See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/326369595

Modeling Ice Formation On Heat exchangers Fins

Conference Paper · August 2011

CITATIONS READS

2 1,131

1 author:

Zoheir Hadid

7 PUBLICATIONS   15 CITATIONS   

SEE PROFILE

All content following this page was uploaded by Zoheir Hadid on 13 July 2018.

The user has requested enhancement of the downloaded file.

 ID: 662

MODELING ICE FORMATION ON HEAT EXCHANGERS FINS

HADID Z.(*), ZOUGHAIB A.(*), BARITEAU N. (**), ROBIDOU H. (**)

(*)
Center For Energy and Processes,MINES ParisTech, 5 rue Léon Blum, Palaiseau, 91120, France
zoheir.hadid@mines-paristech.fr, assaad.zoughaib@mines-paristech.fr
(**)
GEA BTT, 25, rue du Ranzai, 44300 NANTES, FRANCE
nicolas.bariteau@ geagroup.com, Herveline.Robidou@geagroup.com

ABSTRACT

Ice formation on heat exchangers and de-icing are both a design and control constraints for many industrial
systems. Dynamic modeling of the ice formation process allows to propose an optimized design for such heat
exchangers and to predict the best time to start the de-icing process.
This paper presents a dynamic model of the icing process based on the energy and mass conservation
equations. The ice layer is modeled as a 1 dimension porous medium subject to heat and mass transfer. Mass
transfer occurs on the surface and inside the mass layer causing the increase of its thickness and its
densification. The thermal conductivity of the ice layer is modeled as a function of its density.
The best available correlations in the literature, of convective heat and mass transfer, are selected and the
model results are discussed.

1. INTRODUCTION

Frost formation occurs when the cold surface temperature of a heat exchanger is below 0°C. Frost layer acts
as a thermal insulation between the surface and the moist air, reduces significantly the performance of the
heat exchanger and leads to greater pressure drop. Dynamic modeling of the ice formation process allows to
propose an optimized design for such heat exchangers and to predict the best time to start the de-icing
process. A high number of previous publications propose different models and correlations for frost growth
on cold flat surface e.g.: Shin et al. (2003), Hermes et al. (2009), Yang and Lee (2004). This is mainly due to
the complexity of the phenomenon that is non-linear, transient and subject to coupled heat and mass transfer
with large range of boundary conditions (air temperature, absolute air humidity, air velocity, cold and surface
temperature). It is also difficult to study experimentally because of the instability of the ice layer and the
complexity of the dynamic thickness and density measurement.
Ice grows in three periods defined by Hayashi et al. (1977):
• Crystal growth period.
• Frost layer growth period.
• Frost layer full-growth period.

In crystal growth period small drops of water deposits freeze and become a base for crystals growth in linear
dimension, this period is studied by Tao et al. (1993) and has shown that it is a very fast period compared to
the two other periods. In the frost layer growth period, the crystals change their shape by generation of
branch around the top then crystals are branched and interconnected. The frost layer grows and becomes a
porous medium. Frost layer full-growth period occurs when the frost surface temperature reaches 0°C due to
an increase in the frost thermal resistance. The frost surface then begins to melt. Both melted and condensed
water diffuse and freeze into the ice layer causing a sudden increase in the frost layer density.
The heat exchangers models in literature were built based on experimental data from specific type of heat
heat exchangers, their application is limited to the heat exchanger studied technology. Deng et al. (2003)
have studied experimentally the effect of frost growth on the performance of the air cooler with diferent fin
spacings. Seker et al. (2004a) present a model of frost formation on fin and tube heat exchanger where the
validation is based on the air side pressure drop and the overall heat transfert coefficient evolution. Liu et al.
(2005) validated their model of heat pump evaporator by frost accumulation measurements. Tso et al. (2006)
wrote a model that takes into account the frost thickness variation along the fin.
In this paper, a frost layer development model is proposed. It is based on a detailed description of heat and
mass transfer within the frost layer. The vapor diffusivity in the frost layer and the frost equivalent thermal
conductivity are determined using correlations from the literature.

2. MATHEMATICAL MODELING OF HEAT EXCHANGER UNDER ICING

CONDITIONS

The model is divided into two sub-models: frosting sub model and a heat exchanger sub-model. The use of
object based modelling approach allows connecting the submodels using temperature and heat flow
connections. In this paper, the frosting submodel is presented and discussed. The coupling with the heat
exchanger model will be presented in a future paper.

2.1. Frosting Sub-Model (Frost Growth Modelling)

Fig.1 shows the heat and mass transfer balance applied to a frost element of dx thickness and the boundary
conditions on the air side and the fin side.

