EXPERIMENTAL AND NUMERICAL INVESTIGATION OF AIRFLOW AND TEMPERATURE DISTRIBUTION IN A PROTOTYPE COLD...

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print),

ISSN 0976 – 6359(Online), Volume 5, Issue 4, April (2014), pp. 123-137 © IAEME

123

EXPERIMENTAL AND NUMERICAL INVESTIGATION OF AIRFLOW AND

TEMPERATURE DISTRIBUTION IN A PROTOTYPE COLD STORAGE

Qasim S. Mahdi, Husam Mahdi Hadi*

Department of Mechanical Engineering, College of Engineering,

Al-Mustansiriyah University

ABSTRACT

Airflow and temperature distribution inside a cold store are investigated using experimental

and computational fluid dynamic using CFX 14.5. In the present work a prototype cold storage for

meat has been designed. Temperature distributions were determined for different storage

temperature, -2°C, -10°C, -20°C and -21°C, inside empty cold store experimentally. The Air

temperature distribution also been determined for storage temperatures -20°C and -21°C inside

loaded cold storage with 10.8kg. The Mean air velocity distribution also been measured for empty

cold store, by using a hot wire anemometer. Navier-Stokes equations, and the turbulence is taken into

account using a standard εκ− model, incompressible, symmetric cold store used to analysis the

loaded and empty cold storage and the meat are presented as a solid domain with variable

thermophysical properties as a function of temperature. Air flow distribution results in the three

levels (bottom, medium and top) for empty cold store with relative error between experimentally and

numerically equal to 20%. The relative error between the experimental and numerical for

temperature distributions inside empty cold storage equal to 13%. Correlations have been developed

for modeling the evaporator unit in numerical simulation, where the total error between the

experimental results and the correlation that used in numerical is 8.8%.

Keywords: Cold Store; Air Distribution; Temperature Distribution; CFX; Correlations for Modeling

the Evaporator Unit.

INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING

AND TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online)

Volume 5, Issue 4, April (2014), pp. 123-137 © IAEME: www.iaeme.com/ijmet.asp

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124

NOMENCLATURE

Unit Description Symbol

Constant Coefficient in k-

ε Model µC,C,C 21

M Hydraulic diameter Dh

W/m.K Thermal conductivity K

N/m2 Pressure P

N/m2

Modified pressure 'p

S Time T

(m/s) Velocity vector U

m/s

Velocity Components in

X,Y & Z Directions

u,v,w

Greek symbols

m2/s Thermal Diffusivity α

m

Distance Between Scalar

Quantities kji Z,Y,X ∆∆∆

(m2/s

3) turbulence energy

dissipation

ε

Turbulent intensity I

(m2/s

2) Turbulence kinetic energy κ

(kg/m.s) Second viscosity λ

N.s/m2 Dynamic Viscosity µ

(kg/m.s) Effective viscosity effµ

(kg/m.s) Turbulent viscosity Tµ

kg/m3 Density ρ

Empirical Constant ε

σκ

σ ,

Dissipation function Φ

1. INTRODUCTION

Frozen storage requires freezing of the product and storage at the temperaturerange between -

12 º C and -23 º C. Different factors govern the ultimate quality and storage life of any frozen product,

such as: (i) the nature and composition of the product to be frozen. (ii) The careful use in selecting,

handling and preparing the product for freezing. (iii) The freezing method. (iv) The storage



125

conditions [1]. Therefore, the main aim in designing a storage system is to ensure a uniform targeted

temperature and humidity in the bulk of storage product. The temperature distributions inside the

cold store depend on the air flow distribution, where theydependon the product, the cooling medium,

the geometry and characteristic of the cooling room.

They are several studies on the experimental and numerical investigation of air flow,

temperature such as:

M.L. Hoang et al. [2] investigated theairflow inside a cold store using CFX package. The

airflow model is based on the steady state incompressible, Reynolds-averaged Navier-Stokes

equations.The standard as well as the Renormalization Group (RNG) version of the k- Ɛ model is

investigated. Also, the finite volume method of discretization is used.Validation was performed by

comparisons of numerical and experimental data on vertical profiles of air velocity magnitudes. The

accuracy was 26% for the standard k–Ɛ model and 28.5% for the RNG.

