UNIZAH COLLEGE OF ENGINEERING

Mechanical Engineering Department

Thermal Fluid Systems ME495

2. Compressors and Compressed Air System

Dr. Hussain Sadig

 1. Definitions

Compressor:

Is a device that converts mechanical energy (using an electric motor, diesel or

gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,
compressed air). By one of several methods, an air compressor forces more and
more air into a storage tank, increasing the pressure. When tank pressure reaches
its engineered upper limit the air compressor shuts off.

Compressed air system:

Is a number of components that work together to produce and distribute the

compressed air for use. A pneumatic system is a system that uses compressed air
to transmit and control energy.
 2. The advantages of Pneumatic Systems

1- Availability

There is an unlimited supply of air in our atmosphere to produce compressed air.

Moreover, the use of compressed air is not restricted by distance, as it can easily
be transported through pipes.

2- High durability and reliability

Compressed air system components are extremely durable and can not be
damaged easily. Compared to electromotive components, pneumatic components
are more durable and reliable.

3- Simple design

The designs of compressed air system components are relatively simple. They
are thus more suitable for use in simple automatic control systems.
 2. The advantages of Compressed air systems

4- Safety
Compressed air systems are safer than electromotive systems because they can work
in inflammable environment without causing fire or explosion. Unlike electromotive
components, pneumatic components do not burn or get overheated when overloaded.
5- Environmental friendly
The operation of compressed air systems do not produce pollutants. The air released
is also processed in special ways. Therefore, pneumatic systems can work in
environments that demand high level of cleanliness.
6- Economical
The compressed air system components are not expensive, the costs of pneumatic
systems are quite low. Moreover, the cost of repair is significantly lower than that of
other systems.
 3. The Limitation of Compressed air systems

4- Relatively low accuracy

As compressed air systems are powered by the force provided by compressed air,
their operation is subject to the volume of the compressed air. As the volume of air
may change when compressed or heated, the supply of air to the system may not be
accurate, causing a decrease in the overall accuracy of the system.
5- Processing required before use
Compressed air must be processed before use to ensure the absence of water vapour
or dust. Otherwise, the moving parts of the pneumatic components may wear out
quickly due to friction..
6- Noise
Noise will be produced when compressed air is released from the compressed air
components.
 4. The Use of Compressed air Systems

Due to the versatility of compressed air, it is widely used throughout industry to

power machinery, valves and actuators, and hand tools. The broad range of industrial

sectors where it is used includes manufacturing and processing, mineral extraction

and power generation.

Applications of compressed air include: Automotive, Chemical Manufacturing,

Electronics, Food, General Manufacturing, Glass Manufacturing, Hospitals/Medical,

Mining, Pharmaceuticals, Plastics, Power Generation, Wood Products and many

more compressed air is very convenient, but it's also expensive to generate. A typical

compressed air system is shown in the below figure.

4. The Use of Compressed air systems
5. Compressed Air System
 5.1. Compressed Air System Supply Side

Major compressed air supply subsystems typically include:

1. The air intake,

2. Air compressor

3. After cooler,

4. Controls,

5. Treatment equipment

6. Accessories.
 5.1. Compressed Air System Supply Side

Controls: serve to adjust the amount of compressed air being produced to

maintain constant system pressure and manage the interaction between system

components.

Air filters and air dryers: remove moisture, oil and contaminants from the

compressed air.

Compressed air storage: can also be used to improve system efficiency and

stability.

Accumulated water is manually or automatically discharged through drains.

Optional pressure controllers are used to maintain a constant pressure at an end

use device.
 5.2. Compressed Air System Demand Side

The demand side includes distribution piping, secondary storage and end use

equipment. A properly managed demand side would:

1. Minimizes pressure differentials,

2. Reduces wasted air from leakage and drainage and utilizes compressed air

for appropriate applications.

Distribution piping systems transport compressed air from the air compressor to

the end use point where it is required. Compressed air storage receivers on the

demand side can also be used to improve system pressure stability.

 6. Components of a compressed air system

compressed air systems usually consist of the following components:

 Compressor It is a mechanical device that increases the pressure of a gas

by reducing its volume. An air compressor is a specific type of gas

compressor.

 Inter-stage Coolers: Reduce the temperature of the air before it enters the

next stage to reduce the work of compression and increase efficiency. They

are normally water-cooled.

 After Coolers: The objective is to remove the moisture in the air by

reducing the temperature in a water-cooled heat exchanger.

 6. Components of a compressed air system

 Air receiver tank : It provides storage capacity to prevent rapid

compressor cycling, and motor and eliminate pulsing air flow.

 Dryers: Moisture, either liquid or vapor, is present in compressed air as it

exits the compressor system. If this moisture is not properly removed, the

compressed air system may lose efficiency and require dramatically

increased maintenance, which can result in costly downtime.

 6. Components of a compressed air system

 Distribution system The piping distribution system not only controls how

the air gets from the compressor room to the tools, it is a major factor in the

energy consumed by the compressor. Poorly designed or maintained systems

increase pressure losses and increase operating costs.

 A common error is to increase compressor delivery pressure to compensate

for distribution problems. This substantially increases energy costs. Higher

pressure increases leak rates, another major source of waste, thus the waste

and increased cost is compounded.

 6. Components of a compressed air system

 Valves:

• Directional control valves ensure the flow of air between air ports by

opening, closing and switching their internal connections.

• Flow control valve is a valve that controls the flow of air. Examples

include non-return valves, flow control valves, shuttle valves, etc.

 7. Compressors

The compressor produces compressed air at the required pressure.

There are three basic types of air compressors which are used in compressed
air systems:

 Reciprocating

 Rotary Screw

 Rotary Centrifugal

These types are further defined by:

 The number of compression stages

 Method of cooling

 Drive method

 How they are lubricated

7. Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
8. Reciprocating Compressors
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