Figure 1. Energy and mass balance in frost layer with boundary conditions

The air side of the frost layer is subject to convective heat and mass transfer. While on the fin side, the
continuity of the conductive heat flow leads to a wall temperature condition.

2.1.1. Mass Transfer equations

The frost layer receives by convection a water vapor mass flux m " which is the total mass flux transferred
to the frost layer; this quantity causes the variation of both the thickness and density of the frost layer by
equation (1)

d dρ dδ
m" δρ δ ρ 1
dt dt dt

The first term m " δ which contributes to the increase in frost density is the water vapor flux
that diffuses inside the frost layer. The second term m " ρ represents the part of water vapor flux
freezing at the frost surface increasing the frost thickness.

In order to model the mass transfer in the frost layer, mass balance over an element dx is applied; this leads
to model the diffusion process. Water vapor diffusing through a porous frost layer is calculated according to
Fick's law as:
 M P dP
m " D 2
RT P P dx

The effective diffusion coefficient D is calculated versus the free diffusion coefficient D by the equation 3.

D µ. D 3

is called the diffusion resistance factor.

Auracher (1972) gave a simple expression related to the ice phase volumetric fraction. This expression is
used in the developed model (eq. 4)
(ε 1 ε 1 ):

1 ε
µ 4
1 C ε

C was empirically determined, by Auracher (1972) from his measurements, to be 0.58.

Diffusion coefficient in a static air layer is temperature depending and given as empirical correlations by
A. T , A and α are constants empirically found. Different values of A and α are found in the literature and
listed in the table 1.

References A α Users
Eckert and Drake (1972) 9.756E-10 1.81 Yao et al. (2004)
Auracher (1986) 1.432E-9 1.72 Le Gall and Grillot (1997)
-9
Incropera & De Witt (1985) 5.054E 1.5
Hedh (1983) 1.176E-9 1.75
Table 1. Empirical correlations of the diffusion coefficient.

In order to evaluate vapor mass flux m " as a function of the temperature gradient, Le Gall (1994) uses the
expression of Clausius-Clapeyron law:

dP L
5
dT T ν T ν

The specific volume of ice phase ν is negligible compared to the specific volume of vapor phase ν ,
Clausius-Clapeyron law reduces to:

dP L L .ρ T
6
dT T. ν T T

The thermodynamic equilibrium assumption leads to a simple dependency of vapor pressure on temperature
when air is saturated with water vapor:

dP
P . T 7
dT

Diffusion mass vapor flux is finally determined as a function of temperature from equations (2), (6) and (7):

m " µ. f T T 8

where
 M L P T P
f T D 9
R T P P T

Saturation pressure is estimated using the empirical equation from ASHRAE (2005).

2.1.2. Energy Transfer Equations

The energy balance applied to a finite volume element of the frost layer is given by:

∂T
k T L m ρ . Cp 10
∂t
T
Considering the frost layer in quasi-steady-state, the term of energy storage ρ . Cp 0 is neglected.
Therefore equation (10) can be written as in (11).

k T L m " 0 W/m 11

Substituting m " with its expression results in

k T L . µ. f T T 0 12

The frost growth is considered to be a one dimensional heat and mass transfer problem. As a consequence,
the energy balance applied to an elementary volume δV of the frost layer become:

d dT dT
k L . µ. f T 0 13
dx dx dx

2.1.3. Boundary Conditions

Cold surface (fin surface):
The heat flux continuity leads to an imposed temperature condition and the impermeability of this boundary
stops the mass transfer. The two boundary conditions are therefore written by equation (14).

T| T
14
m " 0

Frost surface:
This boundary is subject to convective heat and mass transfer. The sensible and latent heat transfer occurs
simultaneously on the air-frost interface.

. . . " 15

Only the latent heat corresponding to the term that increases the thickness is considered ( " ), while the
term " is included in the energy balance equation.
The frost mass flux increasing the frost thickness is calculated by equation (16)
" mf " " 16

The total frost mass flow is given by the expressions (17) and (18)

". 17

h . AT . L . w w 18
The mass transfer coefficient h can be determined with prior knowledge of the convective heat transfer
coefficient using the Chilton-Colburn analogy

h
h 19
Le. Cp

The total mass flux increasing the frost density is finally evaluated by equation (20)

" . . , " 20

2.2. Discussion
The model is written in Modelica and run using Dymola which allows creating sub-models to be connected.
In order to validate the frosting sub-model the predictions of the theoretical frost growth model are compared
with experiments conducted on a cold flat plate published by Sahin (1994) reported by Cheng and Cheng
(2001). The experimental data of Sahin (1994) has been obtained using a cold aluminum plate having
1.27cm thickness, 50.6cm length and 30.4cm width.
In addition to the comparison with the experimental data of Sahin (1994), the model developed in this study
is compared to Cheng and Cheng (2001), Jones and Parker (1975) and Sherif et al. (1993) models results.

