COMPRESSORS AND

CONDENSERS
Group Members

 Mudit Parnami – 15ume018

 Pratikshit Tiwari – 15ume020
 Rohit Patel – 15ume021
 Saumya Sharma- 15ume022
 What are compressors?

Compressors are mechanical

devices that compresses gases. It is
widely used in industries and has
various applications
 Functions of Compressor

 Considered the heart of the refrigeration systems

 Compressors are vapor pumps
 Responsible for lowering the pressure on the suction side
of the system
 Responsible for increasing the pressure on the discharge
side of the system
 Suction gas from the evaporator enters the compressor
 Refrigerant is discharged to the condenser
 How they are different from
pumps?
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.

Liquidsare relatively incompressible; while some can be

compressed
Centrifugal pump
 What are its applications?
Compressors have many everyday uses, such as in :

 Air conditioners, (car, home)

 Home and industrial refrigeration

 Hydraulic compressors for industrial machines

 Air compressors for industrial manufacturing

Refrigeration compressor
 TWO STAGE COMPRESSION

 Lowers the compression ratio

 Utilizes two compressors
 One compressor discharges into suction of the other
 Also referred to as compound compression
 Often used when the compression ratio of a single
compressor system exceeds 10:1
 Often used in low-temperature commercial and industrial
storage applications
 TYPES OF COMPRESSORS
Compressor classification can be described by following flow chart:
 DYNAMIC COMPRESSORS
The dynamic compressor is continuous flow compressor is
characterized by rotating impeller to add velocity and thus
pressure to fluid.

It is widely used in chemical and petroleum refinery industry for

specific services.

There are two types of dynamic compressors

 Centrifugal Compressor
 Axial Flow Compressor
 Centrifugal Compressor
Achieves compression by applying inertial forces to
the gas by means of rotating impellers.

It is multiple stage ; each stage consists of an impeller

as the rotating element and the stationary element, i.e.
diffuser

 Fluid flow enters the impeller axially and discharged

radially

 The gas next flows through a circular chamber

(diffuser), where it loses velocity and increases
pressure.
 AXIAL FLOW COMPRESSOR

Working fluid principally flows parallel to the axis of rotation.

 The energy level of air or gas flowing through it is increased by the action of the rotor
blades which exert a torque on the fluid

Have the benefits of high efficiency and

large mass flow rate

Require several rows of airfoils to achieve

large pressure rises making them complex and
expensive
 POSITIVE DISPLACEMENT
COMPRESSORS
Positive displacement compressors causes movement by
trapping a fixed amount of air then forcing (displacing) that
trapped volume into the discharge pipe.

It can be further classified according to the mechanism used to

move air.
 Rotary Compressor
 Reciprocating compressor
 ROTARY COMPRESSORS
The gas is compressed by the rotating action of a
roller inside a cylinder.

The roller rotates off-centre around a shaft so

that part of the roller is always in contact with the
cylinder.

 Volume of the gas occupies is reduced and the

refrigerant is compressed.

High efficient as sucking and compressing

refrigerant occur simultaneously.
 RECIPROCATING COMPRESSORS
It is a positive-displacement compressor that

 Uses pistons driven by a crankshaft to deliver

gases at high pressure.

The intake gas enters the suction manifold, then

flows into the compression cylinder

It gets compressed by a piston driven in a

reciprocating motion via a crankshaft,

Discharged at higher pressure

How to select a
particular type
of compressor ?
Graph showing operating regions 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

Axial •High Capacity for given •Low Compression ratios

size •Limited turndown
•High efficiency
•Heavy duty
•Low maintenance
Advantages and disadvantages of
positive displacement type
compressor
Advantages Disadvantages
Positive displacement
compressor
Reciprocating •Wide pressure ratios •Heavy foundation required
•High efficiency •Flow pulsation
•High maintenance

Diaphragm •Very high pressure •Limited capacity range

•Low flow •Periodic replacement of
•No moving seal diaphragm

Screw •Wide application •Expensive

•High efficiency •Unsuitable for corrosive or dirty
•High pressure ratio gases
 Selection Considerations
o Safety

a. Limiting gas properties (e.g., decomposition,

flammability, toxicity).

b. Compatibility of process gas with materials of

construction

c. Over-pressure protection
 Economics

a. Life-cycle cost

b. User and vendor capabilities and facilities for maintaining

equipment

c. Expected equipment reliability

 RECIPROCATING
COMPRESSORS
Detailed Analysis
Block diagram of reciprocating
compressor
It is a piston and
cylinder device with
(automatic) spring
controlled inlet and
exhaust valves

There is a clearance
between the piston
crown and the top of
the cylinder.
 Construction of Reciprocating
Compressors
 Reciprocating compressors can be divided into two
main groups.

