Topic: Air Compressors

(5 period – 4 hours 10 minutes)

Course: Heat Power (ME 3106)

B. Tech. (Electrical Engg.) – 5th Semester
IIEST, Shibpur
2021 – 22
Introduction
Compressors and pumps are devices in which work is done on the substance flowing through
them in order to change the state of the substance, typically to increase the pressure and/or
elevation.
Compressor is used when the substance is a compressible, like a gas or vapor. The pressure of
the gas increases with an appreciable increase in its density. Gas compression is required in
power plants, refrigeration plants, automobiles and other industrial and manufacturing areas.
Pump is used when the substance is incompressible, such as liquid.
Air Compressor compresses air to a higher pressure which may be stored in a pressure vessel
and can be used for:
• For filling the air in tube of vehicles
• For spray painting in paint industries.
• In vehicle to operate air brakes.
• For cleaning in manufacturing workshop, automobile service station, etc.
• For supercharging of an IC engines.
• For operation of pneumatic tools i.e. rock drills, vibrators etc.
Introduction
Compressors are classified into two
major categories:
1) Intermittent Flow compressors:
Operate by trapping a specific
volume of air and forcing it into a
smaller volume. This kind of
compression is done by the
positive displacement of a moving
part like piston or vane
2) Continuous Flow Compressors: As
the name suggests, continuous
flow of high pressure fluid is
delivered at the outlet. Mostly high
velocity of rotating devices or
moving stream accelerates the
fluid. The Kinetic Energy of the
fluid is converted to high pressure
at the outlet by using a diffusor
Air compressor – useful terms
• Compression ratio: It is defined as the ratio of volume of air before compression to the volume of air after compression.
• Compressor capacity: It is the quantity of air actually delivered by a compressor in m3/minute or m3/sec.
• Swept Volume: The volume displaced or swept by the piston when it moves from top dead center to bottom dead center.
• Clearance volume: it is the difference between the total volume and the swept volume, basically the gap that remains
between the piston head and the cylinder head when at top dead center.
• Free Air Delivered (FAD): It is the volume of air delivered by compressor under the compressor intake conditions (i.e.
temperature and pressure of inlet air).

Efficiencies
• Volumetric efficiency: It is the ratio of actual volume of the FAD at standard atmospheric condition in one delivery stroke
(actual air intake) to the swept volume (theoretical air intake) by the piston during the stroke.
• Isothermal efficiency: It is defined as the ratio of isothermal power (Piso) (i.e. required input power at isothermal process)
done to the indicated power (IP) or actual work done.
• Mechanical efficiency: It is the ratio of indicated power (IP) to the shaft (Brake) Power (Pshaft).
• Overall efficiency: It is the ratio of isothermal power (Piso) to the shaft (Brake) Power (Pshaft).
Reciprocating Compressors
• The primary components of the typical
reciprocating compressor system can be seen
in the figures
Working principle of Simple Reciprocating Air Compressor
(Single Cylinder, Single Stage, Single Acting)
Reciprocating Compressor
• The compression cylinders provide confinement for the process gas (gas to be compressed, in this case, air)
during compression.
• If the compression cylinders are used in succession, then those are referred to as stages. Stages may be one
(for low pressure requirement) or more (for high pressure requirement)
• A piston is driven in a reciprocating
action to compress the gas.
• Arrangements may be of single- or
dual-acting design. In the dual-
acting design, compression occurs
on both sides of the piston during
both the advancing and retreating
stroke.
• Some dual-acting cylinders in high-
pressure applications will have a
piston rod to provide linear motion
through a sealed passage.
Single Stage, Single Cylinder
Single Stage, Double Cylinder
Tandem cylinder
arrangements in multi-stage
compression help minimize
dynamic loads by locating
cylinders in pairs, connected
to a common crankshaft, so
that the movements of the
pistons oppose each other.
Two-Stage Two Cylinder
 Multi-Staging
• Multi-staging is done for reduction in
power required to drive the compressor.
• Better mechanical balance of the whole
unit and uniform torque.
• Increase in volumetric efficiency.
• Reduced leakage loss.
• Less difficulty in lubrication due to low
working temperature.
• Lighter cylinders can be used.
• Cheaper materials can be used for
construction as the operating
temperature is lower.
Double Acting
• Double – Acting Compressor is a
compressor that completes two discharge
strokes per revolutions of crankshaft.
• A Long-stroke cylinder needs precision
guides for the piston rod.
• Most heavy-duty (very high pressure)
compressors are double acting.
• Rigorous cooling is required in double
acting compressors, as the operating
temperature is high
• Larger floor space is required
Double Acting, Single Stage Double Acting, Two-Stage

