UNIT IV

AIR COMPRESSORS
4.1. INTRODUCTION
An air compressor is a machine to compress the air to raise its pressure. The air
compressor sucks air from the atmosphere, compresses it and then deliver the same under
a high pressure to a storage vessel; it may be conveyed by the pipe line to the place where
the supply of air compressed air is required. Since the compression of air requires some
work to be done on it, therefore the compressor must be driven by some prime mover.
The compressed air is used for many purposes such as for operating pneumatic
drills, riveters, road drills, paint spraying, in starting and supercharging of internal
combustion engines, in gas turbine plants, Jet engines and air motors, etc. It is also
utilized in the operation of lifts, rams, pumps and variety of devices. In industry,
compressed air is used for producing blast of air in blast furnaces and Bessemer
converters.
4.2. CLASSIFICATION OF AIR COMPRESSORS
The air compressor may be classified into
(i) According to working
(a) Reciprocating compressors
(b) Rotary compressors
(ii) According to the action
(a) Single acting compressors
(b) Double acting compressors
(iii) According to number of stages
(a) Single stage compressors
(b) Multi stage compressors
(c)
4.3. TECHNICAL TERMS
(i) Inlet pressure :
It is the absolute pressure of air at the inlet of a compressor.
(ii) Discharge Pressure :
It is the absolute pressure of air at the outlet of a compressor.
(iii) Pressure Ratio :
It is the ratio of discharge pressure to the inlet pressure .Since the discharge
pressure is always more than the inlet pressure , therefore the value of
compression ratio is more than unity.
(iv) Compressor Capacity :
It is the volume of air delivered by the compressor and it expressed in m
3
/min
or m
3
/sec.
(v) Free air delivery :
It is the actual volume delivered by the compressor when reduced to the
normal temperature and pressure condition. The capacity of compressor is
generally given in the terms of free air delivery .
(vi) Swept Volume:
It is the volume of air sucked by the compressor during its suction stroke.
Mathematically, the swept volume or displacement of a single acting air
compressor is given by,
2
4
s
V D L

D = Diameter of cylinder bore, and
L = Length of piston stroke.
vii. Mean effective pressure :
Air pressure on the compressor piston keeps on changing with the movement
of the piston in the cylinder. The mean effective pressure of the compressor is
equal to the ratio of working done per cycle to the stroke volume.
4.4. WORKING OF SINGLE STAGE AIR COMPRESSOR
A Single stage reciprocating air compressor, in its simplest form, consists of a cylinder,
piston, inlet and discharge valves.
4.4.1. WORK / KG OF AIR WITHOUT CLEARANCE VOLUME:
4 1 Suction: Inlet valve is opened at pressure P
1
1 2 Polytropic Compression Pv
n
= C
2 3 Delivery at pressure P
2
Outlet valve is opened
Work done / cycle = Area 41234
= Area under 2 - 3 + Area under 1 - 2 Area under 1 - 4
= P
2
V
2
+ P
2
V
2
=
2 2 1 1
2 2 1 1
1
PV PV
PV PV
n

= ( )
2 2 1 1
1
1
1
PV PV
n
1
+
1

]
= ( )
2 2 1 1
1 1
1
n
PV PV
n
+ 1

]
=
2 2
1 1
1 1
1
1
PV n
PV
n PV
1

]
3
4
2
1
V
2 V
1
V
P
P
2
P
1
Pv
n
= C
Work Done / Cycle =
2
1 1
1
1
1
mRT n
PV
n mRT
1

]
Work Done / Cycle =
1
2
1 1
1
1
1
n
n
P n
PV
n P

1
_
1

,
1
]
----------------------- (1)
=
1
2
1
1
1
1
n
n
P n
mRT
n P

1
_
1

,
1
]
Work Done / kg of air =
1
2
1
1
1
1
n
n
P n
RT
n P

1
_
1

,
1
]
----------------------- (2)
4.4.2. WORK DONE/Kg OF AIR WITH CLEARANCE VOLUME:
4 1 Suction
1 2 Polytropic Compression
2 3 Delivery
3 4 Polytropic Expansion of Clearance Volume
Work done / cycle = Area 41234
= Area 61256 Area 64356
=
1
2
1 1
1
1
1
n
n
P n
PV
n P

1
_
1

,
1
]
-
1
3
4 4
4
1
1
n
n
P n
PV
n P

1
_
1

,
1
]
But P
3
= P
2
, P
4
= P
1
V
C V
S
V
P
1
2 3
5
6
4 V
a
Work done / cycle = ( )
1
2
1 1 4 4
1
1
1
n
n
P n
PV PV
n P