1. Gas end.
2. Power end.
 Different Parts Of Gas End
Various parts of gas end are:
 Cylinder & liner
 Piston
 Piston rod
 Piston rod packing
 Piston rings
 Valves
 Different Parts of Power End
Various parts of power end are
 Crank and Crankshaft
 Connecting rod
 crosshead

Connecting rod crosshead Crank and crankshaft

 Relief Valve
 Used to control or limit the pressure in a system or
vessel
 The pressure is relieved by allowing the pressurized
fluid to flow from an auxiliary passage out of the
system
 Designed or set to open at a predetermined set
pressure
Cycle Analysis

process

1->2 compression
2->3 discharge
3->4 expansion
4->1 induction
 Mass Flow Definition

Mass flow rate is the rate at which mass enters the inlet
during suction
The mass flow rate is simply given by

Where fc is compressor rotational frequency in Hz

 Volumetric efficiency
 It is Ratio of the actual volume of gas sucked by it to the
theoretical volume that it could have sucked if clearance
volume was not present.

• It is also defined as ratio of intake mass flow rate to the

theoretical swept
volume mass flow rate
 Work and Power Definitions
The theoretical work required for gas compression,
W, calculated by integrating the PV curve is

Where n is polytropic exponent

Adiabatic And Isothermal Power

Power supplied in adiabatic compression

Power supplied in isothermal compression

Shaft Power And Actual Power
Shaft power is the experimentally measured power
required to run a compressor
It is given by

Actual power is defined as the power required for gas

compression only . It is power integrated from an
experimentally measured PV curve
 Various types of efficiencies

Adiabatic efficiency Mechanical efficiency

Isothermal efficiency Overall efficiency

CONDENSERS
 What are Condensers?

In systems involving heat transfer, a

condenser is a device or unit used to
condense a substance from its gaseous to its
liquid state, by cooling it.
Introduction

 The condenser is an important device used in the high pressure side of

a refrigeration system.
 It removes heat of the hot vapour refrigerant discharged from the
compressor which consists of the heat absorbed by the evaporator and
the heat of compression added by the mechanical energy of the
compressed motor.
 The heat from the hot vapour refrigerant in a condenser is removed
first by transferring it to the walls of the condensing or cooling
medium. The cooling medium may be air or water or a combination of
the two.
Selection Considerations

The selection of a condenser depends upon:

 The capacity of the refrigeration system
 The type of refrigeration used
 The type of cooling medium available
Working of a condenser

In a simple refrigerating system, the compressor draws in the superheated

vapour refrigerant that contains the heat it absorbed from the evaporator. The
compressor adds more heat to the superheated vapour. This highly superheated
vapour from the compressor is pumped to the condenser through the discharge
line. The condenser cools the refrigerant in the following three stages:
 The superheated vapour is cooled to saturation temperature (called
desuperheating) corresponding to the pressure of the refrigerant in the
discharge line and in the first few coils of the condenser.
 The saturated vapour refrigerant gives up its latent heat and is condensed to
a saturated liquid refrigerant. This process is called condensation.
 The temperature of the liquid refrigerant is reduced below its saturation
temperature (i.e. subcooling)
Factor affecting the condenser capacity

The condenser capacity is the ability of the condenser to transfer heat from the hot
vapour refrigerant to the condensing medium. The heat transfer capacity of a
condenser depends upon the following factors:
 Material: Since the different materials have different abilities of heat transfer,
therefore the size of a condenser of a given capacity can be varied by selecting
the right material. Higher the ability of a material to transfer heat, the smaller
will be the size of the condenser.
 Amount of contact: The condenser capacity can be varied by controlling the
amount of contact between the condenser surface and the condensing medium.
This can be done by varying the surface area of the condenser surface and the rate
of flow of the condensing medium over the condenser surface. The amount of
liquid refrigerant level in the condenser also affects the amount of contact
between the vapour refrigerant and the condensing medium. The portion of the
condenser used for liquid sub-cooling cannot condense any vapour refrigerant.
 Temperature difference: As the temperature difference increases , the heat
transfer rate increases and therefore the condenser capacity increases.
Heat rejection Factor

 The load on the condenser per unit of refrigeration capacity is known as heat
rejection factor.
 HRF depends on COP.
Classification of Condensers

 According to the condensing medium used, the condensers are classified into
the following three groups:
 Air-cooled condensers,
 Water-cooled condensers, and
 Evaporative condensers.
Air-cooled condensers

 In this type of condenser heat is removed by air.