Using disposable piston rings and rider bands, made of

comparatively softer materials, minimizes wearing of
expensive components and seals off the gas pressure
• Compressing a gas increases its internal energy which in turn raises its temperature.
• Intercoolers and aftercoolers are similar heat exchangers, the only difference is the place
where those are used. Both Intercoolers and Aftercoolers will cause the cooling of
compressed air by removing the heat generated during the compression of air.
Intercooler Aftercooler
An intercooler is a heat exchanger used Aftercoolers are used between the last
to cool compressed gas between compression cylinder and the storage
different stages of compression tank or engine
• These heat exchangers use air-to-air or air-to-liquid cooling
• An efficient intercooling or aftercooling restore the temperature of compressed air to near
environmental levels.
• Use of intercoolers and aftercoolers reduces the volume and increase the air’s density
which in turn, reduce the pipe friction and boosts the overall efficiency and power output
from the compressor.
• An effect of this heat exchange is the condensation of water vapor suspended within the
air. The elimination of water will protect moisture sensitive components from corrosion.
Thermodynamic Analysis of Reciprocating Compressor
• Assumptions:
• Consider single cylinder single acting reciprocating compressor
• The working fluid i.e. air, in this case, is considered to be a perfect gas, i.e. it obeys
simple equation of state 𝑝𝑣 = 𝑅𝑇
• Potential and Kinetic energy contributions in SFEE are negligible
• All processes are reversible

• There are three cases we are considering:

1. Single stage compressor
1. without clearance volume
2. with clearance volume
2. Multistage compressors with clearance
Single Stage Compressor without Clearance Volume
• Stroke 1 – Process 0-1: induction process – Intake valve
opens, while exhaust valve closed. Atmospheric air is drawn
into the cylinder at constant pressure 𝑝1 and temperature 𝑇1 .
Ideally, there is no heat loss to the surrounding from the air.
• Stroke 2 – Process 1-2: compression process – Both intake and
exhaust valves closed. The air is compressed according to a
polytropic law 𝑝𝑣 𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛. Its pressure is increased from
𝑝1 to 𝑝2 . The temperature is also increased from 𝑇1 to 𝑇2 .
• Stroke 2 – Process 2-3: delivery process – The intake valve
closed while the exhaust valve opens. The compressed air is
pushed out of the cylinder at constant pressure 𝑝2 and
temperature 𝑇2 . There is no heat loss from the air to the
surroundings.
Single Stage Compressor without Clearance Volume
Work of Compression
• The total area enclosed by the indicator diagram represents the
actual work done by the compressor on the gas. So, the work done
during the cycle (𝑊) = – (area enclosed by 0-1-2-3-0)
• –ve sign signifies, work is done on the system by the compressor.
• or, 𝑊 = – [(area under curve 1-2) + (area under curve 2-3)
– (area under curve 0-1)]
• Consider that the suction process 0-1 and delivery process 2-3 are
isobaric processes (𝑝 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡) and the compression process 1-2
is reversible polytropic, 𝑝𝑉 𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡
• Area under the process curves, when added algebraically, gives the
𝑝2 𝑉2 −𝑝1 𝑉1
work of compression, 𝑊 = − + 𝑝2 𝑉2 − 𝑝1 𝑉1
𝑛−1
𝑛 𝑛 𝑝 𝑉
• or, 𝑊 = − 𝑝2 𝑉2 − 𝑝1 𝑉1 = − 𝑝1 𝑉1 2 2 −1
𝑛−1 𝑛−1 𝑝1 𝑉1
Single Stage Compressor without Clearance Volume
Work of Compression
1
𝑉2 𝑝1 𝑛
• For reversible polytropic process 1-2, 𝑝𝑉 𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 𝑝1 𝑉1𝑛 = 𝑝2 𝑉2𝑛 or, =
𝑉1 𝑝2
1
𝑛 𝑝2 𝑝1 𝑛
• The indicated work of compression is given by: 𝑊 = − 𝑝 𝑉 −1
𝑛−1 1 1 𝑝1 𝑝2

