Minimising frost growth on cold surfaces exposed to humid air by means of crosslinked hydrophilic polymeric coatings

Experiments have shown that frost growth on cold surfaces exposed to warm humid air streams can be reduced significantly by means of crosslinked hydrophilic polymeric coatings. This derives from the ability of these materials, under frosting conditions, to absorb available water, and hence retard the growth of frost when compared to an uncoated metallic surface. The extent of reduction of frost growth appeared to vary with the water absorbing potential of the polymer-coat, as well as its water content prior to frosting. In general, measurements in over two hours of testing, indicated that the reduction in frost growth rate and subsequently frost thickness lies in the range, 10–30%. The absorbed water improves the thermal conductivity of the polymeric coating. This, consequently, lowers the total thermal resistance between the air stream and the cold plate, and hence retards the frost surface temperature in its rise towards 0°C, an effect that would prolong the effective operation time of the thermal process before there is need for defrosting. Further observations made in this study tend to suggest that the nature of the frost formed with an air stream of low relative humidity (RH) differed from that resulting from a high RH air stream.     

Dimensionless correlations of frost properties on a cold cylinder surface

We propose dimensionless correlations for frost properties on a cold cylinder surface. Frosting experiments were performed while changing various frosting parameters such as the air temperature, cold cylinder surface temperature, air velocity, and absolute humidity. The experimental data showed that a uniform frost layer grew around the circumference of the cylinder at a high air velocity. Dimensionless correlations for the thickness, density, and surface temperature of the frost layer, and for the heat transfer coefficient were obtained as functions of the Reynolds number, Fourier number, absolute humidity, and dimensionless temperature. The applicable ranges of these correlations are Reynolds number of 700–3000 (air velocities of 0.5–2.0 m/s), Fourier number of 56.8–295.7 (operating time of 0–100 min), absolute humidity of 0.00280–0.00568 kg/kg_a, air temperatures of 3–9 °C, and cold cylinder surface temperatures of ?32 to ?20 °C. The proposed correlations agreed with the experimental data within an error of 15%.     

Experimental study of natural frost formation over a horizontal tube with annular compact fins under natural convection

This paper presents experimental measurements of natural convection heat transfer and frost deposition over a horizontal fin‐tube. Measurements are made for a fin‐tube of diameter 25.4 mm, fin thickness 0.4 mm, fin center diameter 56 mm, and fin spacing 2 mm. For measurements the ambient air temperature and relative humidity are changed from 18 to 25°C and from 35% to 55%, respectively. The tube surface temperature is changed from –5 to –9 °C, and super cooling degrees of 7.5 to 24.5 °C. Results include a visualization of frost deposition growth, frost accumulation rate, and heat transfer rate with respect to time for each experiment. The results show that cold air starts from the upper point and moves downward and frost deposition starts on the fin tips, and grows with time both radially and angularly. Frost growth thickness changes significantly from top to bottom, where the boundary layers of both thermal and concentration increase at the bottom of the fin‐tube section without considerable separation. Frost growth only takes place on the fin's tip and it blocks the heat and mass transfer from the fin surfaces and the tube base which reduces convection and frost growth considerably. © 2011 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library ( wileyonlinelibrary.com/journal/htj ). DOI 10.1002/htj.20397     

Free convection frost growth in a narrow vertical channel

Processes involving heat transfer from a humid air stream to a cold plate, with simultaneous deposition of frost, are of great importance in a variety of refrigeration equipment. In this work, frost growth on a vertical plate in free convection has been experimentally investigated. The cold plate (0.095 m high, 0.282 m wide) was placed in a narrow (2.395 m high, 0.01 m deep) vertical channel open at the top and bottom in order to permit the natural circulation of ambient air. The cold plate temperature and the air relative humidity were varied in the −40 to −4 °C and 31–85% range, respectively, with the air temperature held fixed at 27 °C (±1 °C). The main quantities (thickness, temperature and mass of frost, heat flux at the cold plate), measured during the time evolution of the process, are presented as functions of the input parameters (relative humidity and cold plate temperature); in particular, the role exerted by the plate confinement on the frost growth is discussed. Data are recast in order to identify compact parameters able to correlate with good accuracy frost thickness, mass and density data.     