The average value of heat transfer coefficient for forced convection on a flat plat (h ) is evaluated based on
simple correlation of Nusselt for laminar boundary layer Re<5x105, ASHRAE (2005).

/ /
Nu 0.664 Re Pr 21

The thermal conductivity of frost is determined, as a function of its density, by using the correlation provided
by Yonko and Sepsy (1967)

k 0.024248 0.00072311 ρ 0.000001183 ρ 22

The model presented in the present paper is run and the frost thickness are plotted with predictions of three
different models and frost thickness data of Sahin (1994) for four different physical situations (Fig.2, 3,4 and
5). The present frost growth model agree well with the experimental data of Sahin (1994), it presents higher
accuracy in the prediction of frost thickness than Cheng and Cheng (2001) predictions which give inaccurate
results in the fourth case plotted in Fig.5.

The models developed by Cheng and Cheng (2001), Jones and Parker (1975) and Sherif et al. (1993) seem to
be accurate for small temperature difference between air and the plate (fig. 2 and 3) while for large
temperature difference, they present differences with experimental data. In particular, the model of Sherif et
al. has a dynamic behavior that leads to higher differences after a certain period while the two others
represent well the dynamic behavior but with an offset.
Cheng and Cheng (2001) and Sherif et al. (1993) models have a similar dynamic behavior with an offset
depending on atmospheric condition, this can be explained by the fact that both models use an empirical
correlation for the frost density which is established by Hayashi et al. (1977) as a function of only the frost
surface temperature. This can be an over-simplification of the problem.
Both of present model and Jones and Parker (1975) model express the transport of water vapor into the frost
layer using the Fick low. Jones and Parker (1975) model has the same dynamic behavior that the present
model with an offset depending on atmospheric conditions but it underestimate the frost thickness.
In the four situations, (fig. 2, 3, 4 and 5) the developed model prediction is the closest to the experimental
data.
 5
Exp. (Sahin, 1994)
Present model
4 Cheng and Cheng (2001)
Frost Thickness [mm]

Sherif et al (1993)
3 Jones and Parker (1975)

0
0 60 20 80 40 100 120
Time [min]
Figure 2. Ta=286 K, Tw=264 K V=2.18 m/s Wa=0.0069 kgv/kga

5
Exp. (Sahin, 1994)
Present model
4 Cheng and Cheng (2001)
Frost Thickness [mm]

Sherif et al (1993)
3 Jones and Parker (1975)

0
0
60 20 40 80 100 120
Time [min]
Figure 3. Ta=286K, Tw=258 K V=2.18m/s Wa=0.0069 kgv/kga

5
Exp. (Sahin, 1994)
Present model
4 Cheng and Cheng (2001)
Frost Thickness [mm]

Sherif et al (1993)
3 Jones and Parker (1975)

0
0
60 20 40 80 100 120
Time [min]
Figure 4. Ta=293K, Tw=248 K V=2.12m/s Wa=0.007 kgv/kga
 5
Exp. (Sahin, 1994)
Present model
4 Cheng and Cheng (2001)
Frost Thickness [mm]

Sherif et al (1993)
Jones and Parker (1975)
3

0
0 20 60 40 80 100 120
Time [min]
Figure 5. Ta=286K, Tw=248 K V=2.12m/s Wa=0.0039 kgv/kga

3. CONCLUSIONS AND PERSPECTIVES

This paper reports a mathematical model to predict the ice growth on the fin surface of a fin and tube heat
exchanger under frosting conditions. The model is divided into two sub-models: frosting sub-model and a
heat exchanger sub-model. In this paper only the frosting sub-model is presented and discussed.
The model is written under the Modelica language and run using Dymola software. The Modelica language
allows object oriented modelling and thus permits easily the connection of submodels.
The frosting sub-model is validated by a comparison with data of frost layer formed on cold flat plate of
Sahin (1994) reported by Cheng and Cheng (2001).
In order to validate the overall model for different fin and tube heat exchangers configuration, data base of
correlations of fin efficiency, air heat transfer coefficient and pressure drop according to heat exchanger
types will be integrated in the present model and validated using both original and literature experimental
data.