𝑛−1 𝑛−1
𝑛 𝑝2 𝑛 𝑛 𝑝2 𝑛
or, 𝑊 = − 𝑝 𝑉 −1 = − 𝑚𝑅𝑇1 − 1 , considering 𝑝𝑉 = 𝑚𝑅𝑇
𝑛−1 1 1 𝑝1 𝑛−1 𝑝1
for perfect gas of mass 𝑚 which is compressed during the cycle.
• Now, replacing 𝑛 = 1 gives work done for the isothermal compression and 𝑛 = 𝛾 gives
work done for the reversible adiabatic (isentropic) compression
• For isothermal compression, the work is minimum and for isentropic compression, the
work is maximum, for same pressure ratio 𝑝2 /𝑝1
Single Stage Compressor without Clearance Volume
Efficiency of Compression
• All the work done on the gas increases its enthalpy which in turn causes the pressure and
temperature to rise.
• If it is isothermal compression (𝑛 = 1), then the generated heat is dissipated as soon as its
generation and the temperature did not rise.
• But ideal isothermal compression is practically impossible due to high speed of the process.
Therefore, it is attempted to make the compression as near as possible to an isothermal process by
extracting heat as quickly as possible during the process by air cooling using fins and cooling fan or
water jacket. Despite of the efforts, the polytropic index best varies between 1.2 to 1.3.
ℎ2 −ℎ1
• The efficiency of a compressor working in a steady flow process may be defined as: 𝜂 = ,
𝑊
where, 𝑊 is the shaft work supplied to the compressor per unit mass. For isothermal compressors,
ℎ −ℎ ℎ −ℎ
𝜂 = 2𝑇 1 and for adiabatic compressors, 𝜂 = 2𝑠 1
𝑊 𝑊
• For reciprocating machines, the compressors may be an indicated work basis or a brake work basis,
depending on where the input work is measured.
• High speed compressors (mostly dynamic compressors) are essentially adiabatic.
Single Stage Compressor with Clearance Volume
• The clearance volume is the spacing between
the top of the piston and the valve’s heads
when the piston is at the end of the delivery
stroke (TDC). Good quality machines has a
clearance volume of about 6%. But compressors
with clearance of 30 – 35% are also common.
• Clearance gives a mechanical freedom to the
moving parts
• It reduce noise and vibration during operation
• It also prevent damage to moving components
• Stroke 1 – Process 1-2: compression process –
Both intake and exhaust valves remains closed.
The air is compressed following a polytropic
process 𝑝𝑣 𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 . Its pressure is
increased from 𝑝1 to 𝑝2 . The temperature is
also increased from 𝑇1 to 𝑇2 .
Single Stage Compressor with Clearance Volume
• Stroke 1 – Process 2-3: delivery process – when
cylinder pressure reaches 𝑝2 the discharge valve
opens and compressed air is delivered until the
piston reaches TDC.
• Stroke 2 – Process 3-4: Both valves are closed
and the piston withdraws from TDC, causing the
air remained in the clearance volume to expand
following a polytropic process 𝑝𝑣 𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡.
• Stroke 2 – Process 4-1: induction process –
When this withdrawal of piston causes the
pressure in the cylinder falls below the
atmospheric pressure at state 4, intake valve
opens, while exhaust valve closed. Atmospheric
air is drawn into the cylinder at constant
pressure 𝑝1 and temperature 𝑇1 . Ideally, there is
no heat loss to the surrounding from the air.
Single Stage Compressor with Clearance Volume
Work of Compression
• The total area of the indicator diagram represents the actual work
of the compressor on the gas
• Work done on air during the cycle (𝑊) = – (area enclosed by 1-2-3-4-1)
• or, 𝑊 = – [(area under curve 1-2) + (area under curve 2-3)
– (area under curve 3-4) – (area under curve 4-1)]
𝑝2 𝑉2 −𝑝1 𝑉1 𝑝 𝑉 −𝑝 𝑉
• or, 𝑊 = − + 𝑝2 𝑉2 − 𝑉3 − 3 3 4 4 − 𝑝1 𝑉1 − 𝑉4
𝑛−1 𝑛−1
𝑛
• or, 𝑊 = − 𝑝 𝑉 − 𝑉3 − 𝑝1 𝑉1 − 𝑉4
𝑛−1 2 2
𝑛−1
𝑛 𝑝2 𝑛
• or, 𝑊 = − 𝑝 𝑉1 − 𝑉4 −1
𝑛−1 1 𝑝1