Frost growth and densification in laminar flow over flat surfaces

One-dimensional frost growth and densification in laminar flow over flat surfaces has been theoretically investigated. Improved representations of frost density and effective thermal conductivity applicable to a wide range of frost circumstances have been incorporated. The validity of the proposed model considering heat and mass diffusion in the frost layer is tested by a comparison of the predictions with data from various investigators for frost parameters including frost thickness, frost surface temperature, frost density and heat flux. The test conditions cover a range of wall temperature, air humidity ratio, air velocity, and air temperature, and the effect of these variables on the frost parameters has been exemplified. Satisfactory agreement is achieved between the model predictions and the various test data considered. The prevailing uncertainties concerning the role of air velocity and air temperature on frost development have been elucidated. It is concluded that that for flat surfaces increases in air velocity have no appreciable effect on frost thickness but contribute to significant frost densification, while increase in air temperatures results in a slight increase the frost thickness and appreciable frost densification.     

Frost formation on a plate with different surface hydrophilicity

The objectives of this study are to develop frost maps for two different surfaces having two different hydrophilic characteristics and to find ambient conditions associated with the formation of frost structures. Test samples with two different surfaces having dynamic contact angle (DCA) of 23° and 88° were installed in a wind tunnel and exposed to a humid airflow. Frost structure is observed with a visualization system in the operating conditions of household refrigerator: airflow temperature in the range of +10-20 °C, humidity in the range of 2.64-9.36 g/kg^′, Reynolds number in the range of 7000-17,000 and cold plate temperature in the range of −11.6 to −28.4 °C. As results of this study, frost structures are classified and frost maps are proposed for two different surface hydrophilicities. Surface with low DCA (23°) shows lower frost thickness and higher frost density than that with high DCA (88°). It was found that frost structures on surfaces with different DCA are similar. However, low DCA surface at low humidity provides 20-30% denser frost formation due to the shift of areas with different structures.     

Frosting and defrosting characteristics of a fin according to surface contact angle

We investigated the characteristics of frosting and defrosting on a fin according to its surface contact angle under the winter operating conditions of a heat pump. The static contact angles were 2.5°, 75°, and 142° for hydrophilic, bare, and hydrophobic surfaces, respectively. The frost layer exhibited different frost formations for different surface contact angles during the early stages of frost formation. Frost retardation was observed on the hydrophobic fin, but the effect was not significant. The frost layer was thinner and the average frost density was higher on the hydrophilic surface than on the other surface-treated fins. The effect of surface treatment on defrosting time was found to be insignificant. However, the ratio of residual water on the hydrophilic surface was significantly smaller than those on the other surfaces. Because of this, in repeated frosting/defrosting experiments, the fin of the hydrophilic surface was found to show almost the same frosting/defrosting behaviors as those of the first run.     

A comparison of the airside performance of the fin-and-tube heat exchangers in wet conditions; with and without hydrophilic coating

An experimental study was performed on compact fin-and-tube heat exchangers in wet conditions. Airside performance for both hydrophilic coated and un-coated surface is examined. It is found that the effect of inlet relative humidity on the heat transfer performance is small. For un-coated surfaces, the effect of inlet relative humidity has a pronounced effect on pressure drops. It is likely that this phenomenon is related to the condensate flow pattern along the fin surface. The heat transfer performance for the hydrophilic coating surface is lower than the corresponding un-coated surface tested at the same wet condition. Further, the degradation of heat transfer performance may be up to 20% for fin pitches of 1.2 mm. The pressure drops for the hydrophilic coated surface are also lower than the corresponding un-coated surfaces. A maximum 40% reduction is observed for plain fin geometry. The effect of inlet condition on frictional performance is more pronounced in the enhanced slit geometry.     

