UNIT –3

RECIPROCATING AIR COMPRESSORS

An air compressor is a machine to compress the air and to raise its pressure. The air
compressor sucks air from the atmosphere, compresses it and then delivers the same
under a high pressure to a storage vessel. F rom the storage vessel, it may be conveyed
by the pipeline to a place where the supply of compressed air is required.
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.

Classification of Air Compressors

The air compressors may be classified in many ways, but the following are important from
the subject point of view:
I. According to working
(a) Reciprocating Compressors, and (b) Rotary compressors.
2. According to action
(a) Single acting compressors, and (b) Double acting compressors.
3. According to number of stages
(a) Single stage compressors, and (b) Multi-stage compressors
Working of Single Stage Reciprocating Air Compressor
Swept volume: is the volume of air
sucked by the compressor during its
suction stroke. Mathematically, the swept
volume or displacement of a single
Where:
D.V. = Delivery Valve acting air compressor is given by:
I.V. = Inlet Valve π
vs = × D2 × L
4
Where:
D = Diameter of cylinder bore.
L = Length of piston stroke.
(a) Suction stroke (b) Delivery stroke vs = Swept volume

F ree air delivery: It is the actual volume delivered by a compressor when reduced to the
normal temperature and pressure condition. The capacity of a compressor is generally
given in terms of free air delivery.
Compression Ratio or 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.
 Working of Single Stage Reciprocating Air Compressor
D.V.C I.V. O D.V.O I.V. C
TDC
Cylinder D.V → Delivery Valve
Piston I.V. → Inlet Valve
BDC D.V.O → Delivery Valve Open
Connecting I.V. O → Inlet Valve Open
Rod
D.V.C → Delivery Valve Close
Crank I.V. C → Inlet Valve Close
T.D.C→ Top Dead Center
Crank B.D.C→ Bottom Dead Center
Shaft

(a) Suction stroke (b) Delivery stroke

Suction Stroke: A single stage reciprocating air compressor consists of a cylinder, piston, inlet valve
(IV) and discharge valve (DV) as shown in figure. When piston downwards (Moves from TDC to
BDC) during suction stroke, the pressure inside the cylinder falls below the atmospheric pressure.
Due to this pressure difference, the inlet valve gets opened (IVO) and air is sucked into the cylinder
and piston moves to BDC.
Delivery Stroke: When piston starts moving upward (BTD to TDC) during delivery stroke, the
pressure inside the cylinder goes on increasing, the inlet valve closes (IVC). When pressure inside the
cylinder reaches delivery pressure then discharge valve opens (DVO) and air is delivered to the
container. At the end of delivery stroke, the piston moves to TDC, a small quality of air, at high
pressure is left in the clearance space. As the piston starts its suction stroke the air contained in the
clearance space expands till its pressure falls below the atmospheric pressure. At this stage, the inlet
valve gets opened and fresh air is sucked in, and the cycle is repeated.
 Reciprocating Air Compressor With Clearance Volume & Without Clearance Volume
Compressor With Clearance Volume Compressor Without Clearance Volume
Connecting rod Connecting rod
Cylinder Cylinder
Piston Piston
Crank

vc vc= 0

P Crank shaft P Crank shaft

3 2 2
P2 P2 3
P vn= C P vn= C

P1 4 1 P1 4 1
v2 v2
vc vs v v1 v
v1
At the end of delivery stroke, the piston moves to TDC, a small quality of air, at high pressure is left in
the clearance space. As the piston starts its suction stroke the air contained in the clearance space
expands till its pressure falls below the atmospheric pressure. At this stage, the inlet valve gets opened
and fresh air is sucked in, and the cycle is repeated.
 Work done by a Single Stage Reciprocating Air Compressor without Clearance Volume
P
D C1 C C2 T
C2 p2
P2 Isothermal
v2 Polytropic
C
Isentropic
v2 Isentropic
Polytropic
p1
v2 T1 = T2
C1
P1 A B B
Isothermal

E FH G I v S
v1
Work done during
1) Isothermal compression, 2) Polytropic compression and 3) Isentropic compression
1) Work Done During Isothermal Compression
W = Area A B C1 D (Flow Work) W = Area D-C1-F-E + Area C1- B-I-F - Area A-B-I-E
v 
W = p2 v 2 + p2 v 2 In  1  − p1 v1 But P 1v1 = P 2v2
 v2 
v  v  v 
W = p2 v 2 + p2 v 2 In  1  − p1 v1 = p2 v 2 In  1  = p2 v 2 In  1 
 v2   v2   v2 
v  p  p
W = p2 v 2 In  1  = p1 v1 In  2  = p1 v1 In (r p ) But Pressure ratio → r p = 2
 v2   p1  p1

