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Guide to air
compressors
Together with electricity, water and
gas, compressed air keeps our world
running.
We may not always see it, but compressed air is
all around us. It is used in countless applications
in just about every industrial sector imaginable.
From trains and ships to construction sites and
manufacturing plants, the world would stand still
without it.
Sometimes, for example, when we blow up
a balloon or inflate the tires of our bicycles,
we even generate our own compressed air.
In most cases, however, we leave this job to
compressors.
And, because there are so many different uses
for (and demands of) compressed air,
compressors now come in all kinds of different
types and sizes.
Some of them are particularly well suited for the
rough environments you might find in a
construction site in a jungle. In that case, you
want them to be portable and extra reliable.
Others are so big that they can keep entire
. However, it is important to note that a
Others are so big that they can keep entire
production facilities running. And then there are
those that produce the extremely clean
compressed air needed for working with
pharmaceuticals or food.
This means that, if you are looking for a
compressor, there probably is a solution that is
a very good fit for your needs. However, it also
means that, in order to find that optimal
compressor, you either need to understand these
fascinating machines a bit better or find an expert
who does.
This guide will help you with both.
Energy air and
active air
The uses of compressed air are far too
numerous to count. Even listing the industries
that rely on it would take up too much space.
distinction is made between two main types of
compressed air: energy air and active air.
Energy air is used for storing and transmitting
energy in order to do mechanical work, such
as powering pneumatic tools. Here, the air
does not come into direct contact with end
products (and can therefore be less pure).
Active air, on the other hand, is required as an
active and integral part of a certain process.
In this case, the air comes in contact with
the product, which makes air quality very
important.
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How is air
compressed?

Before we look at the different
types of compressors, let’s first
examine how air is compressed.
Basically, to harness the energy of air, you have
to force it into a smaller space. At that time, the
nitrogen and oxygen molecules the air contains
are brought closer together and move more
rapidly.
The energy that gets released when expanding
the air again equals the energy that was needed
to force the air into the smaller space. In other
words, the energy is stored for future use.
,
energy) is released and the balloon zips around
the room at a high speed.
Essentially, that is what a compressor does. It
forces the ambient air that is all around us into a
smaller space. There, the air is either stored to
be used later or released right away to perform
a wide range of tasks, such as powering a
jackhammer or operating the brakes of a train.

While this may sound complicated or overly

scientific, you have probably done this many
times yourself.

When you blow up a balloon, you have to exert

an effort to force the air from your body into the
small opening of the balloon. As it inflates, the air
inside of it is compressed – along with the energy
that you have exerted to force it in there.

Once you let go of the opening, the air (and the

energy) is released and the balloon zips around
Positive displacement and
dynamic compression

Generally speaking, there are two methods

to compress air: Positive displacement
compression and dynamic compression. The
former includes most compressors being
used today, such as piston and rotary screw
compressors.

A displacement compressor encloses a

volume of gas or air and then increases the
pressure by reducing the enclosed volume
through the displacement of one or more
moving members. When the pressure has
reached the designed pressure ratio, a port or
valve is opened and the air is discharged into
the outlet system.
In dynamic compression, the air is drawn
between the blades of a rapidly rotating
compression impeller and accelerates to a
high velocity. It is then discharged through
a diffuser, where the kinetic energy is
transformed into static pressure.
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Why use
compressed air?
Compressed air is an excellent
medium for storing and
transmitting energy.

