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ENGINEERING &
TECHNOLOGY
Sadar, Nagpur
DEPARTMENT OF
MECHANICAL ENGINEERING
A
Presentation on
Air Compressor
COMPRESSOR – A device which takes a definite quantity of fluid ( usually gas, and
•Major difference is that compressors handles the gases and pumps handles the
liquids.
•As gases are compressible, the compressor also reduces the volume of gas.
•Pneumatic devices
It is widely used in chemical and petroleum refinery industry for specific services.
• The gas next flows through a circular chamber (diffuser), where it loses
velocity and increases pressure.
Axial Flow Compressor
Reciprocating Rotary
Centrifugal
Principle of Operation
Fig. shows single-acting piston actions in the
cylinder of a reciprocating compressor.
The piston is driven by a crank shaft via a
connecting rod.
At the top of the cylinder are a suction valve
and a discharge valve.
A reciprocating compressor usually has two,
three, four, or six cylinders in it.
Reciprocating Compressor - Working
Reciprocating Compressor – Equation for Work
3 2’ 2 2”
P2 PV C
(Isothermal)
PV C
(Adiabatic)
Pressure
PV n C
4 1 (Polytropic)
P1
V2 V1
Volume
Operations : 4 – 1 : Volume V1 of air aspirated into Compressor, at P1 and T1.
1 – 2 : Air compressed according to PVn = Const. from P1 to P2.
→ Temp increase from T1 to T2.
2 – 3 : Compressed air at P2 and V2 with temperature T2 is delivered.
Reciprocating Compressor – Equation for Work
During Compression, due to the excess temperature above surrounding, the air will
exchange the heat to the surrounding.
Compression Index, n is always less than γ, the adiabatic index.
As Compressor is a work consuming device, every effort is desired to reduce the work.
n
P2 P1
1/ n
Wiso P1V1 1
n 1 P1 P2
Reciprocating Compressor – Equation for Work
n P P 1/ n
Wiso P1V1 1 2 1
n 1 P1 P2
n P P 1/ n
3 2’ 2 2” P1V1 1 2 2
P2 PV C
n 1 P1 P1
(Isothermal)
PV C n 1
(Adiabatic) n P2 n
PV n C Wiso P1V1 1
P1
4 1(Polytropic) n 1 P1
n 1
V2 V1 n P n
Delivery Temperature, Wiso mRT1 1 2
n 1 n 1 P1
P2 n
T2 T1
P The solution of this equation is always negative.
1 This shows that Work is done ON the Compressor.
Reciprocating Compressor – Equation for Work
Clearance Volume :
6 3 2
P2 Volume that remains inside the cylinder
after the piston reaches the end of its
inward stroke.
PV Cn
5 4 1
P1 Thus, Effective Stroke Volume = V1 – V4
V3 V4 V1
Total Volume, V1
But, P4 = P1 and P3 = P2
Reciprocating Compressor – Volumetric Efficiency
Volumetric Efficiency :
Ratio of free air delivered to the displacement of the compressor.
6 3 2 Ratio of Effective Swept Volume to Swept Volume.
P2
Presence of Clearance Volume
Volumetric Efficiency less than 1. ( 60 – 85 % )
PV n C
Effective Swept Volume
Volumetric Efficiency =
5 4 1 Swept Volume
P1
V1 – V4
V3 V4 V1
=
V1 – V3
Effective Swept Volume, V1-V4
Clearance Volume, Clearance Volume
V3=Vc Swept Volume, V1-V3=Vs Clearance Ratio =
Swept Volume
Total Volume, V1
Vc
= = γ ( 4 – 10 % )
Vs
Reciprocating Compressor – Volumetric Efficiency
↑ Pr. Ratio ↑ Effect of Clearance Volume
….Clearance air expansion through greater volume before intake
6 3 2
6 3 2
V3 V3
P2 vol 1 1
V1 V3 V4
V3 V3
vol 1 1
V1 V3 V4
V3 P3
1/ n
5 4 1 vol 1 1
P1 V1 V3 P4
V3 V4 V1
P 1 / n
Effective Swept Volume, vol 1 3 1
V1-V4 P4
Clearance Volume,
V3=Vc Swept Volume, V -V =V
1 3 s
Total Volume, V1
Reciprocating Compressor – Actual P-V Diagram
Receiver Pressure 1-2-3-4-1 : Theoretical P-V Diagram.
Pressure rise, followed by valve bounce and then pressure settles at a level higher than
the delivery pressure level.
Pt 101.325KN / m 2
Tt 15 C 288K
0
Reciprocating Compressor – Multistage
•High temp rise leads into limitation for the maximum achievable
pressure rise.
•Discharge temperature shall not exceed 150ºC and should not exceed
1350C for hydrogen rich services
Intercooler
Air Intake
Reciprocating Compressor – Multistage
Delivery Pr. 6 9 3 5 Overall Pr. Range : P1 – P3
Perfect Intercooling
P3 or Pd
Single – stage cycle : 8-1-5-6
Without Intercooling
H.P. Without Intercooling :
PV C
n
L.P. : 8-1-4-7
Intermediate Pr. 7 4
P2 2 H.P. : 7-4-5-6
PV C
L.P. With Intercooling :
Intake Pr. 8 1 L.P. : 8-1-4-7
P1 or Ps
H.P. : 7-2-3-6
Volume
Perfect Intercooling : After initial compression in L.P. cylinder, air is cooled in the
Intercooler to its original temperature, before entering H.P. cylinder
i.e. T2 = T1 OR
Points 1 and 2 are on SAME Isothermal line.
