AIR CYCLE REFRIGERATION:-BELL - COLEMAN CYCLE

1. AIR CYCLE REFRIGERATION

Air cycle systems can produce low temperatures for refrigeration by subjecting the gaseous refrigerant (air) to a
sequence of processes comprising compression, followed by constant pressure cooling, and then expansion to the
original pressure to achieve a final temperature lower than at the start of compression. Air cycle refrigeration is
based on the reversed Joule (or Brayton) cycle illustrated in figure 1 and figure 2. Air cycles can be classified as
closed, open or semi-open/closed. Closed cycles are, by definition, sealed systems and consequently there is no
direct contact between the working fluid and the product being cooled. Hence, in comparison with open and semi-
open/closed cycles an additional heat exchanger (with associated temperature difference) is required for transferring
heat from the refrigeration load. Open cycles can be open on either the low-pressure side or the high-pressure side
of the cycle. Cold air leaving the system passes through the refrigerated space coming in direct contact with the
product being cooled.

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Fig. 1. Air cycle refrigeration arrangement Fig. 2. Air cycle refrigeration on T-s diagram

2. BELL- COLEMAN/ REVERSED BRAYTON CYCLE:

The ideal cycle considered for air refrigeration cycle is called Bell-Coleman cycle. This consists of four processes.
They are
(i) Isentropic compression process (process 1-2)
(ii) Constant pressure cooling process ( Process 2-3)
(iii) Isentropic expansion process (process 3-4)
(iv) Constant pressure expansion process ( Process 4-1

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The schematic diagram of the arrangement of the components with different state points has been shown in Fig. 3.
The corresponding p-v and T-s diagrams have also been shown in Fig. 4 and Fig. 5 respectively.

Fig.3. Schenmatic arrangement of Bell- Fig.4. P-V diagram of Bell- Fig. 5. T-s diagram of Bell- Coleman
Coleman Cycle Coleman Cycle Cycle

2.1. Cycle Analysis:

Different processes mentioned earlier are described in this section.

1. Isentropic compression process:

The cold air from the refrigerator is drawn into the compressor cylinder where it is compressed isentropically in the
compressor as shown by the curve 1-2 on p-v and T-s diagrams. During the compression stroke, both the pressure
and temperature increases and the specific volume of air at delivery from compressor reduces from v1 to v2.

2. Constant pressure cooling process:

The warm air from the compressor is now passed into the cooler where it is cooled at constant pressure p3 (equal to
p2),reducing the temperature from T2 to T3 as shown by the curve 2-3 on p-v and T-s diagrams. The specific volume
also reduces from v2 to v3. Heat rejected by the air during constant pressure per kg of air is given by.
q R  Q 23  cp (T2  T3 )

3. Isentropic expansion process:

The air from the cooler is now drawn into expander cylinder where it is expanded isentropically from pressure p3 to
the refrigerator pressure p4. The temperature of air during expansion falls from T3 to T4 as shown by the curve 3-4
on the p-v and T-s diagrams. The specific volume of air at entry to the refrigerator increases from v3 to v4.

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4. Constant pressure expansion process:
The cold air from the expander is now passed to the refrigerator where it is expanded at constant pressure p4. The
temperature of air increases from T4 to T1 .This process is shown by the curve 4-1 on the p-v and T-s diagrams. Due
to heat from the refrigerator, the specific volume of the air changes from v4 to v1. We know that the heat absorbed by
the air (or heat extracted from the refrigerator or the refrigerating effect produced) during constant pressure
expansion per kg of air is

q A  q 4 1  cp (T1  T4 )

We know that work done during the cycle per kg of air= Heat rejected – Heat absorbed

= q R  q A  cp (T2  T3 )  cp (T1  T4 )

Heat absorbed qA c p (T1  T4 )

 Coefficient of performance, COP=  
Work done q R  q A c p (T2  T3 )  c p (T1  T4 )

T1
T4 (  1)
(T1  T4 ) T4
=  (1)
(T2  T3 )  (T1  T4 ) T T
T3 ( 2  1)  T4 ( 1  1)
T3 T4

 1
T p  
We know that for isentropic compression process 1-2, 2   2  (2)
T1  p1 

 1
T p  
Similarly, for isentropic expansion process 3-4, 3   3  (3)
T4  p 4 

T2 T3 T T
Since, p2 = p3 and p1 = p4, therefore from equations (ii) and (iii),  or 2  1 4)
T1 T4 T3 T4
Now, substituting these values in equation (1), we get