• From the gas equation for ideal gas (i.e. air) 𝑝𝑉 = 𝑚𝑅𝑇 evaluated at state 1, 2, 3 and 4, and after some
𝑛
manipulation we get, 𝑊 = − 𝑚1 − 𝑚3 𝑅 𝑇2 − 𝑇1 , where, 𝑚1 − 𝑚3 is the difference between the mass
𝑛−1
of air present at the end of suction and that present at the end of delivery, or net mass to be compressed.
𝑛−1
𝑛 𝑝
• or, 𝑊 = − 𝑚1 − 𝑚3 𝑅𝑇1 2 𝑛 −1
𝑛−1 𝑝1

• Thus the mass of gas in the clearance volume has no effect on the work of compression.
Single Stage Compressor with Clearance Volume
Volumetric Efficiency
• The amount of air dealt with in a given time
by an air compressor is often referred to at
free air conditions, i.e. the temperature and
pressure of the environment (may be taken
as 15°C and 101.325 kPa), it is known as the
Free Air Delivered (FAD)
• The ratio of the actual volume of gas taken
into the cylinder during suction to the
piston displacement volume or the swept
volume is called the volumetric efficiency,
𝑉1 − 𝑉4 𝑉𝑐 + 𝑉𝑠 − 𝑉4 𝑉𝑐 𝑉4
𝜂𝑣𝑜𝑙 = = =1+ −
𝑉1 − 𝑉3 𝑉𝑠 𝑉𝑠 𝑉𝑠
Single Stage Compressor with Clearance Volume
Volumetric Efficiency
𝑉1 − 𝑉4 𝑉𝑐 + 𝑉𝑠 − 𝑉4 𝑉𝑐 𝑉4
𝜂𝑣𝑜𝑙 = = =1+ −
𝑉1 − 𝑉3 𝑉𝑠 𝑉𝑠 𝑉𝑠
𝐶𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑣𝑜𝑙𝑢𝑚𝑒 𝑉𝑐
Let, 𝐶 = =
𝑆𝑤𝑒𝑝𝑡 𝑣𝑜𝑙𝑢𝑚𝑒 𝑉𝑠

And since, 𝑝4 𝑉4𝑛 = 𝑝3 𝑉3𝑛

or, 𝑝1 𝑉4𝑛 = 𝑝2 𝑉3𝑛
1 1
𝑝2 𝑛 𝑝2 𝑛
or, 𝑉4 = 𝑉3 = 𝑉𝑐
𝑝1 𝑝1

Therefore, replacing 𝑉4 we get,

1
𝑉𝑐 𝑉𝑐 𝑝2 𝑛 1
𝜂𝑣𝑜𝑙 =1+ − = 1 + 𝐶 − 𝐶 𝑟𝑝 𝑛
𝑉𝑠 𝑉𝑠 𝑝1
Single Stage Compressor with Clearance Volume
Volumetric Efficiency
• Since, pressure ratio is always greater than unity, it is evident that the volumetric efficiency
decreases as the clearance increases and as the pressure ratio increases.
• In order to get maximum flow capacity, compressors are built with the minimum practical
clearance.
1
• Maximum clearance attainable for 𝜂𝑣𝑜𝑙 = 0 is: 𝐶max = 1
𝑝2 𝑛
−1
𝑝1

