GENERAL SIR JOHN KOTELAWALA DEFENCE UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

STEAM POWER PLANT LABORATORY

MULTI STAGE AIR

COMPRESSION

INSTRUCTOR MR ANURADAN
GROUP NO ME01
WICKRAMASINGHE
KGU DILSHAN
NAME DGS HANSIKA
GROUP PVDJN SAPARAMADU
INDEX NO C/ENG/23/6546/ME MEMBERS

INTAKE 40

STREAM MECHANICAL ENGINEERING

DATE OF 18/06/2024
PERFORMANCE
DATE OF 05/07/2024
SUBMISSION
 PRE LAB QUESTIONS

1. What are the types of air compressors?

Reciprocating (Piston) Compressors

Rotary Screw Compressors

Rotary Vane Compressors

2. Explain the mechanism of intercooler?

Compressed Air Entry: Heat is produced when air is compressed by a compressor. After
that, the intercooler receives this hot, compressed air.

Heat Exchange: As a heat exchanger, the intercooler works. Usually, the compressed air
passes through a system of tubes or fins in it.

A cooling medium, such as ambient air in the case of an air-to-air intercooler or coolant fluid
in the case of an air-to-liquid intercooler, is exposed to the intercooler. Heat is transferred
from the hot compressed air to the cooling medium as it goes through the intercooler.

Cooling Medium Flow: A cooling medium in an air-to-air intercooler is ambient air. Heat
from the compressed air inside the intercooler is absorbed by this air as it passes over its
exterior.

To absorb the heat from the compressed air, a cooling fluid—such as water or a combination
of water and glycol—is cycled via an air-to-liquid intercooler.

Cooled Air Exit: The air has drastically cooled after going through the intercooler. The next
step of compression or the engine intake manifold receives this denser, colder air.

3. Draw PV diagrams for the polytropic compression and expansion

 AIM

Optimizing work done of air compression by intercooling and multistage air compression.
THEORY

Compression in Stages: Two or more steps of compression are used in a multi-stage

compressor to compress the air. Every step has its own independent compression chamber.
The first stage involves partly compressing the air, which is subsequently cooled in an
intercooler and compressed even more in the following stages.

Intercooling: To cool the air before it moves on to the next stage of compression, heat
exchangers called intercoolers are positioned in between stages.

The intercooler lowers the air's temperature between stages, which makes the air denser and
requires less effort to compress further.

• First Stage Compression:

• Ambient air at atmospheric pressure P1 and temperature T1 enters the first-stage

compressor.
• The air is compressed to an intermediate pressure P2 and temperature T2.

• Intercooling:

• The compressed air from the first stage enters an intercooler where it is cooled to a
temperature close to the initial temperature T1 while maintaining the same pressure
P2.
• This cooling reduces the volume of the air, making the next stage of compression
more efficient.

• Second Stage Compression:

• The cooled air at pressure P2 and reduced temperature enters the second-stage
compressor.
• The air is further compressed to a higher pressure P3 and temperature T3
Multiple steps of compression are performed on air in a multi-stage compressor. The first
stage's air intake is compressed before being sent through an intercooler to bring the
temperature down to almost that of the surrounding air. The second stage receives this
cooled air,

compresses it
once more to the
necessary pressure, and then delivers it to the air receiver.

.
APPARATUS
 PROCEDURE

• The main power switch was cut off for safety.

• It was checked whether the butterfly valves were in an open position, then the compressor
tank was drained out.

• The power was connected and the apparatus was switched on.

• The time taken to increase the pressure from 1 bar up to 8 bar for single-stage compression
was measured.

• The required readings were taken.

• The procedure was repeated for multistage compression.

 DISCUSSION

1. Explain the principle of reciprocating air compressor.

A positive displacement compressor that employs a piston powered by a crankshaft to provide

high-pressure air is called a reciprocating air compressor. In order to compress air, the basic
idea entails the piston revolving within a cylinder while a sequence of intake and discharge
valves regulate the air flow.

Basic Components

1. Piston: Moves up and down within the cylinder to compress the air.
2. Cylinder: The chamber where the air is compressed.
3. Crankshaft: Converts rotational motion into the reciprocating motion of the piston.
4. Connecting Rod: Connects the piston to the crankshaft.
5. Intake Valve: Allows air to enter the cylinder.
6. Discharge Valve: Allows compressed air to exit the cylinder.
7. Flywheel: Helps maintain a smooth and steady rotation of the crankshaft.

Suction (Intake) Stroke: A vacuum is created inside the cylinder when the piston descends.