It is flexible, versatile and relatively safe

compared to other methods for storing energy,
like batteries and steam. Batteries, for example,
are bulky and have a limited charge life. Steam,
on the other hand, is neither as cost-effective
nor as user-friendly (it gets extremely hot) as
compressed air.
When comparing compressed air to electricity,
however, we find that the latter is more cost- What are the challenges of A second issue is that the ambient air that is
efficient. At least at first glance. But in that case, compressing air? being compressed inevitably contains
the other benefits of compressed air make the contaminants, such as tiny particles, moisture
difference. Perhaps most importantly, While all of these benefits make compressed air and even traces of oil. The compression process
compressed air is much safer for people and an excellent utility, there are some challenges increases the concentration of these
equipment. It is also more flexible, the tools it that have to be overcome. First of all, it takes a contaminants per cubic meter.
powers are more lightweight, more durable and lot of energy to produce it (just like it takes more
less expensive, which makes up for the higher effort to blow up a balloon than to breathe). Fortunately, there are ways to address both of
cost of compressed air. these problems to make sure that the
All this energy used is not only expensive but compressed air is as clean as it has to be and the
also adds to the environmental footprint of process of making it as sustainable as it can be.
businesses at a time when sustainability is
crucially important.
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Types of
compressors
But before we get into the specific technologies that make compressors
more efficient, let’s first look at the different types of compressors.
The two most prominent are piston and rotary
screw compressors.
Piston compressors are the oldest and most
common of all industrial compressors. They are
fairly simple machines (a piston is used to
compress air in a cylinder) that are often used
by operations with a limited, intermittent
compressed air demand. High-pressure
compressors generally also rely on piston
technology.
Their lower purchase price makes them an
attractive option for do-it-yourselfers and small
workshops. However, they typically cannot run
continuously for long periods of time and have to
cool down periodically. In addition, they feature a
lot of moving parts, which means they are more
subject to wear and tear and may require quite a
bit of maintenance.
That is why many companies with a higher
compressed air demand often turn to rotary
screw compressors.
As the name indicates, there are two screws at
the heart of these machines. These are also
referred to as male and female rotors and they
.
referred to as male and female rotors and they
are driven either by the male rotor (if they are oil-
injected) or by a timing gear (if they are oil-free).
In either case, the male and female rotors are
spinning in opposite directions. As a result, air
is drawn in-between them. As their cycle
progresses, the decreased space between the
rotors and their housing leads to air
compression. This compressed air is displaced
to the outlet.
Compared to piston compressors, screw
compressors offer many advantages. While a
 ,
compressors offer many advantages. While a
little more expensive to buy, they can run
continuously for many hours, are much more
efficient, emit less noise (and can therefore be
installed in more places) and do not require as
much maintenance.
In addition to these two types of compressors,
there are many others that are less frequently
used.
Here is a brief overview of them:
Diaphragm compressors
In these compressors, the diaphragm is actuated
mechanically or hydraulically. While mechanical
diaphragm compressors are used with a small
flow and low pressure or as vacuum pumps,
hydraulic diaphragm compressors are used for
high-pressure applications.
Tooth compressors
Like screw compressors, tooth technology
features two rotors. They rotate in opposite
directions inside a compression chamber. The
rotors, which are always synchronized, are
controlled by gear wheels. When they turn
, ,
controlled by gear wheels. When they turn
toward each other, they draw in air that is then
compressed before being forced out through an
outlet port.
Tooth compressors are often used when
especially pure air is needed, for example in the
health care or pharmaceutical sectors, whenever
the air comes in touch with food or in the
electronics industry.
Scroll compressors
Scroll compressors also rely on positive
displacement. The compressor element consists
of a stator spiral fixed in a housing and a motor-
driven eccentric, orbiting spiral. The spirals are
mounted with 180° phase displacements to form
air pockets with a gradually varying volume.
The
importance of
Total Cost of
Ownership
When looking to invest in a compressor,
keeping in mind the principle of the total cost
of ownership is extremely important and will
likely save you a lot of money in the long run.
Total cost of ownership … what does that
mean?
With total cost of ownership, we are referring
to all of the costs associated with a product.
In some cases, that primarily covers the
purchasing price. For example, when you buy
a couch, then you usually only have to pay for
it and there are no other costs associated with
that purchase (possibly apart from having to
pay people to move it).
This is very different for compressors.

180
air pockets with a gradually varying volume.
When the orbiting spiral moves, air is drawn in
and is captured in one of the air pockets, where
it is compressed gradually while moving towards
the center, where the outlet port and a non-return
valve are situated.
Scroll compressors are efficient and quiet. They
are also perfect for installations near the
operator, like laboratories, dentists or industrial
workshops where quietness is mandatory.
, ,
workshops where quietness is mandatory.
Vane compressors
Vane compressors consist of a rotor with radial,
movable blade-shaped vanes (usually made of
special cast alloys) that is eccentrically mounted
in a stator housing. When it rotates, the vanes
are pressed against the stator walls by
centrifugal force. Air is drawn in when the
distance between the rotor and stator increases.
It is then captured in the different compressor
pockets, which decrease in volume with rotation.
The air is discharged when the vanes pass the
outlet port.
Vane compressors have many applications.
They are used everywhere from the agricultural
and energy sectors to the automotive industry.
In addition, vane compressors also have
pharmaceutical, medical and dental applications.
Roots blowers
Roots blowers are valve-less displacement
compressors without internal compression.
Because they are not very efficient, they are only
used for low-pressure applications.
,
used for low-pressure applications.
A roots blower is comprised of two rotors that
spin in opposite directions. Once the
compression chamber comes into contact with
the outlet port, compressed air flows back into
the housing from the pressure side. Then, as the
volume of the compression chamber decreases
with continued rotation, further compression
takes place.
While the above are all displacement
compressors, there are also different dynamic
compressors.
Centrifugal compressors
These compressors are characterized by their
radial discharge flow. First, air is drawn into the
center of a rotating impeller with radial blades.
Then it is pushed out towards the perimeter of
the impeller by centrifugal forces.
The radial movement of the air simultaneously
results in a pressure increase and the generation
of kinetic energy. Next, before the air is led to
the center of the impeller of the next compressor
stage, it passes through a diffuser and a volute.
This is where the kinetic energy is converted into

