EXPERIMENT NO.

2
2.1 Objective:
To study the two stage air compressor.
2.2 Parts:
 Inlet valve / Suction valve
 Intercooler
 High-pressure cylinder (HPC)
 Low-pressure cylinder (LPC)
 Pistons
 Receiver / Storage tank
 Outlet valve

Figure 2.1 Two Stage Air Compressor

2.3 Theory:
2.3.1 Two Stage Air Compressor:
A two stage air compressor compresses the air two times to
double the pressure, resulting in double efficiency and power. In addition, two stage air compressors
are more reliable and efficient, build less moisture in the tank, and require less maintenance. Two stage
air compressors use two pistons located in two separate cylinders. One piston compresses the air, while
the other piston transfers the compressed air from the cylinder to the other. Two stage air compressors
are used for running high-pressure machinery and with a two stage compressor we can achieve
pressure over 20 bar or 290 psi.
2.3.2 Heat Generation:
The two-stage compression process reduces the amount of heat generated
during compression. In a single-stage compressor, the compressed air can become very hot, which can
result in energy losses due to heat dissipation. In contrast, the two-stage process allows for more
efficient cooling between stages, reducing the overall amount of heat generated.
2.3.3 Efficiency of Two Stage Air Compressor:
Two stage compressors are particularly
efficient at higher pressures. When compressing air to high pressures in a single stage, the compressor
must work harder to overcome the increased resistance, resulting in reduced efficiency. In contrast, a
two-stage compressor can handle the higher pressures more efficiently, as each stage is optimized for
a specific pressure range. The two-stage compression process of a compressor results in less energy
loss and improved efficiency, making it a more energy-efficient option compared to single-
stage compressors.
2.4 Parts Explanation:
2.4.1 Inlet Valve / Suction Valve:
Inlet Valve (also called suction valve) is present on the piston
cylinder and is used to suck the air inside the air compressor cylinder from an external source.

Figure 2.2 Inlet Valve / Suction Valve

2.4.2 Intercooler:
The air becomes too hot after the first stage of compression. So, a cooling pipe is
placed between Low-Pressure Cylinder (LPC) and High-Pressure Cylinder (HPC), an intercooler. An
intercooler’s primary function is to cool down the compressed air before reaching the second cylinder.
This cooling process is done by air or oil, or water.

Figure 2.3 Intercooler

2.4.3 Outlet Valve:
The outlet valve is present inside the cylinder and takes the compressed air out
after the compression process is completed.

Figure 2.4 Outlet Valve

2.4.4 Low Pressure Cylinder (LPC):
This is the larger cylinder that compresses the air to an
intermediate pressure. Due to the low air pressure, this cylinder is named Low-Pressure Cylinder
(LPC). The LPC has high dimensions and compresses the air up to 90 PSI.

Figure 2.5 Low Pressure Cylinder (LPC)

2.4.5 High Pressure Cylinder (HPC):
This is the smaller cylinder that compresses the air to a
higher pressure. Due to the high air pressure, up to 175PSI, this cylinder is named a High-Pressure
Cylinder (LPC). The LPC sends the compressed air again for second-stage compression.

Figure 2.6 High Pressure Cylinder (HPC)

2.4.6 Pistons:
Two stage air compressors have two pistons. One of which is connected with a
crankshaft via a connecting rod. The crankshaft rotates along with the connecting piston, which moves
the piston forward and backward.

Figure 2.7 Piston

2.4.7 Receiver / Storage Tank:
An air receiver tank provides temporary storage for compressed
air. It also helps your air compression system run more efficiently. It stores compressed air that can be
used for short, high-demand events.

Figure 2.8 Receiver / Storage Tank

2.5 Types of Compressor:
Positive Displacement:
Rotary Type:
 Rotary Screw
 Rotary Vane
Reciprocating Type:
 Single Stage
 Two Stage
Dynamic Displacement:
 Axial Compressor
 Centrifugal Compressor
2.5.1 Positive Displacement:
Positive displacement air compressors force air in a chamber where
the volume is decreased to compress the air. Positive displacement is an umbrella term that describes
different air compressors that are power through positive air displacement.
2.5.1.1 Rotary Type:
2.5.1.1.1 Rotary Screw:
Rotary screw compressors have two internal “screws” that rotate in opposite directions,
trapping and compressing air between them. The two screws also generate constant movement as
they rotate around.