 It consists of steel (in ammonia refrigerating systems) or copper (for excellent
heat transfer ability) tubing having fins through which the refrigerant flows.
 The condensers with single row of tubing provides the most efficient heat
transfer because the temperature difference between the air and the vapour
refrigerant decreases in each row becomes less effective.
 The main disadvantage of an air cooled condenser is that it operates at a
higher condensing temperature than a water cooled condenser. The higher
condensing temperature causes the compressor to work more.
Types of Air Cooled Condensers

 Natural convection air-cooled condensers

 Heat transfer from condenser coils to the air is by natural convection.
 Air in contact heats up and rises, causing the colder air below to rise up and take
away the heat.
 Rate of heat transfer is low.
 Larger surface area is required.
 Used only in small-capacity applications such as domestic refrigerators, freezers,
water coolers and room air-conditioners.
 Forced convection air cooled condensers
 The fan is used to force the air over the condenser coils to increase its heat
transfer capacity
 Following are the two types:
 The base mounted air-cooled condensers
 The compressor is belt driven by the motor and the fan that forces the air through is mounted on
the shaft of the motor

 These condensing units are used on a packaged refrigeration systems of 10 tonnes or less.

 The remote air cooled condensers

 These condensing units are used on systems above 10 tonnes and are available to 125 tonnes.

 The fans are mounted on a foundation on ground or on the roof and air is transferred in the
buildings via ducts
Water-Cooled Condensers

 Water is the condensing medium

 Preferred when water supply is adequate and means of water disposal are
available
 Commonly used in commercial and industrial refrigerating unts
 It may use following two water systems:
 Waste water system: when water supply is adequate the water after passing
through the condenser is sent to the sewer
 Recirculated water system: Water circulating in the condenser is cooled and used
again and again. The water is cooled by cooling towers or by circulation through
the roofs
Types of Water-cooled Condensers

 Tube-in-tube or double tube condensers:

 Consists of water tubes inside a large refrigerant tube
 The hot vapour refrigerant enters at the top of the condenser where water absorbs
heat and the condensed liquid refrigerant flows at the bottom
 Some of the heat is also transferred via air
 The system can be counter-flow system or parallel-flow system depending on the
direction of flow of water and that of refrigerant
 Shell and coil condensers
 Consists of one or more water coils enclosed in a welded steel shell
 May be vertical or horizontal
 Hot vapour refrigerant enters at the top of the shell and surrounds the water coils.
As the condensation takes place refrigerant drops to the bottom of the shell which
often serves as a receiver.
 Counter-flow is preferred over parallel-flow due to enhanced efficiency
 Shell and tube condensers
 Consists of a cylindrical steel shell containing a number of straight water tubes
 The hot vapour refrigerant enters at the top of the shell and condenses as it comes
in contact with the water tubes. The condensed liquid refrigerant drops to the
bottom of the shell
Comparison of Air-Cooled and Water-
Cooled Condensers
The Dirt factor or Fouling factor

 Deposition of any undesired material on heat transfer surfaces is called

fouling, and the heat transfer resistance offered by the deposit is called the
fouling factor or dirt factor, commonly denoted by Rd.
 Fouling increases the overall thermal resistance and lowers the overall heat
transfer coefficient of heat exchangers.
 The fouling factor is zero for a new heat exchanger.
 It can be only be determined from experimental data on heat transfer
coefficient of a fouled exchanger and a clean exchanger of similar design
operated at identical conditions.
EVAPORATIVE CONDENSERS

 Use both air and water as condensing mediums to condense the hot vapour
refrigerant to liquid refrigerant
 Performs combine functions of water-cooled condensers and cooling towers
 Water is pumped from sump to a spray header and sprayed through nozzles
over the condenser coils through which the hot vapour refrigerant from the
compressor is passing.
 The heat transfers from the refrigerant through the condensing tube walls
and into the water that is wetting the outside surface of the tubes.
 Simultaneously, a fan draws air from the bottom side of the condenser and
discharged out at the top of the condenser
 The air causes the water on the condenser surface to evaporate and absorb
latent heat from the remaining water to cool it.
COOLING TOWERS

 A cooling tower is an enclosed tower-like structure through which

atmospheric air circulates to cool large quantities of warm water by direct
contact.
 Device used to remove heat from the water used in recirculated water
systems
 Towers can cool the water to a temperature within 7°F of the wet bulb
temperature of the air surrounding the tower
 If the wet bulb temperature is 90 degrees, water can be cooled to a
temperature as low as 83°F
 Natural draft, forced draft, or evaporative
 Hot water in (95°F) Fan motor

Air in 95°F dry bulb,

78°F wet bulb

Air out

Cooled water out (85°F)

NATURAL DRAFT COOLING TOWERS

 Redwood, fiberglass or galvanized sheet metal

 There are no blowers to move air through the tower
 Natural breezes move air through the tower
 Water enters the tower from the top and is cooled as the water falls to the
bottom
 Some water evaporates in the process, helping to cool the remaining water in
the tower
 Additional water is added through a float valve
FORCED OR INDUCED DRAFT TOWERS

 Use a fan or blower to move air through the tower

 As the water falls through the tower, air is moved across it to aid in the
cooling process
 Can be located almost anywhere
 The fan is cycled on and off to maintain the desired water temperature
 Forced draft – Air is pushed through the tower
 Induced draft – Air is pulled through the tower
THANK YOU!!!