A transient three-dimensional CFD model was developed by H.B. Nahor et al. [3] to

calculate the velocity, temperature and moisture distribution in an existing empty and loaded cool

store. An average accuracy of 22% on the velocity magnitudes inside the empty cold store was

achieved and the predicted temperature distribution found more uniform than the predicted results. In

the loaded cold store, an average accuracy of 20% on the velocity magnitudes was observed. Serap

Akdemir and Selcuk Arin[4] studied the spatial distribution of the ambient temperature, relative

humidity and air velocity in cold store. Their results are achieved at ceiling, medium and floor level

in the cold store and for different storage temperatures (0 ºC, 1 ºC, 2 ºC and 3 ºC). Mapping software

was presented to show the variability. Also, they indicated that the spatial distribution of the

temperature and the relative humidity was not uniform in the cold store. Bjorn Margeirsson and

Sigurjon Arason [5] investigated the temperature monitoring in both cold stores and containers

which are used for storage and transportation of frozen fish products. Numerical modeling of airflow

and temperature distribution in one of the cold store was performed using the CFD code Fluent for

both steady and unsteady.Seyed Majid Sajadiye et al. [6] used a multi-scale three-dimensional

CFDcode fluent model, which predicts the airflow, heat and mass transfer in a typical full loaded

cool storage. The model was validated against experiments by means of velocity, product

temperature, and product weight loss measurements in cool storage. The errors of about 23.2% and

9.1% were achieved for velocity magnitude prediction in the cool storage and the product weight loss

after 54 days of cooling in the loaded cool storage, respectively.

2. MODELING

2.1. Physical model The dimensions of the simulated cold store are100cm × 100cm × 100cm and the air cooling

fan dimensionsare74.5 cm × 40 cm × 14.3 cm. The door of the cold store located at the middle of the

front wall with dimensions, 57cm width, 67cm height and 5cm thickness. The structure of the cold

store is made from polyurethane insulation layer, 10 cm thickness, and the dimensions of the cold

store from inside are 80 cm × 80 cm × 80 cm.

2.2. Mathematical model To simplify the model, a number of assumptions were made:

Transient condition as analysis type, total time (1800 second) and times steps (10 second) for

empty cold store and steady state with 370 iterations for loading cold store; Negligible the natural

convection; No heat flow through the door and walls; The Boussinesq model was not adopted; Three

dimensional, Incompressible flow; The radiation between the side walls is ignored; Turbulence

medium intensity equal (5%) and The air flow is assumed as steady turbulent state.



126

According to the above assumption, the following equations for air inside cold store are given [7,8]:

( )

)9(3.1;0.1;92.12

;44.11

;09.0

)8(3.0

2/3,2)(

2

3

)7(2

21)(

)6()(

)5(2

)4(2)(2)(

2)(2)(2)(2)(2)(2

)3()()()()(

)2(2'

)1(0

=====

×=×=

−

∂

∂

+∂

∂

∂

∂=

∂

∂

∂

∂−

∂

∂+

∂

∂

−

∂

∂

+∂

∂

∂

∂=

∂

∂

∂

∂−

∂

∂+

∂

∂

=

+

∂

∂+

∂

∂+

∂

∂+

∂

∂+

∂

∂+

∂

∂+

∂

∂+

∂

∂+

∂

∂

=Φ

Φ++−=+∂

∂

∇+∂

∂−=

∂

∂+

∂

∂

=

∂

∂+

∂

∂+

∂

∂+

∂

∂

εσ

κσ

µµµ

ε

ρκ

εµκ

εµ

ε

εσ

µερ

ρε

ρεµκ

κσ

µκρ

ρκ

ε

κρ

µµ

νλµ

ννρνρ

µρ

ρρ

CCC

hD

kIUk

C

ix

jU

jx

iU

jx

iU

C

jx

T

jxj

U

jxt

ix

jU

jx

iU

jx

iU

Tj

x

T

jxj

U

jxt

CT

Udi

y

w

z

v

x

w

z

u

x

v

y

u

z

w

y

v

x

u

stateof

Equations

gradTkdiUdipTUdit

TEnergy

U ieffx i

pU jU i

x jt

U i

z

w

y

v

x

u

tContinuity

2.3. Initial Boundary Condition The initialization of the model is important for convergence. If the initial conditions are poor,

then it takes longer to converge or it may even result in divergence. In the present work the initial

conditions are:

1- The Cartesian velocity components (U=0, V=0 and W=0) all in m/s.

