retail display and commercial catering cabinets under test conditions

An analysis of the performance of well freezers, chest freezers, frozen and chilled door cabinets (solid or glass door) and open fronted chilled cabinets under EN441 test conditions demonstrated that maximum temperatures in cabinets were generally in the most exposed (to ambient) areas and that minimum temperatures were located in the least exposed areas. Detailed positions of maximum and minimum temperature varied between cabinet types. In chest freezers 95% of the maximum temperature positions were located in the top layer and 95% of the minimum temperature positions were located in the middle layer of the cabinets. In full door frozen cabinets the maximum temperature position was in the majority of cases on the top shelf (64%) with most maximum packs being at the front of the top shelf (53%). In the chilled full door cabinets 94% of the maximum temperature packs were situated at the front of the cabinet. In open fronted cabinets the majority of maximum temperature packs (97%) were located at the front of the cabinet, the largest number (60%) being at the front of the base of the cabinet. In well cabinets the majority of maximum temperature packs (81%) were located in the top layer of the cabinet and the majority (91%) of minimum temperature packs were located in the bottom of the cabinet.Large differences in energy consumed by cabinets of similar size and temperature performance were found indicating that large reductions in energy and CO₂ emissions could be achieved by selection of the most efficient cabinets.     

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.     

Jet entrainment rate in air curtain of open refrigerated display cases

Experimental and computational methods are used to address those parameters that have significant effects on the amount of entrained (warm) air in an open refrigerated display case. These parameters are identified, quantified, and the rate of entrainment is expressed as a function of these parameters. It is found that the turbulence intensity, the shape of the mean velocity profile at the discharge air grill, and the Reynolds number are mainly responsible for the amount of entrained air in a display case. It is also concluded that lower Reynolds numbers will reduce the amount of the entrained air in the display case, however, the trade off will be higher temperature of the food products on shelves. Digital particle image velocimetry (DPIV) was used to map the entire mean velocity flowfield and the turbulence intensity. The laser doppler velocimetry technique was also used to verify the mean velocity and turbulence intensity measurements made by DPIV. The results indicated an excellent agreement between both methods. Parametric studies for the rate of entrainment of the outside air into the display case were performed using a computational fluid dynamics tool. The results indicate that lowering the Reynolds number of the air curtain reduces the entrainment rate. However, sufficiently high momentum should still exist to enforce the integrity of the air curtain structure.     

Numerical study of electroosmotic (EO) flow in microfabricated EO pump with overlapped electrical double layer (EDL)

Micropump is an important component for the development of micro absorption heat pump systems. To study the performance of microfabricated EO pump with the dimension comparable to the electrical double layer (EDL), a model avoiding the use of the Boltzmann equation was developed to investigate the EO flow instead of using the Poisson–Boltzmann (PB) equation. Generally used Debye–Huckle approximation and symmetric condition are also not involved so this model can be applied in the more complicated EO micropumps. Numerical simulation was carried out to study the distributions of potential, ions and net charge density in the EO micropump. Comparison between the present model and the PB equation was conducted. Using the present model, the EO flow in the EO micropump with overlapped EDL was investigated. It shows that the flow is quite different from the channel with dimension much larger than the EDL, which exhibits plug-like flow characteristics. The errors induced by the PB equation for the pumps with different depths were evaluated. It shows that the accuracy of the PB equation is not good when the EO pump is very thin.     

A nonintrusive flow measurement technique to validate the simulated laminar fluid flow in a packed container with vented walls

A nonintrusive flow measurement technique (particle image velocimetry) was used to determine the airflow field in a package with a container-to-product diameter ratio of less than 10. The complexity and uneven distribution of the measured flow field supported the requirement of a geometrical and mathematical model capable of describing the geometry and physics of flow within the package. Using novel computational fluid dynamics (CFD) codes, an accurate model of the packed structure was developed and the 3D Navier–Stokes equations were solved. A good agreement was obtained between experimental and predicted velocities. The detailed insight on the airflow pattern provided by the CFD analysis makes this approach an ideal tool to analyze the effect of different vent designs in the airflow field distribution in complex packaging systems.     

Modeling the thawing of frozen foods using air impingement technology

With the continual growth in the use of frozen foods both in retail and in food service, there is a need to develop improved thawing methods. Current methods are often undesirably slow (still air) or are very expensive and cause uneven thawing (microwave). Air impingement technology is one possible method to improve the thawing of frozen foods. The objectives of this research were to develop a two-dimensional model for air impingement thawing frozen foods and to verify the model experimentally. Frozen products were thawed using a laboratory impingement system with a single impingement jet. A simulated meat product (Tylose gel) was used as the test material. Thawing of a Tylose disk (12.7 cm diameter, 1.98 cm thickness) with air at 6 °C without impingement required more than 12 h, while thawing under a single impingement jet took less than 3 h, over four times faster. Results from the finite difference model gave good agreement with experimental data. Moisture loss during thawing was typically over-predicted because moisture gain due to condensation was not modeled.     

Computation of the airflow in a pilot scale clean room using K- turbulence models

This work deals with the assessment of the airflow in a food-processing clean room. The flow pattern inside the working area of a pilot scale clean room was numerically investigated using a computational fluid dynamics code based on a finite volume formulation. Two versions of the k- turbulence model were tested: the standard and the RNG version. The analysis of the velocity magnitude does not reveal sensitive differences between them. Moreover, both models well predict the main features of the flow and numerical results agree with experimental measurements. However, a further examination shows that the RNG k- turbulence model predicts more swirls and more complex trajectories. As the standard k- model overestimates the turbulent diffusion, the RNG version seems to be more suitable to calculate the airflow in clean rooms. The influence of initial turbulence intensity is also pointed out. Finally, the study of the airflow below a laminar flow unit confirms that the design of clean rooms can benefit from the numerical approach.     

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.     

Steady state CFD modeling of airflow, heat transfer and moisture loss in a commercial potato cold store

Storage loss beyond permissible limit is one of the most important problems in Indian potato cold stores, which has been hindering further growth of this industry. The losses in the stored potatoes have a direct relation to the intricate coupled transport phenomena of heat, mass and momentum transfer therein. Therefore, airflow, heat transfer and moisture loss was investigated in a potato cold store of commercial scale under steady state condition using the computational fluid dynamics technique. The developed CFD model was a two-dimensional simplification of the cold store. Heat and mass transfer at the cooling coils were not modeled, instead temperature and relative humidity in the air space were specified based on measured values. The model was validated in a commercial scale cold store and was found to be capable of predicting the air velocity as well as product temperature with an average accuracy of 19.5% and 0.5 °C, respectively and also the simulated average total moisture loss was found to be only 0.61% water (w.b.) higher than the experimental one for a storage period of 6 months. The main deficiencies of the airflow pattern which resulted in wide variations in temperature and moisture loss within the stored commodity can be investigated. The model located the probable zones of hot and cold spots, excessive product dehydration and moisture condensation within the storage facility, which might lead to qualitative and quantitative deterioration in stored product. This modeling tool could very well be applied to incorporate necessary design improvements with a view to improve the airflow distribution and heat transfer in order to limit the storage losses within the permissible limit.