W = p1 v1 In (r p ) = p2 v 2 In (r p ) = m R T1 In ( r p ) = m R T2 In ( r p ) ⸪ P v = mRT
 Work done by a Single Stage Reciprocating Air Compressor without Clearance Volume
P T
C2 p2
D C1 C C2
P2 Isothermal Isentropic
C
v2 Polytropic
Polytropic
v2 Isentropic p1
T1 = T2
C1
v2 B
P1 A B Isothermal
S
E F G H I v 1
v1 −
v1  p1  n
2) Work Done During Polytropic Compression p1v1 = p2 v 2 ⇒
n n
= 
v 2  p2 
W = Area A B C D (Flow Work) → W = Area D-C-G-E + Area C-B-I-G - Area A-B-I-E
 p v − p1 v1  ( n − 1) p2 v 2 + p2 v 2 − p1 v1 − ( n − 1) p1 v1
W = p2 v 2 +  2 2  − p1 v1 ⇒ taking LCM W =
 n−1  n−1
⸪ Pv = mRT
p2 v 2 n − p2 v 2 + p2 v 2 − p1 v1 − p1 v1n + p1 v1 n n
W = = ( p2 v 2 − p1 v1 ) = m R(T2 − T1 )
n−1 n−1 n−1
Multiplying & dividing by P2 v2
 −1 / n 
n p2 v 2 n  p1 v1  n p1  p1 
W = × ( p2 v 2 − p1 v1 ) = × p2 v 2  1 − ×  = × p2 v 2 1 − ×   
n − 1 p2 v 2 n−1  p2 v 2  n − 1  p2  p2  
 
 n− 1   n− 1 
n   p1  n  n  p2  n  n n
W = × p2 v 2 1 −   =
 n−1 × p 2 2 
v  − 1 = ( p2 v 2 − p1 v1 ) = m R(T2 − T1 )
n−1 p2  p1  n−1 n−1
    
   
 Work done by a Single Stage Reciprocating Air Compressor without Clearance Volume
P T
C2 p2
D C1 C C2
P2 Isothermal Isentropic
C
v2 Polytropic
Polytropic
v2 Isentropic p1
T1 = T2
C1
v2 B
P1 A B Isothermal
S
E F G H I v 1
v1 −
γ γ v1  p1  γ
3) Work Done During Isentropic Compression p1v1 = p2 v 2 ⇒ = 
v1  p2 
W = Area A B C2 D (Flow Work) → W = Area D-C2-H-E + Area C2-B-I-H - Area A-B-I-E
 p v − p1 v1  ( γ − 1) p2 v 2 + p2 v 2 − p1 v1 − ( γ − 1) p1 v1
W = p2 v 2 +  2 2  − p1 v1 ⇒ taking LCM W =
 γ −1  γ −1
⸪ Pv = mRT
p2 v 2 γ − p2 v 2 + p2 v 2 − p1 v1 − p1 v1 γ + p1 v1 γ γ
W = = ( p2 v 2 − p1 v1 ) = m R(T2 − T1 )
γ −1 γ −1 γ −1
Multiplying & dividing by P2 v2
 −1 / γ 
γ p2 v 2 γ  p1 v1  γ p1  p1 
W = × ( p2 v 2 − p1 v1 ) = × p2 v 2  1 − ×  = × p2 v 2 1 − ×   
γ − 1 p2 v 2 γ −1  p2 v 2  γ − 1  p2  p2  
 
 γ −1   γ −1 
γ   p1  γ  γ  p2  γ  γ γ
W = × p2 v 2 1 −   =
 γ −1 × p 2 2 
v  − 1 = ( p2 v 2 − p1 v1 ) = m R(T2 − T1 )
γ −1 p2  p1  γ −1 γ −1
    
   
 Minimum Work done in a Single Stage Reciprocating Air Compressor Wihout Clearence Volume
P T
C2 p2
D C1 C C2
P2 Isothermal Isentropic
C
v2 Polytropic
Polytropic
v2 Isentropic p1
T1 = T2
C1
v2 B
P1 A B Isothermal
S
E F G H I v
v1
1) Work Done During Isothermal Compression
v   p 
W Iso = p2 v 2 In  1  = p1 v1 In  2  = m R T1 In ( r p ) = m R T2 In ( r p )
 v2   p1 

