G A S C O M P R E S S I O N:

A Primer on GAS Compression Equipment & Technology

By W. Norm Shade, PE

Positive Displacement
Compressor s –
Rotar y

C H A P T E R

A basic introduction to gas compression,

intended for operators, maintenance
technicians, supervisors, engineers, stu-
dents, and others who want to gain a fun-
damental understanding of gas compres-
sor rating, application, analysis, and control.

The following is an excerpt from the forthcoming book, Gas Compression: A Primer On Gas Compression Equipment & Technology. Each
month, Gas Compression Magazine will publish approximately one chapter. At a later date, it is planned that all the individual chapters
and sections will be combined into a comprehensive text book that will include sample problems and even some homework assignments.
 Part I:
Introduction to Compression: Compressor Types and Applications

3
CHAPTER

POSITIVE DISPLACEMENT COMPRESSORS – ROTARY

The operation principles of rotary and reciprocating rotor that is powered by an externally connected electric
compressors are basically similar. They differ in that all pro- motor or reciprocating engine driver. The other rotor is the
cesses in the reciprocating compressor take place in the idling rotor. The driving, or male, rotor in a common design
same place, the cylinder, but at different times. Hence, recip- configuration typically has four or five lobes. Compressor
rocating compressors require valves, whereas in the rotary speed is conventionally related to the male rotor. The idling,
compressor, inlet and delivery occur simultaneously but in or female, rotor normally has six lobes. The displacement
different places, separated by the rotating elements. of the compressor is equal to the inter-lobe volume. A de-
There are generally two types of rotary compressors. One signer can control the displacement by changing the rotor
type has a casing or housing with one or more rotating ele- diameter, length, or both. Other lobe combinations are also
ments that are either lobes or helical screws that mesh with useful and are becoming more commonly used.1
each other. The other has sliding vanes or fixed vanes with a
liquid ring, that displace a fixed volume with each revolution.
Rotary compressors have unique advantages of simplicity
and, when properly applied and operated, low maintenance.
They are very common in air compression, refrigeration, a
number of niche natural gas services, and various specialty
gas compression applications. Most types have high rangeabil-
ity in capacity and, especially rotary screw compressors, have
high rangeability in compression ratio as well. They operate
at rotating speeds that are generally higher than reciprocating
compressors but lower than dynamic compressors. Pressure
ratings are low to medium range, depending on the type.
The five basic types of rotary compressors are helical
screw, spiral axial, straight lobe, sliding vane, and liquid ring
(or liner or piston). Each has a somewhat unique set of pre-
ferred applications.

ROTARY SCREW COMPRESSORS

Rotary screw compressors are the most common types
of rotary compressors. The screw compressor is a rotary,
positive displacement machine with continuous internal Figure 3.1 The rotary screw compressor is a rotary, positive
compression. It consists basically of a casing or housing in- displacement machine with continuous internal compres-
corporating two overlapping bores that contain two spiral- sion of the gas trapped in the volume between two spiral-
lobed rotors, as shown in Figure 3.1. One rotor is the driving lobed rotors inside a casing or housing.