2- Relative pressure (0) Pa.

3- All variable are initiated for different temperature dependent on the initial experimental

temperature for each case as follows:

a- The initial temperature inside the empty cold store is 30 º C.

b- The initial temperature inside the loaded cold store is 32 º C and 35ºC for six meats distributed

in three levels.

2.4. Boundary conditions

The air velocity and temperature inlet boundary condition a, which are suggested 3.2m/s and

( evaporatorfromOutletT ) respectively for empty cold store, and 3.2m/s and -21 º C for loaded cold store, are

used in the present work. Where the velocity and temperature open boundary condition are

determined experimentally. These include velocity type Cartesian with insert automatic, with value

(U=0 m/s, V=0 m/s and W=1.78 m/s), the opening temperature ( evaporatortoInletT ) for empty cold store



127

and the opening temperature -21 º C for loaded cold store. Also, the other side inside the cold store,

which is symmetry in a boundary condition, is considered the other half of evaporator fan and trays.

All empirical equations are obtained using the multi-regression analysis technique and then

submitted as an expression in CFX, which depends mainly upon the experimental measurements,

from the inlet and outlet temperature of the evaporator. The empirical formulae of the outlet and inlet

temperature from evaporator as a function of time t are respectively:

sec]/[]sec/[6612763.0

sec]/[002296065.09077291.0][18583.27

]sec/[10719398103.1]sec/[10083517582.8

]sec/[10254451794.1]sec/[10033018813.5

sec]/[60548222298.0][3769572.305

55144411

337225

mVmK

tKTKT

tKtK

tKtK

tKKT

evapratorofback

evaporatorfromOutletevaporatortoInlet

evaporatorfromOutlet

××+

×−×+=

××+××−

××+××−

×−=

−−

−−

Tetrahedral mesh was generated using (3262752) elements, (663589) nodes to empty cold

store and (4475661) elements, (771219) nodes for loading cold store.

3. EXPERIMENTAL WORK

Cold storage has been designed and constructed depends on the provided materials and

equipment to achieve the freezing temperature below -20ºC. The outside and inside volumes of the

cold store are 1m3 and 0.512m

3, respectively, as shown in figure (1-a). Hermetic sealed

compressorsand air cooled condenser was located on the outside of the cold store. Force convection

evaporator was put on the ceiling of the cold storage as shown in figure (1-b),this unit has two fans

and the air velocity for each fan is 3.2m/s. After builds the cold store and before started the

experimental work the temperature distribution in and out from evaporator has been measured as

shown in figure (2).Also the other thermocouples are fixed at different levels, as shown in figure (3-

a). These have the capability to monitor the temperature in case of empty store and in case of loaded

store, see figure (3-a). The data are saved in SD card for the three 12 channel data logger that used in

the present work. The work interested in monitoring the inside and outside temperature, and the

relative humidity in the cold store.

(a) (b)

Figure (1): (a) cold storage and (b) The evaporator of the present design



128

Figure (2): Temperature in and out from the evaporator

(a) (b)

Figure (3): thermocouple distribution in three levels for empty cold store at (a) and loaded cold store

at (b)

4. RESULTS AND DISCUSSION

4.1. Experimental results

4.1.1. Temperature distribution

In the present work an experimental cold store was designed, built and operated to determine

the spatial distribution of the air velocity and air temperature. Since the temperature distribution is a

function of location and time, several cases have been implemented for temperature distribution for

empty and loaded storage which can bedescribed as follows:



129

4.1.1.1. Empty cold store

The air temperatures were determined at three levels located at different height ( 3cm, 28cm

and 53cm) inside the cold store and at different storage temperatures, -2°C, -10°C, -20°C and -21°C

respectively, as shown previously in figure (3-a).