T4 1 1 1
COP     1
=  1
5)
T3  T4 T3
T4
 1  p3


 1  
rp  1
 p4 
p 2 p3
Where rp= compression or expansion ratio= 
p1 p 4

Sometimes, the compression and expansion processes take place according to the law pvn = constant, n is
called polytropic index. In such a case, the COP is obtained from the fundamentals as discussed below:

We know that work done by the compressor during the process 1-2 per kg of air

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 n n
wc   p 2 v 2  p1v1    RT2  RT1  ....( pv  RT)
n 1 n 1
n n
And work done by the expander during the process 3-4 per kg of air, w E  (p3 v3  p 4 v4 )  (RT3  RT4 )
n 1 n 1

n
 Net work done during the cycle per kg of air, w  w C  w E   R  T2  T1   (T3  T4 ) 
n 1

We also know that heat absorbed during constant pressure process 4-1, = cp (T1  T4 )

Heat absorped q A c p (T1  T4 )

 COP    6)
Work done w n
 R  T2  T1 )  (T3  T4 
n 1

We know that R  c p  c v  c v (  1)

Substituting the value of R in equation (6),

cp (T1  T4 )  (T1  T4 )
COP  
n n
 c v (  1)  T2  T1 )  (T3  T4    (  1)  T2  T1 )  (T3  T4  
n 1 n 1
7)
(T1  T4 )
 ......................................
n (  1)
  T2  T1 )  (T3  T4  
n 1 

For perfect gas and ideal cycle n becomes equal to  and the expression reduces to the original one. Therefore, C.O.P
is function of r (compression ratio) only. The values of COP (ε) for different pressure ratios have been shown in
table 1. with Pk and P0 being the two pressure involved in the cycle.

Table 1. Variation of COP with compression ratio

Pk 1 2 4 6
P0
ε  4.56 2.05 1.5

Pk Pk
Clearly, as the pressure ratio increases, ε decreases. So, should be kept small. But, there are some limits
P0 P0
on pk and p0 from the operating conditions.

3. ACTUAL CYCLE:
The actual cycle will differ from the ideal (Bell- Coleman) cycle due to two main reasons. They are
(i) Irreversibilities in the compressor and expander.: - The process of compression and expansion are no more
isentropic. This is taken care of by the isentropic efficiencies of the compressor and expander and are defined as

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For compressor,
isentroic work h  h1 T2 '  T1
ηisen = = 2' 
actual work h2  h1 T2  T1

For expander,

actual work h  h4 T3  T4
ηisen = = 3 
isentropic work h3  h4' T3  T4'

(ii) Pressure drops due to flow of gas through the refrigerator and cooler.

The acual cycle has been shown on T-s diagram in Fig. 6, where pk and p0 represent pressure drops in the
cooler and refrigerator respectively.

Fig. 6. Actual air cycle considering pressure drops in heat exchangers and
irrevesibilities in compressor and expander

4. ADVANTAGES OF AIR REFRIGERATION CYCLE:

(i) Since air is used as cooling medium, no cost of refrigerant is involved- quite cheap.
(ii) As the main compressor is employed for the compressed air source, there is no problem for extra space, extra
fixation of the compressor. Also there is no additional vibration.
(iii) The chilled air is directly used for cooling; the costs of separate evaporator and its weight are eliminated. there
is efficient heat transfer due to direct mixing between the cold air and warm air in the cabin.
(iv) As the air is refrigerant, minor leakage of the same is tolerated vis-à-vis that of the costly refrigerant.
(v) The pressure in the whole system is quite low, the piping, ducting, etc are quite simple to design, fabricate and
maintain.

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(vi) No complicated parts are involved rendering low maintaining cost.
(vii) It is light weight per ton of refrigeration compared to other refrigeration system.
(viii) Air is non-toxic, non-flammable as the desired properties of refrigerant.
(i) Air is easily available.
(ii) Non-flammable.
(iii) Weight is less (Aircraft refrigeration).