1
_
1


1

,
1
]
= ( )
1
2
1 1 4
1
1
1
n
n
P n
P V V
n P

1
_
1


1

,
1
]
Work done / cycle =
1
2
1
1
1
1
n
n
a
P n
PV
n P

1
_
1

,
1
]
----------------- (3)
Where ( )
1 4 a
V V V = Free air delivered
Work done / cycle =
1
2
1
1
1
1
n
n
a
P n
m RT
n P

1
_
1

,
1
]
Work done / kg of air =
1
2
1
1
1
1
n
n
P n
RT
n P

1
_
1

,
1
]
------------------- (4)
Equation (4) is same as Equation (2), (i.e) the clearance will not affect the work of compression
per kg of air.
Clearance = 100
c
s
V
K
V

4.5. VOLUMETRIC EFFICIENCY:
It is the ratio of the actual volume of free air delivered to the displacement
volume.
V
C V
S
V
P
1
2 3
5
6
4 V
a
(i.e)
a
vol
s
V
V

=
1 4
s
V V
V

=
( )
4 s c
s
V V V
V
+
=
( )
4 s c
s
V V V
V

=
4
1
c
s
V V
V
1

1
]
=
4
1
1
c
c
s
V
V
V
V
1 _

1
, ]

' ;



=
4
3
1
1
c
s
V
V
V
V
1 _

1
, ]

' ;



=
1
3
4
1
1
n
c
s
P
V
P
V
1
_
1

1
,
1
]

' ;




3 3 4 4
n n
PV PV
1
4 4
3 3
n
V P
V P
_

,
_

,
vol
=
1
2
1
1
1
n
c
s
P
V
P
V
1
_
1

1
,
1
]

' ;




3 2
P P ;
4 1
P P
=
1
2
1
1 1
n
c
s
V P
V P
1
_
1


1
,
1
]
vol
=
1
2
1
1 1
n
P
K
P
1
_
1


1
,
1
]
Where K =
c
s
V
V
= Clearance Ratio
4.6. ISOTHERMAL EFFICIENCY: PV = C
P
2
V
2

V
1
V
Isothermal Work done / cycle = Area 412
1
34
= Area under 32
1
+ Area under 2
1
1 Area under 41
=
1 1 1
2 2 2 2 1 1 1
2
log
e
V
PV PV PV
V
_
+

,
=
1
1 1 1
2
log
e
V
PV
V
_

,
1 1
2 2 1 1
,12 PV PV Isothermal process 1
]
Q
=
1 2
1 1 1
2 1
log log
e e
V P
mRT mRT
V P
_ _

, ,
(i.e) Work done / cycle =
2
1
1
log
e
P
mRT
P
_

,
Work done / kg =
2
1
1
log
e
P
RT
P
_

,
2
1
1
1
2
1
1
log
1
1
e
Iso
n
n
P
RT
P Isothermal Workdone
Actual Workdone
P n
RT
n P

_

,

1
_
1

,
1
]
P
3
2

2
4
1 P
1
PV
n
=C
PV =C
2
1
1
2
1
log
1
1
e
Iso
n
n
P
P
P n
n P

_

,

1
_
1

,
1
]
4.7. MULTI STAGE COMPRESSORS:
A single stage air compressor suffers the following drawbacks :
(i) The size of the cylinder will be too large .
(ii) Due to compression , there is a rise in temperature of the air
.It is
difficult to reject heat from the air in the small time available
during compression.
(iii) The temperature of air, at the end of compression ,is too high.
It
may heat up the cylinder head or burn the lubricating oil.
In order to over come the above mentioned difficulties, two or more cylinders
are provided in series with intercooling arrangement between them. Such an arrangement
is known as multistage compression.
4.7.1. Advantages of Multi Stage Compression
Following are the main advantages of multistage compression over single stage
compression:
(i) The work done per Kg of air is reduced in Multistage compression with
intercooling as compared to single stage compression for the same
delivery
pressure.
(ii) It improves the volumetric efficiency for the given pressure ratio.
(iii) The size of the cylinders may be adjusted to suit the volume and pressure
of
the air.
(iv) It reduces the leakage loss considerably.
(v) It gives more uniform torque, and hence a smaller size flywheel is
required.
(vi) It provides effective lubrication because of lower temperature range.
(vii) It reduces the cost of compressor.
1
2
1
1 1
n
Vol
P
K
P