Frost formation on a bionic super‐hydrophobic surface under natural convection conditions

A bionic super‐hydrophobic surface has a multiple micro‐nano‐binary structure (MNBS) similar to the lotus leaf surface microstructure. This kind of surface has a contact angle of water greater than 150^° and a roll angle smaller than 5^°. In this paper, the frost deposition phenomena on a bionic super‐hydrophobic surface were observed. The surface has many micro bumps and its contact angle is 162^°. The formation of water droplets, the droplet freezing process, the formation of initial frost crystals and the frost layer structure on a cold bionic super‐hydrophobic surface under natural convection conditions were closely observed. The frost layer structure formed on the super‐hydrophobic surface shows remarkable differences to that on a plain copper surface: the structure is weaker, looser, thin, and easily removed and most importantly, it is of a very special pattern, a pattern similar to a chrysanthemum, a frost layer structure that has not been reported before to the best of the present authors knowledge. The experimental results also show that a super‐hydrophobic surface has a strong ability to restrain frost growth. The frost deposition on this bionic surface was delayed 55 minutes when compared with a plain copper surface under the conditions of a cold plate temperature of ?10.1^°C, air temperature of 18.4^°C, and relative humidity of 40%. A theoretical analysis was also presented to explain the observed phenomena. © 2008 Wiley Periodicals, Inc. Heat Trans Asian Res, 37(7): 412–420, 2008; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20216     

Transient two-dimensional model of frost formation on a fin-and-tube heat exchanger

In the paper, numerical and experimental analyses of heat and mass transfer during frost formation on a fin-and-tube heat exchanger have been presented. Modelling of the frost formation on cold surfaces placed in a humid air stream, requires a complex mathematical approach. A transient two-dimensional mathematical model of frost formation has been developed. The applied mathematical model has been defined using governing equations for the boundary layer that include air and frost sub-domains as well as a boundary condition on the air–frost interface. The mathematical model with initial and boundary conditions has been discretised according to the finite volume method and solved numerically using the SIMPLER algorithm for the velocity–pressure coupling. Results have shown that the frost layer formation significantly influences the heat transfer between air and fins. As a result of numerical calculations, time-wise frost thickness variations for different air humidities, temperatures and velocities have been presented. Using the developed mathematical model, the algorithm and the computer code, which have been experimentally validated, it is possible to predict a decrease of exchanged heat flux in the heat exchanger under frost growth conditions.     

Design,synthesis, and characterization of hybrid micro-nano surface coatings for enhanced heat transfer applications

Metal particles coating is extensively used for surface coating a wide range of application including thermal management of electronics, concentrating photovoltaics, sensors and nuclear power plants. Both micro and nano-scale surfaces have been proven to show an enhanced two-phase heat transfer performance by varying surface properties like area, wettability, and roughness. To combine the unique features of both micro and nano-scale surface coatings, this study presents the design, synthesis, and characterization of new hybrid micro-nano scale surface coating by a new two steps approach. Five different types of surfaces; namely, plain nanocoated (PNC), uniform micro-porous (UMP), uniform hybrid micro-nano porous (UHMNP), 2-D modulated microporous (MMP) and modulated hybrid micro-nano (MHMNP) surfaces were fabricated. A new two steps approach of hot-pressing followed by nucleate boiling is used for the fabrication of these surfaces. Successful coating of hybrid micro-nano scale coating was achieved. Considering the critical surface properties of micro and nanoscale coatings, new hybrid micro-nano surfaces have been characterized for SEM, wettability, roughness test. The comparative analysis of these new hybrid coating is also performed with micro coated and uncoated surfaces. With the coating of nanoparticles, the average roughness of PNC surface increased by 4.67 times and that of hybrid micro-nano particle surface by 2.3 times. The deposition of nanoparticles resulted in an increase in contact angle for PNC surface, while the contact angle of hybrid micro-nano surfaces decreases from 126.4° to 82.1°.     

Nucleate Pool Boiling Heat Transfer of Hydro-Fluorocarbon Refrigerant R134a on TiO2 Nanoparticle Coated Copper Heating Surfaces

