Compressors

Presentation Outline

Introduction
Types
Compressor System
References
Introduction

 Compressors used to increase the pressure

of a gas (compressible fluid)
 Examples
– Increase the pressure for instrument air
systems (to get control valves to operate),
transport gases such as hydrogen,
nitrogen, fuel gas, etc. in a chemical plant
2 Types of Compressors
 Positive Displacement (PD) : Operate by trapping a
specific volume of gas and forcing it into a smaller volume
– 2 Basic Designs for PD Compressors
» Rotary
» Reciprocating
 Centrifugal : Operate by accelerating the gas and
converting the energy to pressure
– 2 Basic Designs for Centrifugal Compressors
» Centrifugal
» Axial
Positive Displacement Compressors:
Rotary Design
 Rotary compressors (get their name from
the rotating motion of the transfer element)
compress gases with lobes, screws, and
vanes into smaller volumes.
 4 Primary Types of Rotary Compressors:
– Rotary Screw
– Sliding Vane
– Lobe
– Liquid Ring
Rotary Screw Compressors

 Commonly used in industry.

 It operates with 2 helical rotors that rotate toward each
other, causing the teeth to mesh.
 As the left rotor turns clockwise, the right rotor rotates
counterclockwise. This forces the gases to become
trapped in the central cavity.
 The 2 rotors are attached to a drive shaft and drive that
provide energy to operate the compressor.
 Have an inlet suction line and outlet discharge port.
Rotary Screw Compressor
Sliding Vane Compressors

 Uses a slightly off-center rotor with sliding vanes

to compress gas.
 Inlet gas flows into the vanes when they are fully
extended and form the largest pocket. As the
vanes turn toward the discharge port, the gases are
compressed.
 As the volume decreases, the pressure increases
until maximum compression is achieved. Then the
gas is discharged out the compressor.
Sliding Vane Compressor
Lobe Compressors
 Characterized by 2 kidney-bean shaped impellers
used to trap and transfer gases.
 The 2 impellers move in opposite directions on
parallel mounted shafts as the lobes sweep across
the suction port.
 Compressed gases are released into the discharge
line.
 The lobes do not touch each other. A few
thousands of an inch clearing exists between the
casing and lobes.
Lobe Compressors

 Designed to have constant volume

discharge pressures and constant speed
drivers.
 Lobe Compressors can be used as
compressors or vacuum pumps.
Lobe Compressor
Liquid Ring Compressors

 Used to compress hazardous and toxic gases as

well as hot gases.
Liquid Ring Compressors

 It has one moving transfer element and a casing

that is filled with water or seal liquid.
 As the rotor turns, the fluid is centrifugally forced
to the outer wall of the elliptical casing. An air
pocket is formed in the center of the casing.
 As the liquid ring compressor rotates, a small % of
the liquid escapes out the discharge port. Make up
water or seal liquid is added to the compressor
during operation. The liquid helps cool the
compressed gases.
Positive Displacement Reciprocating
Compressors

 Most common type of compressors.

 Work by trapping and compressing specific
volumes of gas between a piston and a cylinder
wall.
 The back and forth motion incorporated by a
reciprocating compressor pulls gas in on the suction
(or intake) stroke and discharges it on the other.
 Spring-loaded suction and discharge valves
open/close automatically as the piston moves up and
down in the cylinder chamber.
Positive Displacement Reciprocating
Compressors

 Basic Parts of are:

– Piston
– Connecting Rod
– Crankshaft
– Diver
– Piston Rings
– Suction Line
– Discharge Line
– Spring -Loaded Suction and Discharge Valves
Positive Displacement:Reciprocating
Compressors

 Can have 1 to 4 cylinders. One shown only has one cylinder.

Mulitstage Compressors

 Discharge from Stage 1 is suction for Stage 2.

Centrifugal Compressors

 Centrifugal compressors accelerates the

velocity of the gases (increases kinetic
energy) which is then converted into
pressure as the gas flow leaves the volute
and enters the discharge pipe.
 Usually operate at speeds > 3,000 rpm.
 Deliver much higher flow rates than
positive displacement compressors.
Centrifugal Compressors

 2 Types of Centrifugal Compressors

– Single- Stage : Compress the gas once
» Use for high gas flow rates, low discharge
pressures
– Multi- Stage : Take the discharge of one
stage and pass it to the suction of another
stage
» Use for high gas flow rates, high discharge
pressures
Centrifugal Compressors

 Basic Components
– Impellers, Vanes, Volutes, Suction Eyes,
Discharge lines, Diffuser Plates, Seals,
Shaft, Casing
– Suction Vane Tips = Part of the impeller
vane that comes into contact with gas first.
– Discharge Vane Tips = Part of the impeller
vane that comes into contact with gas last
Centrifugal Compressor
Centrifugal Compressor: Axial
Design

 Composed of a rotor that has rows of fanlike

blades.
 In industry, axial compressors are used alot
high flows and pressures are needed.
 Gas flow is moves along the shaft.
 Rotating blades attached to a shaft push gases
over stationary blades called stators.
 Stator blades are attached to the casing.
Centrifugal Compressor: Axial
Design

 As the gas velocity is increased by the rotating

blades, the stator blades slow it down. As the gas
slows, kinetic energy is converted into pressure.
 Gas velocity increases as it moves from stage to
stage until it reaches the discharge.
 Multi-Stage axial compressors can generate very
high flow rates and discharge pressures.
 Axial compressors are usually limited to 16 stages
(due to temperature/material limitations)
 Pound for pound, axial compressors are lighter, more
efficient, and smaller than centrifugal compressors.
Axial Compressor
Typical Compressor System

Other equipment needed in a process system.

Typical Compressor System

 Safety valves and pressure relief valves used to

remove excess pressure that could damage
equipment and people.
 Silencers are mounted on the inlet and outlet of
a compressor to ‘reduce’ the noise.
Compressors are very noisy. Exxon had one
for a refinery light ends stream nicknamed
“Old Snort” by the technicians.
Typical Compressor System

 Demister removes moisture (liquid) from the

gas stream. The liquid falls to the bottom of the
demister and is removed. The clean gases goes
out the top of the demister.
 Dryer sometimes used on the compressor
discharge line to remove any liquids
(moisture). Silica gel and molecular sieves (3A
mole sieve) often used.
Typical Compressor Start Up
Procedures

 Check valve line up on the compressor and associated

equipment.
 Check compressor oil levels and bearing cooling water
systems.
 Be sure all the compressor controls are set correctly.
 Turn on the compressor.
 Monitor equipment and process until conditions
‘steady’ out.
Reference

 “ The Process Technology Handbook”, by

Charles E. Thomas, UHAI Publishing,
Berne, NY, 1997.