1
_
1


1
,
1
]
For fixed clearance and the
Vol
decreases with increase in
2
1
P
P
_

,
(i.e) Pressure Ratio.
ie
2
1
.
a
Vol
s
Vol
a
V
V
P
ie increases decrease
P
This means thatV decreases withincreasin pressureratio

,
_

,
4.8. CONDITION FOR MINIMUM WORK IN
MULTISTAGE COMPRESSORS:
Consider a two stage air compressor with different n and imperfect inter cooling.
1 2
1 2
1 1
3 1 2 2
1 3
1 1 2 2
n n
WD/Kg = 1 1
1 1
n n
n n
P P
RT RT
n P n P

1 1
_ _
_ _
1 1
+

1 1

, ,
, ,
1 1
] ]
P
3
and P
1
are fixed. Hence P
2
should be determined for maximum work requirement.
The Condition for maximum work is
2
0
dw
dP

1 2
1 2
1 1
3 1 2 2
1 3
2 1 1 2 2
. . 1 1 0
1 1
n n
n n
P n P n d
i e RT RT
dP n P n P

1 1
_ _

1 1
+
' ;
1 1

, ,
1 1
] ]
-------------- (1)
Let
1 2
1 2
1 1 n n
x y
n n


3 2
1 3
2 1 2
1 1
1 1 0
x y
P P d
RT RT
dP x P y P
1 1
_ _

1 1 +
' ;
1 1
, ,
] ]
3 2
1 3
2 1 2
1 1
1 1 0
x y
P P d
T T
dP x P y P
1 1
_ _

1 1 +
' ;
1 1
, ,
] ]
P
V
1
2
3
4
P
1
P
2
P
3
( )
1
1
2
1 3 3 2
1
1 1
( ) 0
x
y y
x
xP
T T P y P
x P y

1
+
1
]
( )
1
3 2
1 3
1
1 2
y x
x y
P P
T T
P P

+
= 0
( )
1
3 2
1 3
1
1 2
y x
x y
P P
T T
P P

( ) 1 1 3
2 2 3 1
1
y x y y
T
P P P P
T
+

( ) 3
2 1 3
1
x y x y
T
P P P
T
+

( )
1
1
3
2 1 3
1
x y
x y
x y
T
P P P
T
+
+
_


,
------
(2)
n
1
= n
2
; x=y
( )
1
1
2
3
2
2 1 3
1
(2)
x
x x
x
T
P P P
T
_


,
( )
1
1 2
3
2
2 1 3
1
x
T
P PP
T
_

,
If T
3
= T
1
; (Perfect Inter cooling) ( )
1
2
2 1 3 1 3
P PP PP ---------------- (3)
This is the condition for minimum work required to run the compressor.
2
2 1 3
P PP
(i.e.)
3 2
1 2
P P
C
P P
(Pressure Ratio is constant)
If there are N stages,
3 1 2 4
1 2 3 1
........
N N
N N
P P P P P
C
P P P P P
+

--------------- (4)
From (4) We get
1 N N
P P C
+

2 3
1 1 1 2 1
........
N
N N N N
P P C P C P C PC
+

1
1
. .
N N
P
i e C
P
+

1
1
1
N
N
P
C
P
+
_


,
1
1 2
1 1
N
N
P P
P P
+
_

,
--------------------- (5)
4.8.1. Minimum Work Required with Perfect Inter Cooling and Same Index of
Compression:
1 2
1 2
1 1
3 1 2 2
1 3
1 1 2 2
n n
WD/Kg = 1 1
1 1
n n
n n
P P
RT RT
n P n P

1 1
_ _
_ _
1 1
+

1 1

, ,
, ,
1 1
] ]
1 1
2 2
1 1
1 1
n n
= 1 1
1 1
n n
n n
P P
RT RT
n P n P

1 1
_ _
_ _
1 1
+

1 1

, ,
, ,
1 1
] ]
3 2
1 2 3 1
1 2
;
P P
n n and T T
P P
1

1
]
Q
1
2
1
1
n
2 1
1
n
n
P
WD
RT
kg
n P

1
_
_
1


1

,
,
1
]
--------------- (6)
There are n stages,
1
2
1
1
n
minimum 1
1
n
n
P
WD
N RT
kg
n P