Figure 2.9 Rotary Screw

2.5.1.1.2 Rotary Vane:
Rotary vane compressors are like rotary screw compressors, but instead of
screws, vanes are mounted on a rotor and rotated inside the cavity. The air compresses between the
vane and its casing and is then pushed out at a different exhaust port.

Figure 2.10 Rotary Vane

2.5.1.2 Reciprocating Type:
2.5.1.2.1 Single Stage:
In the single stage compressors, the air is compressed on one side of the
piston, while the other side deals with the functionality of it: as the piston moves down, the air is drawn
in, and when it moves up, the air is compressed.

Figure 2.11 Single Stage

2.5.1.2.2 Two Stage:
Two stage compressors have two compression chambers on either side of a
piston. Double-acting compressors are typically water-cooled by a continuous stream of water through
the engine. This provides a better cooling system than other compressors.

Figure 2.12 Two Stage

2.5.2 Dynamic Displacement:
Dynamic displacement compressors utilize a rotating blade
powered by an engine to generate airflow. The air is then restricted to create pressure, and the kinetic
energy is stored within the compressor. These are mainly designed for large projects, like at chemical
plants or steel manufacturers, so it’s unlikely you’ll be able to find one at your local mechanic.
2.5.2.1 Axial Compressor:
Axial compressors use a series of turbine blades to generate air,
forcing it through a small area. Although similar to other bladed compressors, axial compressors
operate with stationary blades which slow airflow, increasing pressure.

Figure 2.13 Axial Compressor

2.5.2.2 Centrifugal Compressor:
Centrifugal, or radial compressors, work by bringing air into
the centre through a rotating impeller, which is then pushed forward through centrifugal, or outward,
force. By slowing the flow of air through a diffuser, more kinetic energy is generated.

Figure 2.14 Centrifugal Compressor

2.6 Two Stage Air Compressor Working:
Two-stage air compressors feature two cylinders,
each of a different diameter. Between both compression stages, an intercooler cools down the
compressed air before reaching the second cylinder. The two-stage air compressor has a piston that is
attached to the crankshaft via a connecting rod.

Figure 2.15 P-V Diagram of Two Stage Compressor

2.6.1 Stage 1:
 Air is compressed to medium level.
 High volume.
 Low pressure.

Figure 2.16 Stage 1

2.6.2 Cooling:
 Air is cooled to much low level.
 More efficient.
 Reduces stress on compressor.

Figure 2.17 Cooling

2.6.3 Stage 2:
 Air is compressed further.
 Low volume.
 High pressure.

Figure 2.18 Stage 2

2.7 Applications of Two Stage Air Compressor:
 These compressors highly use in textile industries.
 These compressors use in petrol pumps.
 Uses in plastic industries.
 These compressors use in fertilizers and chemical industries.
2.8 Advantages of Two stage Air Compressor:
 They produce higher compressed air than single-stage compressors.
 These compressors operate with natural gas or electricity. They are more common because they
are easier to use. In contrast, gas compressors can be used in areas where electricity is difficult
to use.
 They are used to drive pneumatic tools like air nailers, ratchet pawls, and spray guns.
 It uses in gas stations and various production power plants.
 These compressors are usually stationary and can be used to power various tools over long
periods.
 It requires low maintenance.
 These compressors have a small footprint.
 They have good reliability.
 Low moisture buildup.
2.9 Disadvantages of Two stage Air Compressor:
 These compressors require more power.
 Requires additional cooling
 Two-stage compressors have more moving parts than single-stage compressors.
 It has a high cost for installation.
 These compressors have heavyweight.
 They are many troubles involved in buying, transporting, and storing gasoline.
 They produce high noise.
 If you want to clean the gas tank from time to time, additional maintenance is required.