𝑝2 𝑚𝑎𝑥 1 𝑛
• Maximum pressure ratio attainable for 𝜂𝑣𝑜𝑙 = 0 is: = 1 +
𝑝1 𝑐
Actual p-V Diagram
• At point 4, the clearance air actually reduced to atmospheric pressure. But, the inlet valve,
in practice, does not open. Reasons: (i) inlet valve inertia, and, (ii) there must be an
adequate vacuum pressure difference.
• With the further movement of the piston towards the BDC, the pressure drops away,
increasing the vacuum until the valve is forced off its seat. Due to sudden opening of the
valve, some valve bounce sets in (wavy 4-1 curve). This intake depression settles naturally
and the intake occurs at some pressure below atmospheric pressure almost steadily.
• Similar situation occurs at point 2. There
occurs a constant pressure rise, followed by
valve bounce and the pressure then settles
at some pressure above external delivery
pressure (i.e. Receiver tank pressure).
• Other small effects at inlet and delivery
would be gas inertia and turbulence.
Multi-stage compression
• The volumetric efficiency decreases with increasing delivery
pressure, as the effective swept volume reduces.
𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑆𝑤𝑒𝑝𝑡 𝑉𝑜𝑙𝑢𝑚𝑒 𝑉𝑎 −𝑉𝑑
𝜂𝑣𝑜𝑙 = = .
𝑆𝑤𝑒𝑝𝑡 𝑉𝑜𝑙𝑢𝑚𝑒 𝑉𝑎 −𝑉𝑐

• The volumetric efficiency can be improved by performing

multistage compression. In case of two-stage compression, after
the first stage of compression (at comparatively lower pressure)
from initial state 𝑝1 , 𝑇1 the fluid is raised to an elevated
𝑛−1
𝑝𝑖 𝑛
intermediate state 𝑝𝑖 , 𝑇𝑖 . Where, 𝑇𝑖 = 𝑇1 (obtained from
𝑝1
the expression of polytropic process)
• The cycle assumes that the delivery process of the first stage and
the induction process of the second stage take place at the same
intermediate pressure 𝑝𝑖 .
Multi-stage compression …contd.
• Then the fluid at 𝑝𝑖 , 𝑇𝑖 is passed into a second comparatively smaller (high pressure) cylinder where
the gas is compressed to a higher final pressure 𝑝2 at delivery temperature 𝑇2 . The delivery
𝑛−1 𝑛−1 𝑛−1 𝑛−1
𝑝2 𝑛 𝑝𝑖 𝑛 𝑝2 𝑛 𝑝2 𝑛
temperature 𝑇2 = 𝑇𝑖 = 𝑇1 = 𝑇1 . So, the delivery temperature
𝑝𝑖 𝑝1 𝑝𝑖 𝑝1
increases with the pressure ratio.
• Using intercooler between stages, improves the volumetric efficiency furthermore. A complete or
perfect intercooling reduces the delivery temperature attained after first stage of compression to
𝑛−1
𝑝2 𝑛
ambient temperature, or, 𝑇𝑖 is reduced to 𝑇1 . So, final delivery temperature, 𝑇2 = 𝑇1 . Again,
𝑝𝑖
𝑝2 𝑝2
< , so the final delivery temperature 𝑇2 is less when an intercooler is used.
𝑝𝑖 𝑝1
• Advantages of multi-stage compression: 1) Each cylinder works with lower pressure ratio. Thus the
operational safety of the compressor is improved. 2) The overall volumetric efficiency, 𝜂𝑣𝑜𝑙 increases.
3) Mass flow rate is increased, as clearance air expansion is reduced and effective swept volume of
each cylinder is increased, 4) low driving power, 5) uniform torque and better mechanical balance.
• In single stage compressor, delivery pressure obtained up to 5 bar, in two stage, 5 to 35 bar; in three
stage 35 to 85 bar; and so on.
Two stage compression with intercooler
Two stage compression with intercooler
• From the figure, process a-b is first polytropic compression
from 𝑝1 , 𝑇1 to 𝑝𝑖 , 𝑇𝑖
• followed by b-c intercooling where the pressure 𝑝𝑖 is
maintained but temperature is brought down to 𝑇1 , such that
point c lies on the isothermal curve a-c.
• Then again, the fluid is compressed following polytropic
process c-d from 𝑝𝑖 , 𝑇1 to 𝑝2 , 𝑇2
• Followed by aftercooling d-d’, which brings temperature 𝑇2 to
𝑇1 while maintaining the pressure at 𝑝2 . Aftercooling helps
reduce the volume of storage by reducing the volume of
compressed gas.
• In both the cylinders, clearance volume is assumed same.
Two stage compression (without clearance) with intercooler
Work of compression
From the previous discussion on single stage single acting compressors, we can say:
𝑛−1 𝑛−1
𝑛 𝑝𝑖 𝑛 𝑛 𝑝2 𝑛
𝑊=− 𝑅𝑇1 −1 + 𝑅𝑇1 −1
𝑛−1 𝑝1 𝑛−1 𝑝𝑖