1
_
_
1


1

,
,
1
]
--------------- (7)
But we know that
1
1 2
1 1
N
N
P P
P P
+
_

,
from (5)
1
1
1
1
n
(7) 1
1
n
Nn
N
P
WD
N RT
kg
n P

+
1
_
_
1


1

,
,
1
]
-------------- (8)
4.9. INDICATED POWER OF COMPRESSION:
. .
60
m
P LAN
I P
Where, P
m
= Mean Effective Pressure in N/m
2
L = Stroke in m
A = Area of the piston
2
4
D
in m
2
N = speed in rpm
For double acting . . 2
60
m
P LAN
I P
1
2
1
1
1
1
n
n
a
P n
WD
PV
cycle
n P

1
_
1


1

,
1
]
1
2
1
1
1
1
n
n
m s a
P n
P V PV
n P

1
_
1


1

,
1
]
1
2
1
1
1
1
n
n
a
m
s
V P n
P P
n V P

1
_
1


1

,
1
]
1
2
1
1
1
1
n
n
m vol
P n
P P
n P

1
_
1


1

,
1
]
m
a
P S
l

Where, a = area of the indicator diagram
l = length of the indicator diagram
S = Spring constant
Indicated power can also be calculated using the relation
1
2
1
1
. 1
1 60
n
n
a
P n RPM
I P PV
n P

1
_
1


1

,
1
]
For multi stage compression with N stages
1
1
1
1
. 1
1 60
n
Nn
N
a
P n RPM
I P N PV
n P

+
1
_
1


1

,
1
]
4.10. MECHANICAL EFFICIENCY:
. .
.
M
I P I P
B P ShaftWork

4.11. EFFECTIVENESS OF INTER COOLER:
Counter flow Water cooled heat exchanger
Actual dropintemperature
MaximumPossibledropintemperatureof air

2 3
2 1
T T
T T

T
3
= T
1
(Perfect Inter cooling)
1 ; Effectiveness is unity.
4.12 ROTARY AIR COMPRESSOR:
T
3
T
W1
T
2
T
W2
T
3
T
w1
T
w2
T
2
In a rotary air compressor the air is entrapped between two sets of engaging surface and
the pressure of the air is increased by squeezing action of back flow of air.
4.12.1 COMPARISION OF RECIPROCATING AND ROTARY AIR
COMPRESSORS
Following are the main points of comparison of reciprocating and rotary air compressor:
S.No Reciprocating Air Compressor
Rotary Air Compressors
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
The maximum delivery pressure may be as
high as 1000 bar.
The maximum free air discharge is about
300 m
3
/min.
They are suitable for low discharge of air at
very high pressure .
The speed of air compressor is low.
The air supply is intermittent.
The size of air compressor is large for the
given discharge.
The balancing is a major problem.
The lubricating system is complicated.
The air delivered is less clean ,as it comes in
contact with the lubricating oil.
Isothermal Efficiency is used for all sorts of
calculation.
The maximum delivery pressure
is10 bar only.
The maximum free air discharge is
as high as 3000 m
3
/min.
They are suitable for large
discharge of air at low pressure .
The speed of air compressor is
high.
The air supply is continuous.
The size of air compressor is small
for the given discharge.
There is no balancing problem.
The lubricating system is simple.
The air delivered is more clean ,as
it does not comes in contact with
the lubricating oil.
Isentropic Efficiency is used for
all sorts of calculation.
4.12.2 TYPES OF ROTARY AIR COMPRESSORS
Though there are many types of rotary air compressors, yet the following are
important types:
(i) Roots blower compressor
(ii) Vane blower compressor
(iii) Centrifugal blower compressor
(iv) Axial flow compressor
The first two compressors are popularly known as Positive displacement compressor,
whereas the last two as Non- Positive displacement compressor.
(i) ROOTS BLOWER COMPRESSOR
(ii) VANE BLOWER COMPRESSOR
(iii) CENTRIFUGAL COMPRESSOR
(iv) AXIAL FLOW COMPRESSOR
4.13 COMPARISION OF CENTRIFUGAL AND AXIAL FLOW AIR
COMPRESSORS
Following are the main points of comparison of the centrifugal and axial flow air compressors:
S.
No.
Centrifugal Compressors Axial Flow Compressors
1.
2.
3.
4.
5.
The flow of air is perpendicular to the axis
of compressor
It has low manufacturing and running
cost.
It requires low starting torque.
It is not suitable for multi- staging
It requires large frontal area for a given
rate of flow.
The flow of air is parallel to the axis of
compressor
It has high manufacturing and running
cost.
It requires high starting torque.
It is suitable for multi- staging
It requires less frontal area for a given
rate of flow. It makes the compressor
suitable for air crafts.