The air temperature was varied between-2.5°C and 2.8°C for -2°C storage temperature, -

10.9°C and -7.8°C for -10°C storage temperature, -21.1°C and -18.3°C for -20°C storage

temperature, and -24.3°C and-20.1°C for -21°C storage temperature, respectively.

In the case of storage temperature -21°C, the temperature inside the cold store was 32°C and

the relative humidity was 32%. It takes 29 minutes to reach therequired storage temperature and then

the system pause due to the presence order, ON-OFF thermostat. The operation started again when

the temperature reached -17°C, due to differential temperature 4=∆T °C, and controlled by using

the thermostat.The air temperature distributions are measured during the operation of the system for

different runs. For each run the data are recorded by 12 channel data logger inside the cold store for

24 locations, six positions distributed in the center of each wall, as shown in figure (4-a), and 18

positions distributed in the air for three levels, as shown in figure (4-b). All temperatures are

recorded with a 2 minute elapse time.

(a) (b)

Figure (4): The measured temperature distribution as a function of time in the cold store for storage

temperature -21°C (a) 6 thermocouples distributed at the center of each wall. (b) 18 thermocouples

distributed on three levels in the air. (See figure (3-a))

4.1.1.2. Loaded cold store At the present work a 10.8 kg of meat, dimension 18cm×11cm×3cm, has been used and

frozen at the cold store. As shown in figure (3-b) thermocouples are distributed and arranged on

three levels within the loaded cold store. The air temperatures are measured at these three levels in

the loaded cold store for different storage temperatures -20°C and 21°C, where the measured air

temperatures are varied between -23.6°C and -20.5°C, for -20°C storage temperature, and -23.7°C

and -22.3°C, for -21° C storage temperature, respectively.

In the case of storage temperature -21°C, the temperature inside the cold store was 37°C and

the relative humidity was 34%. Took the time to reach therequired storage temperature was 62.5

minutes.By using thermocouples and read the temperature by 12 channel data logger inside the cold

store for 24 locations, six thermocouples are distributed in the center of each wall, as shown in figure

(5-a), and 18 are distributed in the air for three levels during each test, as shown in figure (5-b). The

temperature is recorded with 10 minutes time interval.



130

The temperature is recorded with 10 minutes time interval.

Six parts (two for each level) of meat distributed in the left half of the store. Each part have

0.9kg, distributed in the three levels, inside the cold store, and the other half assumed symmetric to

the left one, where (1M, 2M, 3M, 4M, 5M and 6M) referred to the locations of meat inside the cold

store, see figure (3-b) . The thermocouples are inserted inside each part of the meat with

(9cm×5.5cm×1.5cm) fixed locations. The initial temperature in the core of meat, at 1M, 2M, 3M,

4M, 5M and 6M locations, began from 33.9°C, 31.7°C, 34.8°C, 35.2°C, 31.8 °C and 36.5°C

gradually.

(a) (b) Figure (5): The measured temperature distribution as a function of time in the cold store for storage

temperature -21°C (a) 6 thermocouples distributed at the center of each wall. (b) 18 thermocouples

distributed on three levels in the air. (See figure (3-b))

4.1.2. Air velocity The air velocity from the two fans is same in the evaporator, so the flow pattern is

symmetrical in the cold store. Test make for finding the airflow distributions (Note that the points of

airflow distribution are shown in figure (6-a)) inside empty cold store for local air velocity by using a

hot wire anemometer, as shown in figure (7). The reason for non-uniform air temperature

distributions is the bad spatial distribution of air velocity generated by evaporator fan.

Each of velocities is normal to the six faces of parallelepiped of interest

),,,,( 212121 ZZyyXX VandVVVVV . The mean velocity V was then calculated using equation (12):

)12()()()( 2

2

2

2

2

2212121

LZZyyXX VVVVVV

V+++ ++=

The results from the equation above are shown in figure (6-b).

