•Outdoor air relative humidity affects frost accumulation limit temperatures.•Frost growth does not influence the Number of Transfer Units significantly.•Latent heat flux contributed to the local frost density should not be neglected. This paper tackles the issue of frost formation in non-hygroscopic rotary heat exchangers used for energy recovery from exhaust air under high-speed rotor conditions by means of numerical simulations and experimental approaches. On the basis of some idealized assumptions, a frost growth submodel is presented to predict the behavior of the rotary heat exchanger under frosting conditions. Frost formation is modeled by considering the mass diffusion of water vapor through the frost layer, taking into account supersaturation phenomena. Calculations were carried out using a three-zone model based on the modified ε-NTU method. The local heat transfer coefficient and the NTU calculation method resulting from the influence of the heat exchanger entrance region were also applied. The obtained correlations for the temperature effectiveness agree with the simulation data within uncertainty bounds. The results of the numerical simulations allowed us to determine the outdoor air conditions that initiated the frost accumulation phenomenon inside the thermal wheel for two values of return air relative humidity: RH2i=20% and RH2i=40%. In both cases, the threshold temperature for unsafe operating conditions increases with increasing relative humidity of the outdoor air. Under ‘frost accumulation’ operating conditions, the frost growth rate is approximately five times higher at RH2i=40% than at RH2i=20%. In this regard, the need to implement frost protection techniques increases significantly with an increase in relative humidity of return airflow. Further analysis conducted for the operation of a thermal wheel’s operation under frosting conditions revealed that a latent heat flux contributed to the local frost density should not be neglected in a compact heat exchanger’s model. Interestingly, the operation time of the rotary heat exchanger, and hence the growth of the thickness of the frost layer, has a significant influence on a local heat transfer coefficient α, however, it does not affect the Number of Transfer Units (NTU) visibly.