Visualization experiment and numerical simulation on behaviors of gas-liquid falling film flow on the air-side of two-row plain finned-tube heat exchanger

•Air-side falling film flow behaviors of FTHE are studied by visual experiment.•Flow patterns of liquid film are observed on the surface of plain finned-tube.•A 3D model with interfacial shear force is established based on VOF model.•Effects of fin pitch on liquid film formation are investigated numerically.•Critical Reynolds numbers of liquid film flow pattern transition are obtained. The frost-free air-source heat pump (ASHP) with integrated liquid desiccant dehumidification is a more promising energy-saving alternative to the conventional ASHP unit. The performance of spray-type finned-tube heat exchanger (FTHE), as one of the key equipment of this frost-free ASHP system, is affected by a combination of various factors including wall wettability, liquid film flow pattern, liquid film thickness, velocity distribution in a liquid film, interface wave, interface velocity and so on. To provide a theoretical basis for the operation, design and optimization of high-performance spray-type FTHE, a visualization experiment system and a three-dimensional (3D) numerical model are employed to study the behaviors of counter-current gas-liquid falling film flow on the air-side of two-row plain FTHE under different parameters in the present paper. According to the experimental results, the flow pattern of liquid film on the finned-tube surface is a mixture flow composed of the rivulet flow and the thin falling film flow, demonstrating that the assumption of the uniform distribution for liquid film thickness proposed in previous studies is not completely consistent with the actual situation. Meanwhile, the numerical results indicate that the transient-average film thickness on the surface of two-row plain finned-tube is significantly 18.3% – 32.5% higher than that on the vertical plate calculated by Nusselt's model. After that, the critical gas and liquid Reynolds numbers of the flow pattern transition for the liquid film are obtained, and it is pointed out that the wall contact angle of 10° is more conducive to the formation of complete film flow on the air-side of the two-row plain FTHE within the fin pitch range of 4.8 – 6.0 mm. The changes of the falling liquid film and gas-liquid interface characteristics are fundamentally attributed to the drag effect of the interfacial shear force. Furthermore, there is a cubic curve relationship between average interface shear force and gas Reg. A quadratic curve relation exists between average wall shear stress and gas Reg. At