𝑛−1 𝑛−1
𝑛 𝑝𝑖 𝑛 𝑝2 𝑛
or, 𝑊 = − 𝑅𝑇1 + − 2 , – ve sign signifies, work is done on the system.
𝑛−1 𝑝1 𝑝𝑖

Ideal Intermediate Pressure 𝒑𝒊 , for which the work 𝑾 will be minimum

Differentiating the above expression of work w.r.t. 𝑝𝑖 and equated it to zero we get,
𝑛−1 𝑛−1 𝑛−1 𝑛−1
𝑑𝑊 𝑛 𝑛−1 1 𝑛 𝑛
−1 𝑛
− 𝑛 −1 𝑛−1
= − 𝑅𝑇1 𝑝𝑖 + 𝑝2 𝑝𝑖 − =0
𝑑𝑝𝑖 𝑛−1 𝑛 𝑝1 𝑛
𝑛−1 𝑛−1
2 𝑛
or, 𝑝𝑖 = 𝑝1 𝑝2 𝑛 or, 𝑝𝑖 = 𝑝1 𝑝2 , so minimum work will be achieved if the
intermediate pressure is the geometric mean of the suction and discharge pressure.
Two stage compression (without clearance) with intercooler
𝑛−1
2𝑛𝑅𝑇1 𝑝2 2𝑛
• The minimum work done 𝑊min = − − 1 due to intermediate pressure 𝑝𝑖 = 𝑝1 𝑝2
𝑛−1 𝑝1

𝑝𝑖 𝑝2 𝑝2
• Again, from 𝑝𝑖 = 𝑝1 𝑝2 , we can write: = =
𝑝1 𝑝𝑖 𝑝1

or, 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑟𝑎𝑡𝑖𝑜 𝑖𝑛 𝐿. 𝑃. 𝑠𝑡𝑎𝑔𝑒 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑟𝑎𝑡𝑖𝑜 𝑖𝑛 𝐻. 𝑃. 𝑠𝑡𝑎𝑔𝑒