2) Work Done During Polytropicc Compression

 n− 1 
n   p2  n  n n
W Poly = × p2 v 2   − 1 = ( p2 v 2 − p1 v1 ) = m R(T2 − T1 )
n−1  p1  n−1 n−1
 
 
3) Work Done During Isentropic Compression
 γ −1 
γ   p2  γ  γ γ
W Ise = × p2 v 2   − 1 = ( p2 v 2 − p1 v1 ) = m R(T2 − T1 )
γ −1  p1  γ −1 γ −1
 
 

But γ>n γ>1 & n>1 ∴ WISO < Wpoly < WIse
 Work done by a Single Stage Reciprocating Air Compressor with Clearance Volume
P T In the previous articles, we have assumed
B 3 2 that there is no clearance volume in the
P2 p2 = p3
P vn= C 2 compressor cylinder. But in actual practice,
3
it is not possible to reduce the clearance
p1 = p4
volume to zero, for mechanical reasons.
1 Moreover, it is not desirable to allow the
P1 A 4 1 piston head to come in contact with the
P vn= C 4
v4 cylinder head. In addition to this, clearance
S
v volume is required to accommodate the inlet
v2 and exhaust valves.
vc vs
v1 Work Done During Polytropic Compression
Wpoly = Area 4-1-2-3= Area A-1-2-B - Area A-4-3-B

n

  p2  n
n −1 
 n

  p3  n
n −1 

v4 → Expanded Clearance Volume
W poly =
n−1
p1v1   − 1 −
n−1
p4 v 4   − 1 v3 = vc → Clearance Volume
 1   4 
p p
 
    vs → Sroke/Swept Volume
But P 2 = P 3, P 1 = P 4
 n −1  v1 → Initial Volume of air = vs + vc
n  p  n 
W poly = p1 (v1 − v 4 ) 2  − 1 …Eqn.1
n−1
 1 
p

 
(v1 – v4) is the effective swept volume or actual volume of air drawn into cylinder at P 1 & T1
∴ The mass of air drawn into cylinder is determined by using ideal gas equation P 1 va = mRT1→ P 1(v1 – v4) = mRT1
 n −1 
 p  
If P 1(v1 – v4) =mRT1 then the Polytropic
→ n n
W poly = mRT1  2  − 1 …Eqn.1
work (Eqn-1) can be expressed as n−1 
 1
p

 
 Work done by a Single Stage Reciprocating Air Compressor with Clearance Volume
P T
2 Work Done During Isentropic Compression
B 3 2
P2
P vγ = C
3 P vγ = C v4 → Expanded Clearance Volume
v3 = vc → Clearance Volume
1 vs → Sroke/Swept Volume
P1 A 4 1 P vγ = C v1 → Initial Volume of air = vs + vc
v4
4 S
v2 v
vc vs
v1
WIso = Area 4-1-2-3= Area A-1-2-B - Area A-4-3-B
 γ −1   γ −1 
γ   p2  γ  γ   p3  γ 
W Ise = p1v1   − 1 − p4 v 4   − 1 But P 2 = P 3, P 1 = P 4 &
γ −1 γ −1
 1   4 
p p
 
   
But P 2 = P 3, P 1 = P 4 1
 γ −1  −
v  p  γ
γ  p  γ  p1v1γ = p2 v 2γ ⇒ 1 =  1 
W Ise = p1 (v1 − v 4 ) 2  − 1 …Eqn.1 v1  p2 
γ −1
 1 
p

 
(v1 – v4) is the effective swept volume or actual volume of air drawn into cylinder at P 1 & T1
∴ The mass of air drawn into cylinder is determined by using ideal gas equation P 1 va = mRT1→ P 1(v1 – v4) = mRT1
 γ −1 
γ  p  γ 
If P 1(v1 – v4) = mRT1 then the Isentropic
→ W Ise =
γ −1
mrT1  2 