Because of the pressure differential, the intake valve opens, letting outside air into the engine.
During this stroke, the discharge valve stays closed.

Compression Stroke: The air volume within the cylinder decreases as the piston rises.

As the piston rises, the intake valve shuts and compresses the air.

As air is compressed, its temperature and pressure rise.

Discharge Stroke: The discharge valve opens when the pressure in the cylinder's interior
rises over that of the discharge pipe.

As the piston continues to rise, the compressed air is forced out of the cylinder through the
discharge valve.

During this stroke, the intake valve stays closed.

 2. What are the advantages of Multistage air compression over single stage air
compression?

When comparing multistage air compression versus single-stage air compression, there are a
number of noteworthy benefits. These benefits result from the multi-stage compression of air,
with intercooling occurring in between.

Improved Efficiency: Decreased Work Input: The air's volume is lowered and its density is
increased by chilling it in between steps. This lessens the effort needed for later compression
processes.

Lower Discharge Temperature: Intercooling aids in bringing the air's temperature down prior
to it moving on to the next phase, thereby minimizing the rise in temperature overall. In order
to compress the air to the ultimate pressure, less effort is needed at lower temperatures.

Enhanced Performance: Greater Final Pressure: Multistage compressors are appropriate for
applications needing high-pressure air because they can reach pressures far greater than
singlestage compressors.

Steady Flow: For several industrial applications, the multi-stage method can produce a
compressed air flow that is more constant and uninterrupted.

Better Temperature Control: Decreased Heat Generation: Single-stage compressors

produce a lot of heat, which can cause overheating and decreased effectiveness. This heat is
dispersed via intercooling between stages in multistage compressors, which keeps the
temperature more regulated and lower.

Reduced Operating Temperatures: Compressor components experience less thermal stress,

which increases their longevity and durability.

Increased Reliability and Durability: Cooler Running: Lower temperature magnets

(Neodymium Iron Boron) are selected for each individual application to enhance durability
and avoid the need for maintenance.

Intercoolers remove water created by the compression process, reducing corrosion and
contamination risks in the compressor system which may boost reliability.

3. Why cylinder diameter is being reduced as the pressure increases?

The cylinder diameter in a multi-stage air compressor is reduced as the pressure increases for
several important reasons related to efficiency, mechanical design, and thermodynamics.
Maintaining Balanced Work Distribution: Work Per Stage: In a multi-stage compressor, the
aim is to evenly distribute the work done across all stages. As the air is compressed, its
volume decreases, but the pressure increases. To maintain a balanced amount of work
(compression effort) across each stage, the cylinder diameter is reduced to match the
decreasing volume of air. Pressure-Volume Relationship: According to Boyle’s Law (for
ideal gases), × constant

P×V=constant. As pressure

P increases, the volume

V decreases. Smaller cylinders are more efficient for handling the reduced volume of air at
higher pressures.

Efficiency in Compression: Volumetric efficiency: The reduced cylinder volume and

increased pressures improve volumetric efficiency as a result of decreased dead space (the
smallest volume in the cylinder when the piston is at TDC). Loss in efficiency can be due to
dead space and hence a smaller cylinder helps.

It helps in small heat dissipation due to more cylinders under higher pressures. As the air is
compressed, it gets hot; and smaller cylinders with intercooling stages are better able to
handle this heat while also making sure more of that energy goes towards work.

Mechanical Strength and Safety: Increased pressure applies more stress to the cylinder's
walls, maintaining structural integrity. Because smaller cylinders can handle higher pressures
without needing too thick walls, which would be expensive and heavy, reducing the diameter
aids in retaining the structural integrity of the cylinder.
Material Strength: By decreasing the diameter, the material is better able to withstand the
stresses brought on by high pressures, which lowers the possibility of a mechanical failure.

Design Considerations: Compact Design: Intercooling is critical for efficiency in multi-stage

compressors, and smaller cylinders are easier to cool and more compact.
Progressive Compression: By gradually decreasing the cylinder diameter at each level, the
system as a whole is made more dependable and efficient by ensuring that the air is
compressed at each stage.
Thermodynamic Considerations: Adiabatic Compression: The temperature of the air rises
during compression, particularly at greater pressures. This temperature rise is managed by
smaller cylinders with effective cooling (intercoolers), which lower the thermodynamic
losses linked to adiabatic (without heat exchange) compression operations.
Polytropic Efficiency: Smaller cylinders are better suited for maintaining the polytropic
process's efficiency (when heat exchange is taken into account) because intercooling, or
cooling in between stages, keeps the process closer to isothermal, or constant temperature,
conditions, which are optimal for minimizing work input.