gascompressionmagazine.com | SEPTEMBER 2016 35

 Screw compressors have been actively applied to process ficiencies and are quieter than dry screw compressors, be-
and power air compression applications for about 60 years, cause the oil absorbs heat during the compression process
because they offer smooth, relatively pulse-free delivery of and dampens noise. After the compression process, the oil
flow at high output volumes. The first design produced was is recovered from the discharge gas stream, cooled, and
the oil-free type, wherein the rotor motion is synchronized reused. An oil-injected screw compressor requires a prop-
by means of timing gears. In oil-free, or dry, screw com- erly designed and operated oil system, usually provided in a
pressors, the bearing cavities and lubrication systems are factory-packaged unit as shown in Figure 3.2.
isolated from the process gas areas by means of suitable
shaft seals located between the bearings and each rotor ROTARY STRAIGHT-LOBED COMPRESSORS
end plane. This class of machine is applicable in the 300- to Rotary straight-lobed compressors or blowers are posi-
40,000-cfm (8.5- to 1133-m3/min) capacity range, fitting be- tive displacement, constant volume machines capable of
tween most reciprocating and centrifugal compressors, and pumping large volumes, but they achieve only minimal
a pressure range from vacuum to approximately 25 atm. Ap- compression. It is not uncommon, however, to see multiple
plications for dry screw compressors include all processes blower stages, frequently with intercoolers in between to
than cannot tolerate contamination of the compressed gas cool the gas. This type of compressor is typically oil-free,
by lubricant or where lubricating oil would be contaminated which allows it to work in environments where contami-
by the gas. Dry screw compressors are particularly suitable nation control is important. Small versions of this type of
for dirty gasses such as flare gas recovery, styrene vent gas, compressor have been commonly used as superchargers for
acetylene raw gas, etc. reciprocating engines.
The oil-injected — more commonly called oil-flooded — Positive displacement lobed compressors are typically ei-
screw compressor is impor tant to the air and gas compres- ther bi-lobe or tri-lobe meshing rotor configurations, much
sion industries. This class of machine was originally intro- like a set of elongated gears. Rotor, or impeller, lobes may
duced for por table and stationary air compressors, where be involute, cycloidal, modified cycloidal, or other shapes,
it has dominated for decades. The characteristics of this depending on the application. In the bi-lobe or twin ro-
type of compressor make it attractive for other applica- tor compressor, two symmetrical, figure-eight-shaped lobe
tions as well, especially for refrigeration, vapor recovery, impellers mounted on parallel shafts rotate in opposite di-
and low-pressure wellhead compression services. Machines rections within an elongated casing or housing, as shown in
are commonly available in the range of 25 to 35,000 cfm Figure 3.3.
(0.7 to 991 m3/min) and pressure ranges from about 150
to 350 psig (10 to 24 bar), depending on the model and
manufacturer. Pressure capabilities to 750 psig (52 bar)
or more are available in some niche models in single- and
2-stage configurations.

Figure 3.3 A rotary straight-lobed compressor has two or

three meshing rotors that move gas from an inlet to an exit
por t with little or no internal compression.

As each impeller passes the compressor inlet, it traps a

finite volume of gas and carries it around the case to the
Figure 3.2 An oil-injected screw compressor requires a compressor outlet, where the gas is discharged. The entrap-
properly designed and operated oil system, usually provided ment occurs four times per revolution (twice per impeller),
in a factory-pakcaged unit as shown here. moving gas from the inlet to the outlet. With constant speed
Source: HY-BON Engineering operation, the displaced volume is essentially the same re-
gardless of pressure or temperature. Timing gears control
Oil-injected screw compressors are generally supplied the relative position of the impellers to each other and
without timing gears. The injected lubricant provides a layer maintain small, but finite, clearances. This allows operation
separating the two screw profiles as one screw rotor drives without lubrication being required inside the lobe cavity.
the other. Oil-injected machines generally have higher ef- With the rotation of the meshing rotors, the volume of gas