− 1 …Eqn.1
work (Eqn-1) can be expressed as  1
p

 
 Work done by a Single Stage
T Reciprocating Air Compressor with Clearance Volume
P
T Work Done During Isothermal Compression
B 3 2
P2
T= C 4
v4 → Expanded Clearance Volume
T3 = T4
3
v3 = vc → Clearance Volume
vs → Sroke/Swept Volume
P1 A 4 1 1 T1 = T2 2 v1 → Initial Volume of air = vs + vc
v4 S
v2 v
vc vs
v1
WIso = Area 4-1-2-3= Area A-1-2-B - Area A-4-3-B
 p   p 
W Iso = p1v1 In 2  − p4 v 4 In 3  But P 2 = P 3, P 1 = P 4
 p1   p4 
 p   p 
W Iso = p1v1 In 2  − p1v 4 In 2 
 p1   p2 
 p 
W Iso = p1 ( v1 − v 4 ) In 2  …Eqn.1
 p1 
(v1 – v4) is the effective swept volume or actual volume of air drawn into cylinder at P 1 & T1
∴ The mass of air drawn into cylinder is determined by using ideal gas equation P va = mRT1→ P 1(v1 – v4) = mRT1


If P 1(v1 – v4) = mRT1 then the Isentropic
work (Eqn-1) can be expressed as
→ W Iso = mRT1 In pp2  …Eqn.1
 1 
 Power Required to Drive a Single-stage Reciprocating Air Compressor
The power required to drive the compressor may be obtained from the usual relation
P = work done per cycle × Number of Cycles per second
P = W × Number of Cycles per minute/60
P = W × Nw /60
If N is the speed of the compressor in r.p.m.
Then number of working strokes per minute is Nw
Nw = N (F or single acting Reciprocating Compressor)
Nw = 2N (F or double acting Reciprocating Compressor)
I) Isothermal power = WIso × Nw /60 ….. Watts
II) Polytropic power = Wpoly × Nw /60 ….. Watts
III) Isentropic power = WIse × Nw /60 ….. Watts
With clearance Volume Without clearance Volume
F or Polytropic process
 n −1 
F or Polytropic process
n   p2  n   n− 1 
W poly = mRT1   − 1 n   p2  n 
n−1 = × p2 v 2    − 1
 1 
p W Poly  
 n−1
   1 
p

 
F or Isentropic process F or Isentropic process
 γ −1 
 γ −1 
γ  p2  γ 
W Ise = mRT1   − 1 γ   p2  γ 
γ −1 p  W Ise = × p2 v 2  
 
 − 1
 1   γ −1
 1 
p

   
F or Isothermal
F or Isothermal
p 
W Iso = mRT1 In 2   p 
 p1  W Iso = mR T1 In  2 
 p1 
 Volumetric Efficiency of a Reciprocating Air Compressor with Clearance Volume
The volumetric efficiency of a reciprocating air compressor is defined as the ratio of volume of free air
delivered per stroke to swept volume of the piston.
Volum of free air delivery per stroke Actual volume of air sucked reffered to ambient condition
ηvol = =
Swept volume of the pistion Swept volume of the pistion
P 1, v1 & T1 are initial pressure, volume and temperature of air before compression.
P 2, v2 & T2 are the final pressure, volume and temperature of air at the delivery point.
P a , va & Ta are the pressure, volume and temperature of air at ambient condition.
vs is swept volume of piston, vc is clearance volume and n is polytropic index Pa
In actual practice, the temperature at the end of suction i.e. at point 1 is not
atmospheric because the fresh air passes over hot valves and mixes with the
residual air. Also, the pressure at point 1 is not atmospheric as there are
obstructions in suction of fresh air. Applying general gas equation to the
atmospheric condition of air and the condition of air before compression (at
state 1), we have
Volume of air sucked with respect to
→ →
ambient conditions

Volumetric efficiency →

Multiply and divide by vc pa

va
Ta

For Polytropic process 3-4→ (v4 / v3) = (p3 / p4) 1/n → (v4 / vc) = (p3 / p4)1/n → (v4 / vc) = (p2 / p1)1/n

When the ambient and suction conditions are

same, then pa = p1 and Ta = T1 . In such a case
Problem 1
A single stage reciprocating air compressor without clearance volume is required to compress the air at
the rate of 1.2 kg/min from I bar to 4 bar following the law pv1.3 = C. The initial temperature of air is 27 °C.
The stroke volume of the cylinder is 0.01 m3 . Calculate the following: 1) stroke of the cylinder if bore is 150
mm, 2) Speed of the compressor, 3) increase in internal energy of the air 4) Indicated power of the
compressor, Take R =287 J/kg K, Cv = 718 J/kg K.
Solution ma = 1.2 kg/min = 0.02 kg/s, P1 = 1 bar, P2 = to 4 bar, n = 1.3, T1 = 27 °C = 300 K, v1 = 0.01 m3, d
= 150 mm = 0.15 m, R = 287 J/kg K, Cv = 718 J/kg K, L = ?, N = ?, Δu = ? and power =?