4. REFERENCES

Auracher H. 1972, Water vapor diffusion and frost formation in capillaries Annex 1972-1 . Bulletin of the
International Institute of Refrigeration, Communications B1, B2, and El, Freudenstadt:477-488.
Cheng C H, Cheng Y C. 2001, Predictions of frost growth on a cold plate in atmospheric air, Int. Commun.
Heat Mass Transfer, 28: 953-962.
Deng D Q et al . 2003, Experimental investigation on the performance of air cooler under frosting
conditions, Appl. Therm. Eng. 23(7): 905-912.
Fundamentals: 2005 Ashrae Handbook : SI Edition.
Hayashi Y et al. 1977, Study of frost properties correlation with frost formation types, J. Heat Transfer, 99:
239-245.
Hermes C J et al. 2009, A study of frost growth and densification on flat surfaces, Exp. Therm. Fluid Sci.
33(2): 371-379.
Jones B W, Parker J D. 1975, Frost Formation With Varying Environmental Parameters, J. Heat Transfer,
ASME, 97(2): 255-259
Le Gall R, Grillot J.M. 1997, Modelling of frost growth and densification, Int. J. Heat Mass Transfer,
40(13): 3177-3187.
Le Gall R. 1994, Experimental study and modeling of frost formation in heat exchangers, PhD thesis, Institut
National Polytechnique de Grenoble.
Liu Z et al. 2005, Study on transient distributed model of frost on heat pump evaporator, J. Asian Architect.
Build. Eng. 4(1): 265-270.
Seker D et al. 2004, Frost formation on fin- and- tube heat exchangers. Part II—Experimental investigation
of frost formation on fin- and- tube heat exchangers, Int. J. Refrig. 27(4): 375- 377.
Seker D et al. 2004, Frost formation on fin-and-tube heat exchangers. Part I—Modeling of frost formation on
fin-and-tube heat exchangers. Int. J. Refrig. 27(4): 367- 374.
Sherif S A et al. 1993, A semi-empirical transient method for modelling frost formation on a flat plate, Int.
J. Refrig. 16(5): 321- 329
Shin J et al. 2003, Experimental study on frost structure on surfaces with different hydrophilicity: density
and thermal conductivity, J. Heat Transfer, 125(1): 84-94.
Tao Y X et al. 1993, A mathematical model for predicting the densification and growth of frost on a flat
plate, Int. J. Heat Mass Transfer, 36(2): 353-363.
Tso C P et al. 2006, An improved model for predicting performance of finned tube heat exchanger under
frosting condition, with frost thickness variation along fin, Appl. Therm. Eng. 26(1): 111- 120.
Yang D K et al. 2006, Modeling for predicting frosting behavior of a fin-tube heat exchanger, Int. J. Heat
Mass Transfer 49(7–8): 1472-1479.
Yang D K, Lee K S. 2004, Dimensionless correlations of frost properties on a cold plate. Int. J. Refrig. 27(1):
89-96.
Yao Y et al. 2004, A study on the performance of the airside heat exchanger under frosting in a air source
heat pump water heater/chiller unit, Int. J. Heat Mass Transfer,47(17-18): 3745-3756.
Yonko J D, Sepsy C F. 1967, An Investigation of the Thermal Conductivity of Frost While Forming on a
Flat Horizontal Plate, ASHRAE Trans., 73, Part 2, (2043):1.1-1.11.

NOMENCLATURE

A Heat transfer area [m2]

Cp Specific heat at constant pressure [J kg-1 K-1]
D Effective diffusivity [m2 s-1]
h Air side heat transfer coefficient [W m-2 K-1]
h Mass transfer coefficient [kg m-2 s-1]
k Thermal conductivity of frost [W m-1 K-1]
Le Lewis number
L Latent heat of sublimation [J kg-1]
m " Water vapor mass flux increasing the frost thickness [kgm-2s-1]
m" Total water vapor mass flux transferred to the frost layer [kg m-2 s-1]
m " Water vapor mass flux diffusing through frost layer evaluated at point x [kg/m2s]
T Temperature [K]
w Absolute humidity

Greek symbols

δ Frost thickness [m]

ε porosity
µ D
Diffusion resistance factor
D
ν Specific volume of vapor phase [m3kg-1]
ρ Density [kg m-3]
 Subscripts
a Air
f Frost
ice Ice phase
in inlet
out outlet
ref Refrigerant
s Frost surface
T Total
w Cold surface
Superscripts
” Per m2
. Time-derivative

View publication stats