36 gascompressionmagazine.com | SEPTEMBER 2016

does not change. The gas simply moves from the inlet por- the rotary screw compressor, the injected oil is recovered
tion of the cylinder’s interior to the discharge end. Once it is via a downstream scrubber or separator and recycled to
forced from the cylinder, the gas is restricted from re-enter- the inlet.
ing. This type of positive displacement compressor provides
100% oil-free compression because each lobe just clears
the inside of the casing. Because rotary-lobed compressors
need to maintain a clearance between the lobes, pressure
differential, and therefore pressure ratio, is limited. Pressure
ratio capability is limited to generally much less than 2.0,
because the only pressure increase from this type of com-
pressor results from packing the delivered gas volume into
the discharge line or receiver.
A twin lobe rotary compressor produces an almost con-
stant flow rate, which is a function of the operating speed.
However, since the compressor pumps gas in discrete pulses,
unlike a screw compressor, pulsation, noise, and turbulence
may be transmitted downstream. The tri-lobed positive
displacement compressor has a three-lobe configuration.
Well-designed and well-built tri-lobed positive displacement
compressors typically allow higher throughput than their
twin-lobe counterpar ts, and they operate with less noise Figure 3.4 A rotary sliding vane compressor is a positive
and lower pulsation levels. displacement machine with an eccentric rotor with radial
Various types of straight-lobed rotary compressors are vanes that are forced against the bore of a stationary hous-
available in flow ranges from 20 to 30,000 cfm (0.6 to 850 ing by centrifugal force.
m3/min). Low-pressure models can operate near vacuum,
and high-pressure models are rated up to about 360 psig Sliding vane compressors are available in single- and multi-
(24.8 bar). stage configurations. Typical single-stage capacities range to
Some lobed rotary compressors may have more complex 3200 cfm (91 m3/min) with atmospheric inlet pressure and
profiles for increased efficiency. For example, a helical design discharge pressures from 5 to 50 psig (0.3 to 3.4 bar). The
may be added to a tri-lobe compressor, similar to a screw pressure ratio in a single-stage rotary sliding vane compres-
compressor, which reduces noise and pulsation for quieter, sor is usually limited to 3.0 to 3.8, but some are adver tised
more efficient operation. up to 6.0. Two-stage sliding vane compressors can deliver
pressures from 60 to 150 psig (4.1 to 10.3 bar). Sliding vane
ROTARY SLIDING VANE COMPRESSORS compressors are also frequently used as vacuum pumps.
Rotary sliding vane compressors are positive displace- Among the advantages of sliding vane compressors are in-
ment machines with continuous internal compression. Ro- expensive installation, compact design, low vibration, low op-
tary vane compressors and pumps use an older technol- erating costs, and low starting torque requirements. There are
ogy, having been produced since the early 1900s. They have relatively few wearing parts that require routine maintenance.
several common applications, including vapor recovery and
vacuum service, and they are also commonly used as pumps ROTARY LIQUID RING COMPRESSORS
in automotive and hydraulic applications. Liquid ring compressors, also known as liquid piston or
These compressors have a cylindrical rotor eccentrically liquid liner compressors, are machines in which water or
mounted inside a water-jacketed casing or housing. The ro- another liquid is used, usually in a single rotating element,
tor is fitted with a number of vanes that are free to move to displace the gas and move it from inlet to discharge. A
radially in and out of longitudinal slots. As the rotor spins, the typical configuration is shown in Figure 3.5.
vanes are forced against the bore of the housing by centrifu- Liquid, usually water, is fed into the compressor and, by
gal force, as shown in Figure 3.4. Oil is injected into the flow centrifugal acceleration from a rotor with multiple forward
stream and forms a thin film between each vane tip and the curved blades, forms a moving cylindrical captive ring against
housing bore, providing a seal and lubrication. the inside of the elliptical casing. Gas is drawn into the com-
As the rotor turns through and past the inlet por t, gas is pressor through an inlet por t in the end of the casing. At
trapped between adjacent vanes. As the rotor fur ther turns the inner diameter, these rotor chambers have openings
through the arc of rotation between the inlet and discharge that are sealed by, and revolve about, a stationary central
ports, gas trapped between adjacent vanes is compressed plug or cone. This plug is designed with permanently open
as the pocket volume is gradually reduced. The reduction in ports so placed as to permit gas to be taken into and then
volume raises the pressure of the gas. After discharging the discharged from the revolving rotor chambers. The gas is
gas, there is a section that separates and seals the discharge trapped in the compression chambers formed by the pairs
from the inlet before the pockets, then expands again to of adjacent impeller vanes and the inner surface of the liquid
induct gas from the inlet in a continuous process. Similar to ring. The reduction in volume caused by the impeller rota-

gascompressionmagazine.com | SEPTEMBER 2016 37

 tion inside the elliptical casing compresses the gas, increas- according to the same fundamental equation describing a re-
ing its pressure and finally transferring it to the discharge ciprocating compressor.3
port in the rotor and then through passages in the casing to
the discharge connection.
(3.1)

where:
Pd = absolute discharge pressure
Ps = absolute suction pressure
Vd = volume at discharge
Vs = volume at suction

As the components rotate, they expose a discharge por t

and gas is pushed out of the pocket volume into a discharge
collector, receiver, or pipe.
Since significant amounts of oil or water are injected into
most rotary positive displacement compressors, prediction
of the temperature rise and discharge temperature is a
more complex matter than it is for reciprocating or dynamic
Figure 3.5 A liquid ring compressor is a positive displace- compressors. Compressor manufacturers typically provide
ment machine in which water or another liquid is used, usu- guidance or computerized performance programs that can
ally in a single rotating element, to displace the trapped gas be used for calculations.
and move it from inlet to discharge.
ABOUT THE AUTHOR
Two eccentric sweeps or lobes are usually provided to W. Norm Shade is Sr. Consultant and President-Emeritus of
form the elliptical casing. These are diametrically opposed to ACI Services Inc., a leading manufacturer of custom-engineered
each other. For each revolution, two compression cycles are reciprocating gas compressor products. Shade received BME
completed in each rotor chamber. The result is a continuous and MSME degrees from The Ohio State University, graduating
flow with little or no pulsation in the discharge. There are Summa Cum Laude in 1970. He is a registered professional
also designs with a single eccentric sweep, which provides engineer in Ohio, Oklahoma, and Texas. He has more than 40
one compression cycle per revolution. years of gas compression experience. Prior to joining ACI, Shade
Cooling of liquid ring compressors is direct rather than spent 32 years with Cooper Energy Services and Cooper Cam-
through the walls of a casing. The required additional cool- eron Corporation in design and development positions involv-
ing liquid is fed into the ring where it comes into contact ing reciprocating and centrifugal gas compressors, reciprocating
with the gas being compressed. The gas is thereby cooled, engines, and gas turbines, as well as management positions
and the excess liquid is discharged with the gas and col- that included Director of Engineering, General Manager, and
lected from the discharge stream by a separator. Depending Vice President. In 2003, he started WiNS Consulting Services
on the application, the separated liquid is either recirculated Inc., a consulting company that continues to provide market
or disposed of. research and technical services for the oil and gas industry. He
Liquid ring compressors are available in sizes from approxi- has written more than 300 published technical papers and
mately 2 to 18,500 cfm (0.06 to 524 m3/min).2 They are avail- articles related to the gas compression industry and has taught