2
3

1
4 V1 = vs × N →

Polytropic Work

Polytropic Power

Change in Internal Energy

Delivery Temperature ∆U = ma × C v × (T1 − T2 )
∆U = 0.02 × 0.718 × (413.1 − 300)
∆U = 1.62 kJ / kg
 Multistage Compression
In single stage compression, air is sucked, compressed in the cylinder and then delivered at a higher
pressure. But sometimes, the air is required at a high pressure. In such cases, either we employ a
large pressure ratio (in single cylinder) or compress the air in two or more cylinders in series. It has
been experienced that if we employ single stage compression for producing high pressure air (say 8
to 10 bar), it suffers the following drawbacks: (Drawback of Single Stage Compression )
 The size of the cylinder will be too large.
 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.
 Sometimes, the temperature of air, at the end of compression, is too high. It may heat up the
cylinder head or burn the lubricating oil.
Multistage Compression: In order to overcome 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.
Advantages of Multistage Compression over of Single Stage Compression
I. The work done per kg of air is reduced in multistage compression with intercooler as compared
to single stage compression for the same delivery pressure.
2. It improves the volumetric efficiency for the given pressure ratio.
3. The sizes of the two cylinders (i.e. high pressure and low pressure) may be adjusted to suit the
volume and pressure of the air.
4. It reduces the leakage loss considerably.
5. It gives more uniform torque, and hence a smaller size flywheel is required.
6. It provides effective lubrication because of lower temperature range.
7. It reduces the cost of compressor.
 Two-stage Reciprocating Air Compressor with Intercooler
The figure shows a two-stage reciprocating air
compressor with water cooled intercooler. heat transferred
from air to water
F irst the fresh air is sucked from the
atmosphere in the low pressure (L.P.)-cylinder 2 P= C 3
during its suction stroke at intake pressure P 1
P2 , T2 P3 , T3
and temperature T1 . The air, after compression P2 = P3
Ist 2nd
in the L.P. cylinder (i.e. first stage) from 1 to 2, LP Cylinder Stage Stage
is delivered to the intercooler at pressure P 2 and
temperature T2. Now the air is cooled in the
intercooler from 2 to 3 at constant pressure (P 2
P vn = C
P4 , T4
1 4
= P 3 ) and from temperature T2 to T3. After that, P1 , T1

the air is sucked into the high pressure (H.P.)

cylinder during its suction stroke.
F inally, the air, after further compression in the H.P. cylinder (i.e. second stage) from 3 to 4, is
delivered by the compressor at pressure P 4 and temperature T4.

Assumptions in Two-stage Compression with Intercooler

I. The effect of clearance is neglected (vc = 0).
2. There is no pressure drop in the intercooler (P 2 = P 3 )
3. The compression in both the cylinders (i.e. L.P. and H.P.) is polytropic (i.e. Pv n = C).
4. The suction and delivery of air takes place at constant pressure.
 Work Done in Two Stage Reciprocating Air Compression with Complete /Perfect Inter-cooling

T Saved Work
2 P= C 3 P vn =c P
4"' 4" 4 4' 4'"
P2 , T2 P3 ,T3 P4
P2 = P3 4'

LP Cylinder Ist Stage 2nd Stage 4

2
P2 = P3 P2 = P3

1 T3 = T1
P vn = c 4" 3
P4 , T4 P1
1 4
P1 , T1 T3 = T1 S V

Complete or Perfect Intercooling

When the temperature of the air leaving the intercooler (T3) is equal to the original atmospheric air
temperature (T1), ie.T3 = T1, then the intercooling is known as complete or perfect intercooling. In this
case, the point 3 lies on the isothermal curve as shown in F igure. The amount of worked saved in
multistage compressor with complete cooling is more than that of incomplete intercooling.
Work done by a Two-stage Reciprocating Air Compressor with Perfect Intercooling
P 1 = Pressure at inlet of L.P. cylinder,
Work done per cycle in L.P. cylinder Work done per cycle in H.P. cylinder v = Volume of the L.P. cylinder,
1
 n− 1  n− 1
  P 2 = Pressure at outlet of L.P. cylinder
n   p2  n   p  n 
W1 = × p1 v1   − 1 W2 =
n
× p3 v 3  4  − 1 Or at inlet of the H.P. cylinder,
n−1
 1  n−1
p
  3 
p
   v3 = Volume of H.P. cylinder,
  P 3 = Pressure at inlet of H.P. cylinder, and
Total work done per cycle W = W1+W2 n = Polytropic index for both the cylinders.