ABSTRACT

Pool boiling heat transfer performance of hydro-fluorocarbon refrigerant R-134a on titanium dioxide (TiO₂) nanoparticle coated surface is experimentally studied in the article. The test surfaces, viz, 100 nm, 200 nm and 300 nm thick TiO₂ nanoparticle coated surfaces over 100 nm thin film surface are used in this experimentation. The surfaces are synthesized and fabricated by simple and cost-effective electron beam evaporation method. The test surfaces were characterized by scanning electron microscope and atomic force microscope to uncover the formation of crystalline structure on coated surfaces. These surfaces are utilized in pool boiling test rig using refrigerant R134a at 10°C saturation temperatures. The result indicated that a maximum of 87.5% augmentation in the boiling heat transfer has been achieved by higher thickness of TiO₂ coated surface than the bare copper surface. In addition, the incipience wall superheat is reduced for higher thickness coated surface. The augmentation of heat transfer coefficient might be the reason for increase in micro/nano-porosity, active nucleation site density and surface area of the heating surface. It is observed that with the increase of sub-cooling temperature of liquid, the bubble departure diameter was reduced while the heat transfer coefficient has been increased.     

Experimental study of free convection heat transfer and condensation of vapor of humid air over an inclined cold tube

In this study condensation heat transfer on a cold inclined circular cylinder due to natural convection for various conditions is investigated experimentally. The cylinder is placed in an isolated test room to permit pure natural circulation of ambient air. Ambient temperature and humidity of the test room are controlled by a refrigeration cycle and humidifying. The ambient relative air humidity changed in the range of 30 to 50% and temperature from 25 to 35 °C. The ethylene‐glycol/water solution is used as a refrigerant to control and keep the temperature of the test section at a constant value. The cold surface temperature is varied from 2 to 6 °C. The condensation rate and heat flux are found to depend mainly on time, temperature difference between ambient air and cold surface, ambient relative humidity, and tube inclination. Results are plotted for various conditions with respect to time. The experimental results are used to propose a correlation to predict the condensate mass flow rate for free convection heat transfer. © 2012 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library ( wileyonlinelibrary.com/journal/htj ). DOI 10.1002/htj.21015     

Analysis of heat transfer and frost layer formation on a cryogenic tank wall exposed to the humid atmospheric air

In this paper heat transfer characteristics and frost layer formation are investigated numerically on the surface of a cryogenic oxidizer tank for a liquid propulsion rocket, where a frost layer could be a significant factor in maintaining oxidizer temperature within a required range. Frost formation is modeled by considering mass diffusion of water vapor in the air into the frost layer and various heat transfer modes such as natural and forced convection, latent heat, solar radiation of short wavelength, and ambient radiation of long wavelength. Computational results are first compared with the available measurements and show favorable agreement on thickness and effective thermal conductivity of the frost layer. In the case of the cryogenic tank, a series of parametric studies is presented in order to examine the effects of important parameters such as temperature and wind speed of ambient air, air humidity, and tank wall temperature on the frost layer formation and the amount of heat transfer into the tank. It is found that the heat transfer by solar radiation is significant and also that heat transfer strongly depends on air humidity, ambient air temperature, and wind speed but not tank wall temperature.     

Perfluoropolyethers Coatings Design for Fouling Reduction on Heat Transfer Stainless-Steel Surfaces

The scope of this research is to obtain a film coating on stainless-steel surfaces in order to reduce the interaction between the metal surface and the precipitates, so as to mitigate fouling in heat exchangers. Perfuoropolyethers were used to obtain nano-range fluorinated layers in order to make hydrophobic the stainless-steel surfaces. A pilot plant with two identical heat exchangers was built to investigate the ability of the hydrophobic coating of preventing fouling. The heat exchangers, installed in parallel, operated at the same temperature and pressure conditions, namely, laminar flow regime and inlet flow temperatures of 291–293 K for cold streams and 313–333 K for hot streams. We compared the heat transfer performance of the two heat exchangers. After a 5-month operation, the decrease in the heat transferred was 56% for the coated heat exchanger and 62% for the uncoated heat exchanger. Moreover, the increase of heat transfer resistance due to scale on the uncoated heat exchanger, with respect to the coated one, was three times higher.     

Predictions of frost growth on a cold plate in atmospheric air

A theoretical model for frost formation on a cold plate placed in atmospheric air has been developed in this study. Effects of plate surface temperature (T_w) and air conditions, such as air velocity (V), temperature (T_a), and humidity ratio (ω_a), on the frost growth rate can be evaluated by using this model. Results show that the predictions of frost growth rate by the developed model agree closely with the existing experimental data during the forst layer growth period for most of the cases considered. Predictions by this model have also been compared with those obtained by the existing theoretical models.     