H ableOTSTART’s
spheric
as vacuum new
heating
small-engine
pressures as
discharge
pumps CSE
systempressures,
hazardous
for (Coolant
low suction
is a complete
high as about
Small
or as coolant
location100
pressures
compressors
applications.
Explosion
heating
psig (6.9 bar).
and Proof)
atmo-
forsystem
According
discharge
This type
for
to theof
also identifishort
numerous ed a courses
need forona gas
smallcompression.
coolant system that could pro-
vide cold start support. This small coolant heater fits this need by
keeping
REFERENCES the engines warm and reduce damaging condensation in
company,
compressor the CSEis designed
is the tofirsthandle
explosion-proof
highly toxic,coolant
explosive,
forced
and cylinders
1
Ingram, andW.B.,
critical
“Ancomponents.
Introduction” to Rotary Screw Com-
circulating
corrosivesystemgases, having
that isa built
history
directly
of reliable
for smaller
performance
horsepower
under HOTSTART
pressors,” presented
serves the to global
the Society
oil and
of Petroleum
gas marketEngi- with
engines
demandingwith aconditions.
small foot print. forced
neerscirculation
(Richardson, preheating
TX: Society
systemsof designed
PetroleumtoEngineers
heat cool-
“HOTSTART already has general purpose small coolant heat- ant, [SPE],
oil, or 1995).
an oil/coolant combination. High capacity units are
ersBASIC
like theROTARY
CSM (CoolantCOMPRESSION
Small Mechanical)
PROCESS and CMM (Coolant available
2
Rollins,in weather
J.P., ed., Compressed
tight or hazardous
Air andlocation configurations
Gas Handbook, 4th
Medium A rotary
Mechanical)
compressor but nothing
operates that
by isconfi
builtning
for aa volume
hazardousof thated.meet(Newrecognized
York, NY:CSA Compressed
or ATEX standards
Air and Gasfor Institute,
safety and
application,
gas in a pocket
” said Patformed
Norwood,
by oneMarket
or moreManager
intermeshing
– Oil & Gas.
rotating
“An performance.
1973).
existing
components
system for within
largera stationary
engine applications
housing (600L)
or a single
was our
rotating
only The
3
Nisenfeld,
CSE features
A.Eli, Centrifugal
a positive Compressors,
displacement Principals
pump which pulls
of Op-
option
component
for smalloperating
65L engines eccentrically
previously.within a stationary hous- coolant fromand
eration theControl
low end (Research
of the system,
Triangle
heats
Park,and
NC:circulates
Instru- it
ing.
“A few
As the years
components
ago, we identifi
rotate,
edana inlet
needportfor ais small
exposed
oil heating
to the backment
into the
Society
system of America,
to heat the1982).
block and cylinders. Preheating
system
pocket forvolume
hazardousand low-pressure
applications ingasboth
is drawn
gas compression
into the volume.
and of small engines enhances engine startup in cold environments,
CNGAs these
distribution,
components
” addedcontinue
Norwood. their
“During
rotation,
thethe
development
volume of theCorrection:
company said. In Chapter
In addition1, to
Frick
being
wasa cold
inadver
starting
tentlyaid,
omitted
the CSE
of the
the pocket
OSE (Oil is decreased,
Small Explosion
increasing
Proof)theoilpressure
heating system,
of the gas,
we canfrom
be used
the list
in applications
of rotary compressor
located in warmer
manufacturers.
climates and high

38 gascompressionmagazine.com | SEPTEMBER 2016