, .
This is where the kinetic energy is converted into
pressure.
The impeller shaft reaches extremely high
speeds. At 15,000-100,000 rpm, these are much
higher than those of the aforementioned
compressors.
Axial compressors
These compressors have an axial flow, which
means the air passes along the compressor shaft
through rows of rotating and stationary blades.
As a result, the velocity of the air is gradually
increased at the same time as the stationary
blades convert the kinetic energy to pressure.
A balancing drum is usually built into the
.
A balancing drum is usually built into the with determining what size it should be. This is
compressor to counterbalance axial thrust. so important because of the amount of energy it
takes to compress air. If the compressor is too
large, you risk wasting a lot of energy (especially
if you choose a fixed-speed model). And that will
add a lot of unnecessary expenses to your
operation.
If the compressor is too small, on the other
hand, you will not be able to meet your demand.
That is also why it is important to take into
account any future expansion. By factoring in
your future compressed air needs, you can
avoid having to purchase another compressor
again too soon.
But how do you properly size a compressor?
Axial compressors are generally smaller and
lighter than their equivalent centrifugal
compressors and normally operate at higher
speeds. They are used for constant and high-
volume flow rates at a relatively moderate
pressure, for instance, in ventilation systems.
Given their high rotational speed, they are
ideally coupled to gas turbines for electricity
generation and aircraft propulsion.
The search for the optimal compressor begins
with determining what size it should be. This is
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Sizing your
compressor
The search for the optimal
compressor begins with
determining what size it should be.
This is so important because of the amount of
energy it takes to compress air. If the
compressor is too large, you risk wasting a lot of
energy (especially if you choose a fixed-speed
model). And that will add a lot of unnecessary
expenses to your operation.
If the compressor is too small, on the other
hand, you will not be able to meet your demand.
That is also why it is important to take into
account any future expansion. By factoring in
your future compressed air needs, you can
avoid having to purchase another compressor
again too soon.
But how do you properly size a compressor?
Determining your air requirement
and working pressure
To determine the ideal size for your compressor,
you should know your air requirement and
working pressure.
,
The latter is measured in pounds per square connected, and estimating their individual
inch (psi) or bar (metric measure of pressure). If utilization factor by experience. In addition, you
you are unfamiliar with these terms, just think of should also take into account leakage, wear and
pressure as the amount of force that is required future air requirement changes when sizing the
to perform a task at any given point in time. To compressor.
go back to our earlier example, it is the amount
of effort you have to exert to push air from your If you are confident in being able to determine
mouth into the small opening of a balloon. your own air requirement and working pressure,
then you should calculate and periodically
In order to complete the task without wasting reassess it. However, if you need help with this
energy, you want to make sure that you get the task, do get in touch with an Atlas Copco
pressure just right. representative, who will be happy to assist you.
The air requirement, on the other hand, refers to
the total volume of compressed air you need. It
is calculated as the sum of the air consumption
of all tools, machines and processes that will be
connected, and estimating their individual
Be mindful of your surroundings
when sizing a compressor
When sizing a compressor, many users do not take into account the ambient conditions of
where and how they want to set it up.

These include the elevation above sea level, ambient pressure and temperature, and humidity.
Coolant pressure, compressor type and power source must also be considered.

All of these factors can affect the maximum working pressure, the compressor’s capacity, its
power consumption and the cooling requirement.

The most important factor is the inlet pressure variations at altitude. For example, a compressor
with a pressure ratio of 8.0 at sea level will have a pressure ratio of 11.1 at an altitude of 3,000
meters (if the application’s operating pressure remains constant).