Reciprocating Compressor – Multistage
Ideal Conditions for Multi – Stage Compressors :
n
n P5
n 1
H.P. W P1 V1 1
n 1 P1
7 PV n C
4
2 PV C Delivery Temperature,
L.P. n 1
8 1 P5 n
T5 T1
P
1
Reciprocating Compressor – Multistage
B. Two – Stage Compressor (Without Intercooling) :
Without Intercooling :
6 9 3 5 L.P. : 8-1-4-7
H.P. : 7-4-5-6
H.P. n 1
n P4 n
PV n C W P1 V1 1
7 4 n 1 P1
2 PV C
L.P. n 1
n P5 n
8 1 P4 V4 1
n 1 P4
With Intercooling :
6 9 3 5 L.P. : 8-1-4-7-8
H.P. : 7-2-3-6-7
n 1
n P n
W P1 V1 1 4
H.P. n 1 P1
7 PV n C
4
n 1
n P n
P2 V2 1 3
2 PV C
L.P. n 1 P2
8 1
Delivery Temperature,
n 1 n 1
P3 n P3 n
T3 T2 T1 , as T2 T1
P2 P2
Reciprocating Compressor – Multistage
C. Two – Stage Compressor (With Perfect Intercooling) :
6 9 3 5
With Intercooling :
L.P. : 8-1-4-7-8
H.P. H.P. : 7-2-3-6-7
7 PV n C Now, T2 = T 1
4
2 PV C P2V2 = P1V1
L.P.
8 1
Also P 4 = P2
n 1 n 1
n P2 n P3 n
W P1 V1 2
n 1 P1 P2
Shaded Area 2-4-5-3-2 : Work Saving due to Intercooler…!!
Reciprocating Compressor – Multistage
Condition for Min. Work :
Intermediate Pr. P2 → P1 : Area 2-4-5-3-2 → 0
1 n 1 n 1 n 1 n 1 n 1
P2 P3 n P2 n 0
1 1
n 1
n
P1 n n n
6 9 3 5
P2 1/ n P1 P
n 1
n
2 n 1 3
H.P. P2 n
PV n C
7
2
4
PV C P2 2 P1 P3
L.P.
8 P2 P
1 P2 P1 P3 OR 3
P1 P2
Reciprocating Compressor – Multistage
P2 obtained with this condition (Pr. Ratio per stage is equal) is the Ideal Intermediate
Pr. Which, with Perfect Intercooling, gives Minimum Work, Wmin.
Equal Work per cylinder…!!
n 1
W
2n PP 1/ 2
P1 V1 1 1 3
n
n 1 P1
n 1
2n P n
W P1 V1 1 2
n 1 P1
n 1
2n P 2 n
W P1 V1 1 3
n 1 P1
Reciprocating Compressor – Efficiency
Indicated Power : Power obtained from the actual indicator card taken during a
test on the compressor.
A. Spray Injection : Assimilation of water into the compressor cylinder towards the
compression stroke.
Object is to cool the air for next operation.
B. Water Jacketing : Circulating water around the cylinder to help for cooling the
air during compression.
Reciprocating Compressor – Efficiency
How to Increase Isothermal Efficiency ?
C. Inter – Cooling : For high speed and high Pr. Ratio compressors.
Compressed air from earlier stage is cooled to its original
temperature before passing it to the next stage.
D. External Fins : For small capacity compressors, fins on external surfaces are useful.
E. Cylinder Proportions : Short stroke and large bore provides much greater surface
for cooling.
Cylinder head surface is far more effective than barrel
surface.
Reciprocating Compressor – Efficiency
Clearance Volume : Consists of two spaces.
1. Space between cylinder end & the piston to allow for wear.
2. Space for reception of valves.
P3 = P 2 and P4 = P1
n 1
5 4 1 n P2 n
P1 W P1 (V1 V4 ) 1
n 1 P1
V3 V4 V1
Effective Swept Volume,
V1-V4 n 1
n P n
P1 Va 1 2
Clearance Volume,
V3=Vc Swept Volume, V1-V4=Vs
n 1 P1
Total Volume, V1
Reciprocating Compressor – Work Done
n 1
n P2
n
6 3 W m1 R T1 1
P2
2
n 1 P1
m1 is the actual mass of air delivered.
Taken from
PIP REEC001
Compressor Selection
Guidelines
Table showing operating conditions of various compressors
Taken from
PIP REEC001
Compressor Selection Guidelines
Advantages and Disadvantages of Dynamic compressors
Advantages Disadvantages
Dynamic
Compressors
Centrifugal •Wide operating range •Instability at reduced flow
•High reliability •Sensitive to gas composition
•Low Maintenance change