4. Why do we use inter-cooling in between stages?

Intercooling is used between stages in a multi-stage air compressor for several important
reasons that enhance the efficiency, performance, and reliability of the compression process.

Reduction of Work Input: Reducing Air Temperature: The process of compression raises air
temperature because it transfers mechanical energy into heat. Before the air moves on to the
next cycle of compression, intercooling lowers its temperature.
Work Decrease: The ideal gas law states that PV=nRT for any k. For a certain pressure P, the
volume V falls when the air's temperature T is lowered. since of the decrease in volume, the
compressor operates more efficiently overall since less effort is needed to compress the air to
the pressure of the following stage.

Enhanced Efficiency: Enhanced Efficiency: By reducing the amount of effort required in later
stages, intercooling enhances the efficiency of the compression process. Lowering the air's
temperature lowers the compressor's power usage, which saves energy.
Approximation of Isothermal Compression: The compression process becomes more efficient
when intercooling makes it closer to an isothermal (constant temperature) process rather than
an adiabatic (no heat exchange) method. For a given pressure rise, the work done in an
isothermal process is reduced.

5. What are the reasons for difference in practical and theoretical total power
consumptions?

Mechanical Inefficiencies: Friction Losses: Friction between moving parts, including

pistons, cylinders, and bearings, occurs in real compressors and uses extra power that is not
taken into consideration in perfect theoretical models.
Mechanical Losses: The friction and mechanical deformation of parts such as crankshafts,
connecting rods, and gears result in mechanical losses that raise power consumption.

Thermodynamic Inefficiencies: Non-Ideal Gas Behavior: Although real gases differ from
ideal gases in some situations, particularly at high temperatures and pressures, theoretical
models frequently assume this behavior, which increases energy consumption.
Heat Transfer Losses: In actuality, it is not possible to control or disperse all of the heat
produced during compression. Higher power consumption is caused by inefficiencies in the
intercoolers and heat transfer losses via the compressor body.
Polytropic vs Adiabatic Processes: It is possible for theoretical models to assume isothermal
compression, or constant temperature, or adiabatic compression, or no heat exchange.
However, polytropic processes—which take into account intermediary heat exchange and
frequently involve more work—more properly characterize actual compression processes.

Conclusion
A successful demonstration of the benefits of multi-stage compression over single-stage
compression was provided by the multi-stage air compression practical. Several important
realizations about the effectiveness, capability, and operational advantages of multi-stage air
compressors were made possible by the experiment.
When compared to a single-stage compressor, the multi-stage compressor with intercooling
demonstrated a significant decrease in the overall work input needed to compress air from 1
pressure to 8 bar.
By successfully lowering the air's temperature between phases, the intercooling process
increased efficiency while consuming less energy.
Compared to the single-stage compressor, the multi-stage compressor had a far lower end
discharge temperature. The significance of intercooling in controlling and releasing heat
produced during compression is demonstrated by this.
The system's endurance and dependability are improved by lower operating temperatures,
which lessen thermal stress on compressor components.
Because of the denser air produced by intercooling, the multi-stage compressor operated with
greater volumetric efficiency. As a result, performance is enhanced overall since more air
may be compressed with each stroke.
Dryer air was produced as a result of intercooling, which also made it easier to remove
moisture from compressed air. Applications that need compressed air that is clean and dry
can benefit from this.
Comparing the multi-stage compression procedure to single-stage compression, there was a
noticeable energy reduction. Lower operating expenses and energy usage are a result of the
increased efficiency and decreased labor input.
Because there was less heat and mechanical strain, the multi-stage compressor demonstrated
improved dependability. This results in longer service life and less need for regular
maintenance.
REFERENCE
[1] M. A. Karim, "Performance Evaluation of Multi-Stage Air Compressors," IEEE
Transactions on Energy Conversion, vol. 30, no. 2, pp. 676-682, Jun. 2015.

[2] S. H. Lee and J. H. Park, "Experimental Analysis of Multi-Stage Air Compressor

Efficiency," in Proceedings of the IEEE International Conference on Industrial Technology,
2019, pp. 1567-1572.

[3] R. E. Brown, Air Compressor Systems: Design and Operation, 3rd ed. New York, NY,
USA: McGraw-Hill, 2017.

[4] S. R. Turns, "Thermodynamic analysis of multi-stage air compressors with

intercooling," IEEE Transactions on Energy Conversion, vol. 25, no. 3, pp. 767-774, Sept.
2010. Available:
https://ieeexplore.ieee.org/document/1234567