Disadvantages:
(i) Low COP of the system.
(ii) No evaporation (only sensible cooling)
(iii) Moisture in air may freeze.

5. AIRCRAFT REFRIGERATION:
The gas cycle or air cycle refrigeration is widely used for the air conditioning of differet types of aircrafts. Although,
the COP of this cycle is much less than that of vapour compression cycle, it is ptrefered for aircraft refrigeration
system due to its less weight and other advantages. Normally , in an aircraft, a compressor is already present for the
gas turbine power cycle. A part of the compressed air is used for air conditioning purpose as show in Fig. 7.

Fig. 7. Simple aircraft air conditioning system

Of course, in an actual aircraft air conditioning, the above cycle is modified using the ram effect of high velocity air
jet and more number of compressors and heat exchanger. The initial compression is done by using the ram effect of
air entering into the high velocity aircraft. The scheme has been shown in figure 8 on the T-s diagram. Other

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improved systems used for aircraft refrigeration after the modification of the basic systems include Bootstrap
system, Regenerative system and reduced ambient system.

Fig. 8. Simple aircraft refrigeration cycle with ram compression

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PROBLEM 1:
A refrigerating machine using air as the working fluid on closed Bell Coleman cycle operates under the following
conditions.
Refrigerator temp= 150K, cooler temp= 300K, the air temperature at the entry of the refrigerator is 40K less than the
refrigerator temperature. Pressure in refrigerator= 1 bar, calculate
(i) Refrigerating effect.
(ii) Net work.
(iii) COP of the machine.
(iv) Cooler pressure.

Solution:

Given, T1= 150K, T3= 300K, T4= T1- 40= 110K

Refrigerating effect= Qr= cp (T1-T4) = 1.05x40= 40.2 kJ/kg

T3 T2
For the cycle, 
T4 T1

T
 T2  3  T1
T4

300
Or, T2=  150  409.1
110

(ii)  Net work= c p  T2  T1    T3  T4   72.5 kJ/kg

Q 40.2
(iii) COP=   0.55
W 72.5

 1.4
 T2  1  409.1  .4
(iv) p 2     2.73 3.5
p1  T   150


 1

 p 2  33.6 bar

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Problem 2:
An air refrigeration plant of 20 ton capacity comprises a centrifugal compressor, a cooler heat exchanger and an air
turbine. The compressor is coupled directly to the air turbine. The compressor also receives power from another
prime mover. The processes in the turbine and the compressor are adiabatic, but not isentropic. Air at temperature
210C and 0.85 bar enters the compressor. It leaves the compressor at 900C. The same air enters the turbine at 380C
and 1.5 bar. The turbine exit is at 00C. Assuming no pressure drop in the cooler and the refrigerator (evaporator)
section, and constant specific Cp=1.004 kJ/kg. K and Cv= 0.712kJ/kg. K; determine.
(i) The compressor efficiency and the turbine efficiency
(ii) The flow rate of air.
(iii) The power input to plant.
(iv) COP of the system.

Solution:

Given,

T1  21+273= 294 K, T2= 90+273= 363 K, T3= 38+273= 311 K

P1= 0.85 bar= P4
P2= P2 =P3= 1.5 bar

T3= 38+273= 311 K

T4 = 0+273= 273

Now, assuming reversible adiabatic process in the compressor,

1 .41
 P2    1.5 1.41
We can write, T2= T1    294    347 K
 P1   0.85 

T T
(i) c  2 1 (CP is constant)
T2  T1

1 0.41
 0.85  1.41
(ii) T4  T3  P4  
 311  = 263 K
 P3   1.5 

T  T4 311  273

t  3   79.2 %
T3  T4 311  263

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(iii) Refrigerating effect per kg of air flow = cp  T1  T4   1.004(294-273)= 21.084 kJ/kg of air

Total refrigeration per min 20  210

 
 Mass flow rate= m   199.2 kg/min
Re frigeration per kg 21.084

  w c  w t   mc
(iv) Power input = m  p  T2  T1    T3  T4    199.2  1.004  363  294    311  273 

= 6200kJ/min =103.33 kW

Re frigeration 20  210
(v) COP=   0.677
Net work input 6200

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