Experiment No.

1
COMPRESSORS

Aim: To study compressors and its types

Introduction: It is a mechanical component (machine) to compress the air
which raises its pressure.
The air compressor sucks air from the atmosphere, compresses it and delivers it
with a higher pressure to a storage vessel. From the storage vessel it may be
transmitted by the channel (pipeline) to any place which requires air at high
pressure.
The compressor requires some work to be done on it, therefore a compressor
must be drive by some prime mover.

1) Rotodynamic compressors-

a) Centrifugal compressor –The idealized compressive dynamic

turbo-
machine achieves a pressure rise by adding kinetic energy/velocity to a
continuous flow of fluid through the rotor or impeller. This kinetic energy is
then converted to an increase in potential energy/static pressure by slowing
the flow through a diffuser. The pressure rise in impeller is in most cases
almost equal to the rise in the diffuser section.

Application-
Suited for large cooling applications above 200 tons (industries and commercial
systems).

Advantages-
• Largest capacity up to 10,000 tons.
• Higher efficiency under partial loads
• Higher reliability and low maintenance.
• Less vibration due to continuous gas displacement.

Limitations-
• Capital cost premium.
• Requires high quality material, high precision machinery, higher quality
manufacturing.
• Impractical to use below 20 tons

b) Axial type compressor-

In axial flow compressors, flow enters the first blade row
and leaves the last blade row in axial direction. Flow through the machine is
parallel to the axis of the shaft. Axial compressors are characterised by lower
pressure ratio per stage at higher mass flow rates compared to centrifugal
compressors; and hence these machines are preferred for civil and military aero
engines as well as for industrial gas turbines. Higher mass flow rate produces
higher thrust.

Advantages-
 High peak efficiency.
 Reduced drag.
 Improved high altitude performance
 Greater flexibility

Disadvantages-
 Chances of compressor stall
 Rapid temperature increase.

Application-
 Jet engines

2. Positive Displacement: They are so called as they deliver fluid by positive

displacement of fluid i.e., by changing its volume.

A)Rotary compressor-

1) Screw compressor-
A rotary-screw compressor is a type of gas compressor that uses a rotary-type
positive-displacement mechanism. They are commonly used to replace piston
compressors where large volumes of high-pressure air are needed, either for
large industrial applications or to operate high-power air tools such as
jackhammers.
The gas compression process of a rotary screw is a continuous sweeping
motion, so there is very little pulsation or surging of flow, as occurs with piston
compressors.

Applications-
Used for commercial and industrial air conditioning and refrigeration
application with a capacity range from 20 to 750 ton.

Advantages-
• Simple structure, less no. of components, larger capacity, higher
efficiency.
• Less vibrations and less surging due to continuous gas displacement via
the sweeping motion.
• Better adjustment in cooling capacity without causing unstable
operation, which is sometimes an issue with centrifugal compressors less
sensitive to liquid surging.
Limitation-
Impractical to design to a capacity below 20 ton due to rotor processing
technology.

2) Vane compressor-
A rotary-vane compressor is also known as a rotary piston compressor because
the function of the vane is like that of piston. The fixed casting is known as
cylinder. The vane splits the space between the cylinder and rolling piston into
two sections (suction and discharge). As the rolling piston rotates, these two
volumes are increased and decreased to achieve gas suction, compression and
discharge.
The capacity can be adjusted through cylinder, unloading and inverter drive.

Application-
• Appliance such as household refrigerators and freezers.
• Residential air conditioning and heat pump product below 5 tons.
Advantages-
• Higher efficiency due to less losses from clearances volume and discharge
valve resistance.
• Smaller dimension and lighter weight per unit capacity.
• Less vibration.
• Less components.
• Higher reliability because there is no conversion from rotation to
reciprocation.
Limitation (when compared to other rotary compressors)-
• Smaller capacity, normally below 5 ton due to the limitation of its
structure.
• Lower reliability due to more components.
• Lower energy efficiency due to losses from clearance volume.

3) Scroll compressor:
A rotary scroll compressor is used to compress larger volumes of gaseous
refrigerant to a higher pressure and temperature via a fixed orbital scroll. The
cool vapor refrigerant is drawn into it from outside fixed scroll, then
compressed in between the fixed and orbital scroll. Finally, the compressed
refrigerant is discharged from the centre of the fixed scroll with a continuous
displacement.
 Applications-
• Commercial air conditioning
• Refrigeration (compressor capacity from 5 to 10 ton)
Advantages-
• Higher reliability due to simple structure and less components.
• Higher efficiency due to less losses because it requires neither suction nor
discharge values, meanwhile there is no clearance.
• Less vibration and less surging due to continuous gas displacement
through the sweeping motion of the rotors.

Limitation-
Compared with rotary screw and centrifugal compressor discussed, the rotary
scroll compressor has lower efficiency and smaller capacity.

3) Lobe type compressor- There are two lobes attached to the driving shaft
by prime mover. These lobes are displaced with 90 degrees to one
another. Thus, if one of the lobe is in horizontal direction the other lobes
will be exactly positioned at 90 degrees i.e. vertical direction. The air gets
trapped from one end and as the lobe rotates the air gets compressed.
Air is then delivered to delivery line.
Application-
Pulp and paper industries, chemical industries, food and beverage industries,
etc.

5) Reciprocating compressor:
A reciprocating compressor is also called a piston
compressor which adopts the back and forth piston motion in a cylinder
synchronized with suction and discharge valves to compress the vaporized
refrigerant from low pressure and temperature to a high pressure and
temperature. The motion of the piston is achieved via a crankshaft which
converts motor rotation to piston applications. Each operation cycle includes
three actions: suction, compression and discharge. Each crankshaft rotation can
achieve these three actions in a sequence; as a result, the gas displacement is
discontinuous which causes vibrations However, the actual gas displacement is
also determined by volume efficiency which depends on clearance volume,
resistance of suction and discharge valves, leakage between piston and
cylinder, etc. Depending on the location of working fluid, the reciprocating
compressor can be sub-classified as single acting or double acting. Single acting
means that the refrigerant acts only on one side of the piston. Double acting
means the working fluid vapour acts on the sides of the piston.
Applications-
• Household refrigerator and freezes with welded hermetic type.
• Residential and commercial air conditioning.
Advantages-
• Capable of compressing wide range of gases such as refrigerant,
hydrogen, natural gas, etc.
• Broad capacity range: Welded hermetic compressor can be designed to a
very small capacity. Open and serviceable semi-hermetic compressor can
be designed to a hundred ton (350 kW).

Limitation-
• Low energy efficiency because of clearance volume, resistance due to
suction and discharge valves, gas leakage.
• Larger dimension and greater weight per unit capacity.
• Difficult to maintain due to complex structure.
• Vibrations due to discontinuous gas displacement.

6)Diaphragm type-
A diaphragm compressor is a variant of the classic reciprocating
compressor with backup and piston rings and rod seal. The compression of gas
occurs by means of a flexible membrane, instead of an intake element. The back
and forth moving membrane is driven by a rod and a crankshaft mechanism.
Only the membrane and the compressor box come in touch with pumped gas.
For this reason this construction is the best suited for pumping toxic and
explosive gases. The membrane has to be reliable enough to take the strain of
pumped gas. It must also have adequate chemical properties and sufficient
temperature resistance.

Application-
 Hydrogen fuel cell station
 Hydrogenation of edible oils

Advantages-
 Lower cost
 Advanced design
 High pressure

Disadvantages-
 Requires more damping
 More air intake