The figures(6-b and 7) show the air velocity distributions are the best at the top level, due to

exposure to the higher air velocity, and the best points in the lower level are (1,2 and 1M). Also, one

can see from these figures the medium level has less airflow distributions and this explains the bad

temperature distribution in this area.

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

ISSN 0976 – 6359(Online), Volume 5, Issue

Figure (6): air velocity distribution

(a), and Mean velocity distributionsby using a hot wire anemometer at (b)

Figure (7): the airflow distributions for

using a hot wire anemometer ((i) at x

4.2. Numerical results

4.2.1. Air flow and temperature distribution inside empty cold store for transient simulationThe initial temperature inside the cold store was 30°C for Air at 25 °C.

distributions, in a form of contours maps

transient.It takes 4 hours and 52 minutes to reach below

store.The air temperatures were determined at three levels located at different height, 5cm, 30cm and

55cm respectively inside the cold store, where three ZX

figure (8-a, 8-b,8-c) and after accumulating time steps

has been determined at different points, the locations of t

the results of the temperature distribution at these points are shown in figure (

Three dimensional ε−K turbulent models are used to simulate the air distribution in the

cold store. Figures (10-a, 10-b and 1

(10cm, 20cm and 30cm) respectively, inside the cold store.It is observed that the high velocity zones

were concentrated between the ceiling fan, from the inlet with constan

coils, at the back of the evaporator with constant velocity 1.78 m/s, and the approximation average

air velocity at the top, medium and bottom levels are

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

6359(Online), Volume 5, Issue 4, April (2014), pp. 123-137 © IAEME

131

air velocity distribution points for empty cold store by using a hot wire anemometer at

y distributionsby using a hot wire anemometer at (b)

the airflow distributions for the three levels in the cold storeand at different directions by

using a hot wire anemometer ((i) at x-direction, (ii) at y-direction and (iii) at z

distribution inside empty cold store for transient simulationThe initial temperature inside the cold store was 30°C for Air at 25 °C.

distributions, in a form of contours maps and charts, are presented in figures (

takes 4 hours and 52 minutes to reach below -21°C inside the simulation of cold

The air temperatures were determined at three levels located at different height, 5cm, 30cm and

spectively inside the cold store, where three ZX-planes are in the same locations,

accumulating time steps equal to 30 minutes. The air temperature also

has been determined at different points, the locations of these points are the same of figure (

temperature distribution at these points are shown in figure (9).

turbulent models are used to simulate the air distribution in the

0-c) show as the velocity vectors in YZ-planes at different length


were concentrated between the ceiling fan, from the inlet with constant velocity 3.2m/s, and cooling

evaporator with constant velocity 1.78 m/s, and the approximation average

air velocity at the top, medium and bottom levels are 0.55 m/s, 0.283 m/s and 0.303


by using a hot wire anemometer at

y distributionsby using a hot wire anemometer at (b)

the three levels in the cold storeand at different directions by

direction and (iii) at z-direction)

distribution inside empty cold store for transient simulation The initial temperature inside the cold store was 30°C for Air at 25 °C. The temperature

and charts, are presented in figures (8) and (9) with

21°C inside the simulation of cold

The air temperatures were determined at three levels located at different height, 5cm, 30cm and

planes are in the same locations, as shown in

The air temperature also

hese points are the same of figure (3-a) and

turbulent models are used to simulate the air distribution in the

planes at different length


t velocity 3.2m/s, and cooling

evaporator with constant velocity 1.78 m/s, and the approximation average

m/s respectively.



132

(a) (b)

(c)

Figure (8): Temperature distribution inside empty cold store at accumulate time step 30 minute

located at: (a) top level, (b) medium level and (c) bottom level

Figure (9): Air temperature distribution as a function of time in the cold store for 18 points

distributed on three levels



133

(a) (b)

(c)

Figure (10): velocity vectors distribution at different locations in YZ plane: ((a) at x=10cm, (b) at

x=20cm and (c) at x=30cm) inside empty cold store

4.2.2. Airflow and air temperature distribution inside loaded cold store for steady state

simulation

The initial temperature inside the cold store was 35°C for Air at 25 °C, The temperature and

airflow distribution in a form of contour maps are presented in figures (11) and (13) with steady

state. It takes 370 iterations to reach whole cold store under -20°C inside the simulation of cold store.