And this also proves, 𝑤𝑜𝑟𝑘 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑖𝑛 𝐿. 𝑃. 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟 = 𝑤𝑜𝑟𝑘 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑖𝑛 𝐻. 𝑃. 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟
𝑛−1 𝑛−1
𝑝𝑖 𝑛 𝑝2 𝑛
• Also, from the expression of delivery temperature, 𝑇𝑖 = 𝑇1 and 𝑇2 = 𝑇1 , substituting
𝑝1 𝑝𝑖
𝑝𝑖 𝑝2
= we get, 𝑇𝑖 = 𝑇2
𝑝1 𝑝𝑖
or, 𝑑𝑖𝑠𝑐𝑕𝑎𝑟𝑔𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝐿. 𝑃. 𝑠𝑡𝑎𝑔𝑒 = 𝑑𝑖𝑠𝑐𝑕𝑎𝑟𝑔𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑓 𝐻. 𝑃. 𝑠𝑡𝑎𝑔𝑒
Centrifugal Compressors
• A centrifugal compressor is a radial
flow roto-dynamic fluid machine that
uses gas (compressible), mostly air, as
the working fluid. It essentially consists
of three major components: 1) rotating
impeller, 2) stationary diffuser, and 3)
stationary volute casing.
• Air enters axially to the compressor
and forced to flow radially (hence
called radial flow compressor) through
the specifically curved rotating vanes
or blades of the impeller while the
kinetic energy of the air get increased.
• This high velocity air, then, continues to flow through diverging diffuser sections which
decelerates the fluid and increase its static pressure.
Centrifugal Compressors
Impeller used in Centrifugal Compressors
• For any rotary machine, the geometry of the rotatable part of the machine is of primary
importance. For radial flow are compressors, centrifugal impellers are used.
• The specific geometric shape of compressor’s impeller vanes (or, blades) provide the fluid
flow passages. The gain in momentum is due to the transfer of momentum from the high-
speed impeller blades to the fluid confined momentarily between the blade passages.
There is also an increase in static pressure in the fluid due to the self-compression caused
by the centrifugal action.
• Euler’s pump and turbine equation in fluid dynamics plays an important role in
understanding impeller performance.
• The blades of the compressor or either forward curved or backward curved or radial.
Forward curved blades are not preferred for dynamic instability. Backward and radial
blades are most commonly used.
Impeller …contd.