Frost distribution characteristics of laminar airflow on cold surface of mini-channels

This study was performed for simulating frosting characteristics that occurred on the surface of plate fins of the outside heat exchanger. Test section with local cooling modules at the central part was made as the rectangular cross sectional passage to imitate the outside heat exchanger. Local frost thickness distributions for test conditions having three experimental parameters (plate wall temperature, air humidity and velocity) were presented. Leading edge effect of the plate was clearly confirmed from the measured frost thickness distributions. The central part of the plate had the highest frost thickness because cooling devices were installed at the center of the plate. Due to different heat and mass transfer characteristics of upstream flow and downstream flow, the frost thickness of upstream area was much higher than that of downstream. The effects of plate surface temperature, humidity and velocity of inlet flow on frost thickness, and sensible and latent heat fluxes were analyzed.     

Measurements of Frost Thickness and Frost Mass on a Flat Plate under Heat Pump Condition

This study measured the frost thickness and frost mass on a flat plate to propose the correlation equations for the local and average frost thickness, frost density, and frost mass. Key parameters were the cooling surface temperature of the flat plate from 258.2 to 268.2 K, absolute humidity of air from 2.98 to 4.16 g/kg_DA, air temperature from 273.5 to 280.2 K, and air velocity from 1.0 to 2.5 m/s. A 50% ethylene glycol aqueous solution was used as a coolant. The sensitivity analysis of the parameters such as air temperature, air humidity, air velocity, and surface temperature on the frost thickness and frost mass were experimentally investigated under the heat pump condition. Correlation equations for the local and average frost thickness and frost mass under the heat pump condition were proposed. The values predicted by the correlation equations under the freezer condition were larger by a maximum of 30–50% than the values predicted by the present correlation equations under the heat pump condition. The proposed correlation equations might be applied to the part of the freezer condition.     

An experimental investigation on frosting characteristics of a microchannel outdoor heat exchanger in an air conditioning heat pump system for electric vehicles

To increase the driving range of electric vehicles in cold climate, air conditioning heat pump (ACHP) system is supposed to be the most effective solution. Working near 0°C with high humidity, the microchannel outdoor heat exchanger (OHX) in system would experience badly frosting process, like traditional residential heat pump system. It would lead to a significant reduction of system performance without defrosting in time. In this article, experimental investigation has been implemented on the frosting process of ACHP system of electric vehicles which is with a microchannel OHX. The phenomenon of frosting distribution was observed, the frosted part on surface shows uneven with various flows paths. The typical frosting characteristics of an outdoor microchannel heat exchanger were also obtained. In a self-designed three-heat exchanger ACHP system, the inlet and outlet refrigerant temperature of OHX as well as the outlet air temperature of system decrease with increasing frosting coverage rate. The frosting phenomenon was analyzed with variation of ambient temperature and humidity. System influence by frosting was also studied with under different ambient conditions. When OHX begins to frost, the heating capacity reduction of system under different ambient conditions were both increased but the differences in the coefficient of performance (COP) variations under different ambient conditions were small as frosting progressed.     

Experimental Investigation of the Defrosting Process on Domestic Refrigerator Finned Tube Evaporators

Frost formation is an important problem for household refrigerator and air conditioning equipment manufacturers. When frost accumulates on the evaporator surface, it acts as a thermal insulator and reduces heat flow. Therefore, frost negatively affects evaporator performance. The purpose of this study is to decrease energy consumption and increase the efficiency of the defrosting process. In the first part of the experiment, frost formation on a no-frost refrigerator evaporator at real operating conditions was investigated. The ambient temperature was maintained at a constant 23°C. It was observed that when the evaporation temperature reaches –35°C, the frost formation on the evaporator exhibits a rather dense structure that is unlike the needle-type structure observed at higher temperatures. In the second part of the experiment, the defrosting process was observed with an endoscopic camera, and the initial melting points were investigated. The experiment revealed that although the heater density is higher on the lower rows, the frost on the higher rows of the evaporator melts faster. On the theoretical side, we prepared an analytical model that calculates the melting time of the frost on the fin. The experimental and theoretical results are within 5%.