 n− 1   n− 1    n−1   n− 1
n  p  n  n 
 p  n  n   p2  n   p4  n 
W = × p1 v1  2  − 1 + × p3 v 3  4  − 1 W = 1 1   − 1 + p3 v 3   − 
n − 1 
p v 1
n−1 n−1  p1   p3 
 1   3   
p p
 
        …Eqn-1  
 Work Done in Two Stage Reciprocating Air Compression with Complete /Perfect Inter-cooling

T Saved Work
2 P= C 3 P vn =c P
4"' 4" 4 4' 4'"
P2 , T2 P3 ,T3 P3
P2 = P3 4'

LP Cylinder Ist Stage 2nd Stage 4

2 P2 = P3 P= C

1 T3 = T1
P vn = c 4" 3
P4 , T4 P1
1 4
P1 , T1 T3 = T1 S V

Work done by a Two-stage Reciprocating Air Compressor with Perfect Intercooling

P 1 = Pressure at inlet of L.P. cylinder,
  n−1   n− 1 
n   p2  n   
p4 n  v1 = Volume of the L.P. cylinder,
W =  p1 v1   − 1 + p3 v 3   − 1  …Eqn-1
n−1  p1    p3  
P 2 = Pressure at outlet of L.P. cylinder
     Or at inlet of the H.P. cylinder,
v3 = Volume of H.P. cylinder,
F or Perfect Intercooling (T3 = T1)
P 3 = Pressure at inlet of H.P. cylinder, and
Applying equation of state for States 1 & 3 we get n = Polytropic index for both the cylinders.
p1 v1 p v
= 3 3 But T3 = T1 ∴ P 1v1 = P 3 v3 Substituting P 1v1 = P 3 v3 in Eqn -1 we get
T1 T3
 n− 1 n− 1   n− 1 n− 1 
n   p2  n  p4  n  n  p  n p  n 
W = P1 v1   +   − 2 OR W = m R T1  2  +  4  − 2 …Eqn-2
n−1  p1   p3   n−1  p1   p3  
   
 Work Done in Two Stage Reciprocating Compression with Incomplete /Imperfect Inter-cooling
Reduction in
T Saved Work
2 P= C P
3
P vn =c 4" 4 4' 4'"
4"' P4
P2 , T2 P3 ,T3
P2 = P3 4'

LP Cylinder Ist Stage 4

2nd Stage P= C
2 P2 = P3

3
P vn =c 4" 1 T3 > T1
P4 , T4
1 4 P1
P1 , T1 T3 > T1 S

Complete or Perfect Intercooling

When the temperature of the air leaving the intercooler (T3) is greater than the original atmospheric air
temperature (T1), ie.T3 > T1, then the intercooling is known as Incomplete or Imperfect intercooling. In
this case, the point 3 lies on the isothermal curve as shown in F igure. The amount of worked saved in
multistage compressor with incomplete cooling is less than that of complete intercooling.
Work done by a Two-stage Reciprocating Air Compressor with Perfect Intercooling
P 1 = Pressure at inlet of L.P. cylinder,
Work done per cycle in L.P. cylinder Work done per cycle in H.P. cylinder
v1 = Volume of the L.P. cylinder,
 n− 1   n− 1  P 2 = Pressure at outlet of L.P. cylinder
n   p2  n  n 
 p  n 
W1 = × p1 v1   − 1 W2 = × p3 v 3  4  − 1 Or at inlet of the H.P. cylinder,
n−1 n−1
 1   3 
p p
  v3 = Volume of H.P. cylinder,
   
P 3 = Pressure at inlet of H.P. cylinder, and
Total work done per cycle W = W1+W2 n = Polytropic index for both the cylinders

 n− 1   n− 1    n−1   n− 1
n   p2  n  n  p4  n  n   p2  n   p4  n 
W = × p1 v1   − 1 + × p3 v 3   − 1 W = 1 1   − 1 + p3 v 3   − 
n − 1 
p v 1
n−1 n−1 p1  p3 
 1   3   
p p  
 