The air temperatures were determined at three levels located at different height (5cm, 30cm and

55cm ) inside the cold store, three ZX- planes at the same locations, as shown in figures (11-a,11-b

and 11-c).

The Air velocity vector distribution also has been determined at different length in a form of

YZ-planes at the same locations, as shown in figures (12-a, 12-b and 12-c). It is observed that the

high velocity zones were concentrated between the ceiling fan, from the inlet with constant velocity

3.2m/s, and cooling coils, at the back of the evaporator with constant velocity 1.78 m/s. The

approximation of the average air velocity at the top, medium and bottom levels are 0.603 m/s, 0.377

m/s and 0.366 m/s respectively.



134

(a) (b)

(c)

Figure (11): Temperature distribution inside loaded cold store located at (a) top level, (b) medium

level and (c) bottom level

(a) (b)

(c)

Figure (12): velocity vectors distribution at different locations at YZ- plane: ((a) at x=10cm,

(b) at x=20cm and (c) at x=30cm) inside empty cold store



135

4.3. Comparison between experimental and numerical results

Temperature and air flow distribution inside empty cold store

The temperature distribution results in the three levels (bottom, medium and top) for empty

cold store as shown in the figures (13-i, 13-ii and 13-iii) respectively. Average of the relative error

between experimental and numerical air temperature distribution is equal to 13%. Air flow

distribution results in the three levels (bottom, medium and top) for empty cold store as shown in the

figure (14) with relative error between experimentally and numerically equal to 20%.

(i) (ii)

(iii)

Figure (13): Comparison between experimental and numerical for air temperature distribution inside

empty cold store: (i) Bottom level, (ii) Medium level and (iii) top level



136

Figure (14): Comparison between experimental and numerical for air velocity distribution inside

empty cold store: (i) Numerical and (ii) Experimental

4.4. CONCLUSIONS From the present work results for the airflow and temperature distribution in a cold store,

different distinguish conclusions have been pointed out:

1- From the analysis of the variation of the air velocity at the middle and bottom of the cold store,

it was found that the variation is less than the top level of cold store because the evaporator was

placed at the top level of cold store.

2- The numerical results show the average air velocity for empty cold store at the top, medium

and bottom levels are 0.55 m/s, 0.283 m/s and 0.303 m/s respectively. Also, they show the

average air velocity for loading cold store at the top, medium and bottom levels 0.603 m/s,

0.377 m/s and 0.366 m/s respectively.

3- The air velocity strongly influences the performance of the unit. If the air velocity is too low

the necessary refrigerating effect and the correct storage temperature cannot be guaranteed. If

air velocity is too high the air stream becomes more turbulent thus increasing heat transfer with

the environment and the correct storage temperature can be guaranteed.

4- The two fans operate in normal conditions and therefore, the flow pattern is symmetrical inside

the cold store.

5- The air stacks appeared inside empty and loaded cold storage in several points; first stack

introduced should be close to the evaporator with minimum and maximum velocity equal to

0.038 m/sec and 0.431 m/sec for empty cold store, 0.08m/sec and 0.587 m/sec for loading cold

store respectively. Other stack appeared two more in empty store and four more in loaded store

with minimum and maximum velocity range equal to 0.025 m/sec and 0.46 m/sec for empty

store, 0.019 m/sec and 0.718 m/sec for loading store respectively.

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Shape on Airflow Distribution for a Generic 2-D Room Model with and Without Passive

Control”, International Journal of Mechanical Engineering & Technology (IJMET), Volume

5, Issue 1, 2014, pp. 10 - 25, ISSN Print: 0976 – 6340, ISSN Online: 0976 – 6359.

Date post:	11-Apr-2017
Category:	Engineering
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