Note that the ambient temperature, humidity and coolant temperature all interact and affect the
compressor performance to different degrees depending on the compressor type.
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Optimal compressor
placement and
working conditions

Your compressor room, which is
the place where you place the main
part of your compressed air
system, should be carefully chosen
to ensure the optimal operation of
the equipment and the system as a
whole.
Here are some of the things you should take into
account when selecting it:
1. A central location to minimize the piping you
need to get the air to the point of use and reduce
the pressure drop.
2. A solid, flat foundation (in some cases it has to
be reinforced or vibration-dampened)
3. The acceptable noise level in that location.
4. An environment as free as possible from
contaminants and hazardous substances to
have clean intake air.
5. The proper ventilation required to keep the
equipment from overheating.
,
compressor room for harsh conditions. For
example, you have to ensure that the cooling
water or condensate cannot freeze and that
drains and the piping system are insulated.
In addition, the drains should also be checked
for malfunctions, the filters should be maintained
and leaks located and repaired.
5.
equipment from overheating.
6. A temperature that protects the equipment.
7. Drainage for the condensation. Tip
8. User friendliness and ease of service.
You should consider adding a heat
9. Protection against unauthorized access. recovery system to your installation.
Compressing air generates a lot of heat.
10. Protection from the elements (if the Fortunately, the vast majority of it can be
compressor room is outdoors) recovered, which can save you a lot of
energy and money.
In addition, it is also important to prepare the
compressor room for harsh conditions. For
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The importance of
clean compressed
air

The cleaner your air, the better
protected your equipment,
processes and end products are.
There is just one problem: Ambient air always
contains some (or many) contaminants.
As a result, compressed air is under constant
assault from tiny particles, moisture and oil.
Keeping them out, e.g. with oil-free compressors,
dryers, water separators and filters, is not just
good business, in many cases it is also required
to meet air quality standards.
Compliance with air quality and
compressor regulations
Compressed air equipment, as well as the air it
produces, is subject to national and international
standards and recommendations.
In terms of air quality, the most important of them
is ISO 8573-1:2010. This international standard
for air purity classes defines the acceptable level
of moisture, particulate, oil and other pollutants in
of moisture, particulate, oil and other pollutants in
a compressed air stream.
There are lots of applications for which purity is
of little importance. For example, when it comes
to operating a jackhammer, the only reason why
you have to pay attention to keeping
contaminants out of the compressed air is to
protect the tool and the system itself.
There are many others, however, in which purity
is very important, especially when the
, ,
is very important, especially when the
compressed air comes into contact with end
products that are later consumed, such as food
or pharmaceuticals.
As a rule of thumb, you can broadly categorize
air into four groups: Breathing air, such as that
used in hospitals, has to be the purest. Next is
process air, which is the air that comes into
contact with end products. Then you have
instrument air, which is used for pneumatic
equipment, valves and electrical controls. Finally,
there is plant air, which is needed for applications
such as air drying and doesn’t have to be clean
at all.
In addition to the air itself, you should also find
out what standards and regulations the
compressed air equipment in your country or
industry is subject to.
In the EU, for example, compressors have to
comply with a variety of general machinery,
electrical safety, noise and environmental
standards as well as those governing pressure
equipment.
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The compressors of
the future are
already here
When it comes to compressors,
meeting all of these standards
should only be the minimum goal.
Especially in light of their environmental footprint
(and the cost of energy, of course), choosing
especially sustainable models can help
companies meet their climate goals.
And, in this regard, compressors have come a
long way.
A long time ago, they were often very simple
machines: You flip a switch and they give you
a continuous stream of compressed air that is
generated in a manner that is not exactly
environment friendly.
Now, however, they have become sophisticated
machines, some of which are at the cutting edge
of sustainability and connectivity.
Take the GA VSDS series from Atlas Copco.
Compared to fixed-speed compressors, the
models of this range can offer you energy
savings of up to 60%. That not only makes a
savings of up to 60%. That not only makes a
tremendous difference in terms of the total cost
of ownership but also their environmental
footprint.
In addition to drastically reducing its energy
consumption, the VSDS range was designed with
sustainability in mind. Its IE5-efficiency motor
with sustainably resourced materials is just one
example.
And when it comes to connectivity, compressors
have definitely arrived in the age of the Internet of
Things. You can monitor state-of-the-art models
from just about anywhere on earth to optimize
their performance. New compressors will alert
you if there is (or might be) a problem so that you
can address it right away before it affects your
operation.
The VSDS series is the world’s first that is OPC
UA enabled. In layperson’s terms, that means
it speaks a common machine language that the
surrounding machines in a production
environment can understand to ensure that the
system overall operates more smoothly and
reliably.
If you are confident in being able to determine
your own air requirement and working pressure,
then you should calculate and periodically
reassess it. However, if you need help with this
task, do get in touch with an Atlas Copco
representative, who will be happy to assist you.
Finding help if you need it
Hopefully, this guide will have given you an overview of what compressors do, why you need
them and what types of options are available to you.

If you need additional assistance, just reach out to Atlas Copco to talk compressors!
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Guide to air
compressors
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