Lesson Notes

ME 501
Topic : Compressors

Introduction

A compressor is a machine used to increase the pressure of a gas by decreasing its volume. Industrial plants
use compressed air throughout their production operations, which is produced by compressed air units.

It is worth noting that the running cost of a compressed air system is far higher than the cost of a compressor
itself (see Figure 1). Energy savings from system improvements can range from 20 to 50 percent or more of
electricity consumption, resulting in thousands to hundreds of thousands of pesos. A properly managed
compressed air system can save energy, reduce maintenance, decrease downtime, increase production
throughput, and improve product quality.

Capital
9%
Maintenance 3%

Water 8%

Energy, 80%

Figure 1. Cost components in a typical compressed air system

Glossary of Compressor Terms

Absolute pressure: Total pressure measured from absolute zero.

Aftercooler: Heat exchanger for cooling air discharged from air compressor.

Atmospheric pressure: Pressure above absolute zero at a specific location and altitude

Capacity: The amount of air flow delivered or required under some specific conditions. May be stated as acfm,
scfm, or cfm FAD.

Cubic feet of air per minute (cfm): Volume delivery rate of air flow.

Cubic feet of air per minute, free air (cfm FAD): cfm of air delivered to some specific point and converted
back to ambient air (free air) conditions.

Actual cubic feet per minute (acfm): Flow rate of air measured at some reference point and based on actual
conditions at that reference point.

Inlet cubic feet per minute (icfm): cfm flowing through the compressor inlet filter or inlet valve under rated
conditions.

Standard cubic feet per minute (scfm):Flow of free air measured at a reference point and converted to a
standard set of reference conditions (e.g., 101.3 kPa, 16 0C, and 0% relative humidity).

Demand: Flow of air under specific conditions required at a particular point.

Discharge pressure, rated: Air pressure produced at a reference point.

Discharge pressure, required: Air pressure required at the system inlet.

Displacement: Amount of air (in cfm) displaced by the compressor piston under no load, discharging
directly to the atmosphere.

Dual control: Load/unload control system that maximizes compressor efficiency. Compressor is normally
operated at full load or idle, and is stopped (cut-out pressure)and restarted (cut-in pressure) automatically
depending on demand.

Free air: Air at ambient conditions of temperature, humidity, and atmospheric pressure at any specific location.

Inlet pressure: The total pressure at the inlet flange of the compressor.

Load factor: Ratio of the average compressor load to the maximum rated compressor load during a given
period of time.

Pounds per square inch differential (psid): Pressure difference between two defined points in the system.

Pressure dew point: Temperature at which water will begin to condense out of air at a given pressure.

Pressure drop: Loss of pressure in a compressed air system due to friction or flow restriction.

2. Main Components of Compressed Air Systems

Compressed air systems consist of a supply side, which includes compressors and air treatment, and a
demand side, which includes distribution and storage systems and end -use equipment. A properly managed
supply side will result in clean, dry, stable air being delivered at the appropriate pressure in a dependable,
cost-effective manner. A properly managed demand side minimizes wasted air and uses compressed air for
appropriate applications. Improving and maintaining peak compressed air system performance requires
addressing both the supply and demand sides of the system and how the two interact.

Compressed air systems consist of following major components: Intake air filters, inter-stage coolers, after-
coolers, air-dryers, moisture drain traps, receivers, piping network, filters, regulators and lubricators

 Intake Air Filters : Prevent dust from entering a compressor; Dust causes sticking valves, scoured
cylinders, excessive wear etc.
 Inter-stage Coolers : Reduce the temperature of the air before it enters the next stage to reduce the
work of compression and increase efficiency. They are normally water-cooled.
 After-Coolers: The objective is to remove the moisture in the air by reducing the temperature in a
water-cooled heat exchanger.
 Air-dryers : The remaining traces of moisture after after-cooler are removed using air dryers, as air for
instrument and pneumatic equipment has to be relatively free of any moisture. The moisture is
removed by using adsorbents like silica gel /activated carbon, or refrigerant dryers, or heat of
compression dryers.
 Moisture Drain Traps: Moisture drain traps are used for removal of moisture in the compressed air.
These traps resemble steam traps. Various types of traps used are manual drain cocks, timer based /
automatic drain valves etc.
 Receivers : Air receivers are provided as storage and smoothening pulsating air output - reducing
pressure variations from the compressor.

3. TYPES OF COMPRESSORS

As shown in Figure 2, there are two basic compressor types: positive-displacement and dynamic. In the
positive-displacement type, a given quantity of air or gas is trapped in a compression chamber and the volume
it occupies is mechanically reduced, causing a corresponding rise in pressure prior to discharge. At constant
speed, the air flow remains essentially constant with variations in discharge pressure. Dynamic compressors
impart velocity energy to continuously flowing air or gas by means of impellers rotating at very high speeds.
The velocity energy is changed into pressure energy both by the impellers and the discharge volutes or
diffusers. In the centrifugal-type dynamic compressors, the shape of the impeller blades determines the
relationship between air flow and the pressure (or head) generated.
 COMPRESSORS

Positive Displacement Dynamic

Reciprocating Rotary Centrifugal Axial

Single Acting
Helical Screw Scroll Sliding Vane Lobe Liquid Ring
Double Acting

Multi-Stage
Figure 2. Types of Compressors

Table 1. General Selection Criteria of Compressors

Type of Inlet Max. Adiabatic Operating Maximum Application

Compressor Capacity Discharge Efficiency( Speed(rpm) Power(MW)
(acmh,m3/h) Pressure(bar) %)
Dynamic
Centrifugal 170-850,000 690 70-87 1,800-50,000 38 Process gas & air
Axial 50,000-
17 87-90+ 1,500-10,000 75 Mainly air
850,000
Positive
Displacement
Reciprocating 20-34,000 4,150 80-90 200-900 15 Air & process gas
Diaphragm Corrosive &
0-250 1,400 60-70 300-500 1.5
hazardous gas
Helical Screw Air & dirty process
200-100,000 1-50 55-70 1,000-20,000 6
gas
Lobe Pneumatic
25-50,000 0.3-1.7 55-65 300-4,000 0.4 conveying, process
gas & vacuum
Sliding Vane Vacuum service &
15-5000 10 40-70 400-1,800 0.35
process gas
Vacuum service &
Liquid Ring 10-17,000 5.5-10.5 25-50 200-3600 0.3 corrosive process
gas

Rules of Thumb

1. Air compressors normally deliver 4 to 5 cfm per horsepower at 100 psig discharge pressure.
2. Every 2 psi pressure drop costs 1% of compressor horsepower in efficiency.
3. A 50 hp compressor rejects heat at approximately 126,000 Btu per hour.
4. Size air receivers for about 2-5 gallon capacity for each cfm of compressor capacity.
5. The water vapor content at 100°F of saturated compressed air equals about 6 gallons per day for each
100 cfm of compressor capacity.