        …Eqn-1  
Minimum Work Required for a Two-stage Reciprocating Air Compressor (Perfect Inter-cooling)
We have already discussed that maximum work is saved in
a two-stage reciprocating air compressor with complete 2 P= C 3
intercooling. We have also obtained a relation that work P2 , T2 P3 ,T3
required to be done by a two-stage reciprocating air P2 = P3

compressor with complete intercooling is found to be LP Cylinder Ist Stage 2nd Stage

 n− 1 n− 1 
n   p2  n  p4  n  P vn = c
W = P1 v1   +   − 2 …Eqn-2
n−1  p1   p3   1 4
P4 , T4
P1 , T1
  T3 = T1
If the intake pressure P1 and the delivery pressure P3 are fixed, then least value of the intermediate or
intercooler pressure P2 may be obtained by differentiating the above equation with respect to P2. It maybe noted
that value of P2 thus obtained denotes the pressure of the intercooler at which the work required to drive the
compressor is minimum. Thus work required is minimum, when
  n− 1 n− 1 
P1 v1 d  p2  
a a
dW d  n  p2  n  p4  n   n − 1  p4 
=0⇒  P1 v1   +   − 2  = 0 put   = a & P3 = P2 ⇒   +   − 2 = 0
dP2 dP2  n − 1  p1   p3    n  a dP2  p1   p2  
 
  
 p2 
a
 p4 
a   1 a
 a ( p2 )a − 1 + p4a (− a )( p2 )− a − 1 = a p1− a p2a − 1 − a p4a p2− a − 1 = p1− a p2a − 1 − p4a p2− a − 1 = 0
d
  +   − 2 = 
dP2  p1   p2    p1 
 
p2a − 1 p4a
p1− a p2a − 1 = p4a p2− a − 1 ⇒ = ⇒ p2a − 1 p2a + 1 = p4a p1a ⇒ p22a = ( p4 p1 )a ⇒ p22a = ( p4 p1 )a ⇒ p22 = p4 p1 ⇒ p2 = p4 p1
p2− a − 1 p1− a

p2 × p2 p × p1 p2 p
p22 = p4 p1 ⇒ p2 = p4 p1 …Eqn-3 p22 = p4 p1 ⇒ = 4 ⇒ = 4 …Eqn-4 F rom Eqns-4 &5
p1 p1 p1 p2
12
p2 p p 
2 2 12
= 4 =  4 
p22 p4 p1  p2  p4 × p1  p2  p4 p  p4  p1 p2  p1 
F rom Eqn-3 p22 = p4 p1 ⇒ = 
⇒  
 = p × p ⇒ p   = ⇒ 2 = 
p12 p12  p1  1 1  1 p1 p1  p1  …Eqn-5
…Eqn-6
Minimum Work Required for a Two-stage Reciprocating Air Compressor (Perfect Inter-cooling)
Conditions for Minimum Work for 2-stage Workdone for 2-stage with perfect cooling
 n− 1 n− 1 
12
p2 p p  n   p2  n  p4  n 
= 4 =  4  W = P1 v1   +   −2
…Eqn-6 n−1
 1   p3 
p1 p3  p1  p
 …Eqn-2
 
The minimum work require is obtained by substituting condition for minimum work (Eqn-6) in
work done equation for 2-stage compression with perfect cooling (Eqn-2) as :
 n− 1 n− 1   n− 1   n− 1 
n   p2  n  p2  n  n   p2  n  n   p2  n 
Wmin = P1 v1   +   −2= P1 v1  2  −2=2 P1 v1   − 1 …Eqn-7
n−1 n−1 n−1
 1   p1    1  1 
p p p
  
     
 n− 1 
12
p2  p4    p2  2 n
Substituting the condition (Eqn-6) in Eqn -7 = 
p1  p1 
⇒ Wmin =2
n
n−1
P1 v1  

− 1  …Eqn-8
 1 
p

 
Similarly Conditions for Minimum Minimum Work for 3-stages
Work for 3-stages  n− 1 
13 n  p6  3 n 
p2 p4 p4 p6  p6  =3 P1 v1   −1 
= = = = 
p1 p2 p3 p5  p1 
⇒ W min
n−1
 1 
p