• In multistage centrifugal compressors, the impeller diameter of all stages remains same,
but the width of the impeller becomes progressively narrower in the direction of flow as
fluid density increases progressively.
• Impellers are designed in many configurations including “open” (visible blades), “covered
or shrouded”, “with splitters”. Most modern high efficiency impellers use “back sweep” in
the blade shape.
Diffuser
• The next key component is the diffuser. Bernoulli’s fluid dynamic principle plays an important role in
understanding diffuser performance.
• Downstream of the impeller in the flow path, it is the diffuser’s responsibility to convert the kinetic
energy (high velocity) of the gas into pressure by gradually slowing (diffusing) the gas velocity.
• Diffusers can be vane less, vaned or an alternating combination. They can be fixed or adjustable. In
turbocharger applications, no diffusers are used.
• The diffuser discharges into a large empty chamber called the collector or casing of a centrifugal compressor.
It can take many shapes and forms. It may also contain valves and instrumentation to control the flow.
Diffuser
Centrifugal Compressors – Advantages, Disadvantages and Use
• Advantages: 1) much higher flow rate at delivery than positive displacement
compressors, 2) smaller length, 3) contaminated atmosphere does not affect the
performance
• Disadvantages: 1) usually operates at higher speed (>3000 rpm), 2) used for low pressure
ratio (<4:1), (axial, for higher, but requires larger space), 3) larger frontal area, 4) lower
maximum efficiency
• Uses: 1) Centrifugal compressors are used in smaller gas turbine (turbo-jet) engines, like
small aero engines and auxiliary power units in the aircrafts, 2) Some of the aircraft air
conditioning systems employ centrifugal compressors, 3) For larger engines, axial
compressors need lesser frontal area and are more efficient, 4) Centrifugal compressors
can develop higher per stage pressure ratios. Sometimes it is used only in the last stage of
compression
Work of compression in radial flow centrifugal compressor
• For the continuous flow compressors, neglecting the kinetic and potential energy changes
from inlet to outlet, the SFEE becomes, −𝑄 + 𝑚 𝑕1 = −𝑊 + 𝑚 𝑕2 . Here 𝑚 is the mass flow
rate and h is the specific enthalpy of the fluid.
• In a centrifugal compressor, the heat transfer rate 𝑄 is negligible, so, 𝑊 = 𝑚 𝑕2 − 𝑕1
• The above equation is valid for both reversible as well as irreversible adiabatic compression,
provided the actual enthalpy is used at the exit in case of irreversible compression.
• Due to high speed of the process, the compression is reversible adiabatic or isentropic in
centrifugal compression. Then, the thermodynamic relation 𝑇 𝑑𝑠 = 𝑑𝑕– 𝑣 𝑑𝑝, the isentropic
𝑊 2
work of compression is given by: = 𝑤 = 𝑕2 − 𝑕1 = 1 𝑣𝑑𝑝
𝑚
• If the kinetic is not negligible for fluid velocity 𝑉, then specific enthalpy is replaced by total
𝑉2
or stagnation enthalpy, 𝑕𝑡 = 𝑕 +
2
𝑉2
• In this case, for ideal gas, 𝑤 = 𝑕2𝑡 − 𝑕1𝑡 = 𝑐𝑝 𝑇2𝑡 − 𝑇1𝑡 , where, 𝑇𝑡 = 𝑇 + is the
2 𝑐𝑝
stagnation temperature.
Work of compression
• If we consider polytropic compression, then, 𝑝𝑣 𝑛 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 𝑝1 𝑣1𝑛 = 𝑝2 𝑣2𝑛
1
𝑛
𝑝1 𝑣1
• So, 𝑣 = 1 , replacing v in the expression of work and integrating we get,
𝑝𝑛
1 1 2
1 1 −𝑛+1 1 𝑛−1 𝑛−1
2 2 𝑝1𝑛 𝑣1 2 𝑑𝑝 𝑝 𝑛
• 𝑤= 𝑣𝑑𝑝 = 𝑛
𝑑𝑝 = 𝑝1 𝑣1 𝑛
= 𝑝1 𝑣1 = 𝑛
𝑝 𝑣 𝑝2𝑛
− 𝑝1𝑛
1 1 1 1 1 1
−𝑛+1 𝑛−1 1 1
𝑝𝑛 𝑝𝑛 1
𝑛−1
𝑛 𝑝2 𝑛
• or, 𝑤 = 𝑝 𝑣 −1
𝑛−1 1 1 𝑝1

• Thus the expression for reversible, isentropic work of compression is same for both
reciprocating as well as centrifugal compressors.
Difference between reciprocating & centrifugal compressors
• The basic difference between actual reciprocating compressors and actual centrifugal
compressors lies in the source of irreversibility.
• In case of reciprocating compressors, the irreversibility is mainly due to heat transfer and
pressure drops across valves and connecting pipelines.
• in case of centrifugal compressors, since the fluid has to flow at very high velocities through
the impeller blade passages for a finite pressure rise, the major source of irreversibility is
due to the viscous shear stresses at the interface between the fluid and the impeller blade
surface.
Axial Flow Compressors
• Fluid (air) flows in the axial direction through the converging flow area, in an axial flow
compressor.
• The mass flow rate 𝑚 = 𝜌𝐴𝑉 is constant by decreasing the flow area as the density of the
fluid increases due to compression
• Air flow rate is higher than that of
the centrifugal compressor.
• Per unit performance wise axial
compressors are lighter, more
efficient, and smaller than the
centrifugal compressors.
Axial Flow Compressors
• Compression is done in multiple (usually 5 to 14, due to
temperature/material limitations) stages throughout the
length of the compressor. At every stage, pressure ratio
achieved is about 1.1 to 1.2.
• A pair of rotor blades and stator blades comprises one
stage. Rotor blades are mounted on the drum type of
disk type rotor whereas the stator blades are mounted
on the stationary casing.
• In the rotor, kinetic energy is imparted on the fluid by
trapping them temporarily inside the vanes. Some
amount of static pressure is also increased due to the
centrifugal action while rotating. And then, the high
velocity fluid is passed through the stator diffuser vanes
where the static pressure rises significantly in the fluid in
expense of its kinetic energy.