…Eqn-9
 
Similarly Conditions for Minimum
Minimum Work for q number of stages
Work for q number of stages
 n− 1 
1q 
 2q  
 p2 q 
⇒
p2 p p p n p qn
= 4 = 4 = 6 =   Wmin =q P1 v1  
 − 1  …Eqn-10
p1 p2 p3 p5  p1  n−1   p1  
 
 Heat Rejected in a Reciprocating Air Compressor per kg of air

The total heat rejected in a

2 P= C 3
reciprocating air compressor is the
sum of the heat rejected during P2 , T2 P3 ,T3
P2 = P3
polytropic compression per kg of
LP Cylinder Ist Stage 2nd Stage
air (Q comp) and heat rejected in the
intercooler per kg of air (QIC) .
P vn = c
Heat rejected in Polytropic Compression P4 , T4
1 4
per kg of air P1 , T1

γ−n γ − n  P2 v 2 − P1 v1 
Qcomp = × Workdone = ×  Note
γ −1 γ −1  n−1 
F or the calculation of heat
Heat rejected in Intercooler per kg of air rejection, compression process is
(Isobaric Process) considered to take place in a
Q IC = Cp (T2 - T3 ) closed system (non flow process)

Total heat rejected (Qtotal) = Heat rejected in compressor (Qcomp) + Heat rejected in intercooler (QIC)

γ − n  P2 v 2 − P1 v1 
Qtotal = Qcomp + Q IC =   + Cp (T2 - T3 )
γ −1 n−1 

γ − n R(T2 − T1 )
Qtotal = × + Cp (T2 - T3 )
γ −1 n−1
 Problem-1

P4

P4

Volume flow rate (v1) = Volume displaced per stroke (vL) × No. of strokes per second (Nw/60)
v1 = vL × N/60
vL = (v1 × 60)/N Nw =N = 600
F or perfect Intercooling
(T3 = T1)→ P 1 vL = P 3 vH 2 P= C 3
P1 0.1 P2 , T2 P3 ,T3
vH = vL × = 0.02 × = 0.00756 m 3 P2 = P3
P2 0.2646
LP Cylinder Ist Stage 2nd Stage
v H = 0.00756 m 3

P vn = c
P4 , T4
1 4
P1 , T1 T3 = T1
Rate of heat rejection in the intercooler

F or perfect Intercooling (T3 = T1)

Problem-2
A two- stage single acting reciprocating air compressor draws in air at a pressure of 1 bar
and 17° C and compresses it to a pressure of 60 bar. After compression in the L.P. cylinder,
the air is cooled at constant pressure of 8 bar to a temperature of 37° C. The low pressure
cylinder has a diameter of 150 mm and both the cylinders have 200 mm stroke. If the law
of compression is Pv1.35 = C, find the power of the compressor, when it runs at 260 r.p.m.
Take R = 287 J /kg K.
Solution
P 1 = 1 bar = 1 × 105 N/m2; T1 = 7 °C = 17 + 273 = 290K; P 4= 60 bar = 60 ×105 N/m2; P 2 = 8
bar = 8 ×105 N/m2 ;T3 = 37 °C = 37 + 273 = 310 K; D = I50 mm = 0.15 m; L = 200 mm = 0.2
m; n = 1.35 N = 200 r.p.m. R = 287 J /kg K
We know that volume of L.P. cylinder ,
π π
v1 = × D 2 × L = × 0.15 2 × 0.2 = 0.0035m 3
4 4
v1 = 0.0035 m3
v 3 = Volume of H . P . cylinder
p1 v1 p3 v 3
We know that =
T1 T3
p1 v1T3 1 × 105 × 0 .0035 × 310
v3 = = = 0 . 00047 m 3
p3 T1 8 × 105 × 290
v3 = 0.00047 m3
Workedone by the compressor per stroke
Since T3 is more than T1, therefore it is a case of incomplete intercooling
  n−1   n− 1 
n   p  n   p  n 
W =  p1 v1  2  − 1 + p3 v 3  4  − 1 
n−1  p1     p3  
    
  1.35 − 1   1.35 − 1 
1.35   8  1.35   60  1.35 
W = 1 × 10 5
× 0 .0035    − 1 + 8 × 10 5
× 0 .00047    − 1
1.35 − 1    1     8  
    

W = 3.86 (250+258) = 1961 N-m

Since the compressor is single acting, therefore number of working strokes per minute,
NW = N =200

We know that power of the compressor,

W × NW 1961 × 200
P= = = 6540kW = 6.54kW
60 60

P = 6.54 kW