COMPRESSORS

What is a
Compressor?
These are machines
that are used to
transfer gasses from
one location to another
at a higher differential
pressure ranges.
What is a
Compressor?
There are various types of
compressors and they are
classified in two major categories:
(1) dynamic or also known as
continuous flow or turbo
compressor and (2) positive
displacement or intermittent
compressor.
Dynamic
Compressor
Dynamic or continuous flow
are types of compressor in
which the flow of gas is
accelerated thru high speed
rotating element, converting
velocity head into pressure
head. Continuous flow
includes centrifugal and axial
flow compressors.
Intermittent
Compressor
Positive displacement or
intermittent flow type
compressor, however, are
those units that confine gas in
a closed space, reducing its
volume and discharging it at a
higher pressure. Intermittent
flow includes reciprocating,
screw, and root types of
compressors.
Some other ways of classifying
compressors includes the following:

a) Number of stages: single, two, three-stages or multi-stage

b) Reciprocating compressor element: single acting or double acting
c) Cylinder arrangement: vertical, horizontal, V-type
d) Cooling system: water cooled, air cooled
e) Mounting condition: portable, stationary
RECIPROCATING
COMPRESSORS
Reciprocating compressors are
positive displacement, intermittent
flow machines that are capable of
delivering air from a pressure of 35
psig up to 250 psig. They are
widely used in industrial
applications because of their
overall efficiency, wide range of
capacity simplicity of use and
compactness.
RECIPROCATING
COMPRESSORS
Some of the disadvantages of
reciprocating compressors are the
excessive vibrations due to the
forces exhibited by the
reciprocating movement of the
piston. This requires strong
machine foundation and higher
maintenance cost compared with
other types of compressor. Figure
3.1 shows a typical reciprocating
compressor with its parts.
RECIPROCATING
COMPRESSORS
A reciprocating compressor
resembles automotive engines and
can be air-cooled or liquid-cooled.
Generally, low capacity compressor
are air-cooled and they have air fins
cast around the cylinder to dissipate
heat. On the other hand, liquid-
cooled compressors have cooling
fins and water jackets cast around
the cylinder to circulate water.
RECIPROCATING
COMPRESSORS
Reciprocating compressors needs
lubrication to reduce wear, provide
cooling and to act as a sealant
between moving parts. Lubricant is
distributed thru a splash system
crank and connecting rods with oil
in the crankcase.
RECIPROCATING
COMPRESSORS
Non-lubricating reciprocating
compressors use special design
piston and non-metallic piston rings
without oil in the crankcase. They
have higher maintenance cost
because valves and piston rings
wear faster than in lubricated
reciprocating compressor.

Fig. 1Schematic view of air-cooled single-stage, single-acting

reciprocating compressor
Single-Acting Reciprocating
Compressor
The cylinders of reciprocating compressors can be classified as single-acting and
double –acting.
Single-acting compressors as shown in Figure 3.3, compresses gas in one side of
the piston only. They are commonly air cooled and widely used for small capacity
applications.

Fig 2. Single-acting Reciprocating Air compressor and P-v diagram

Single-Acting Reciprocating
Compressor

Compression stroke starts at point 1. As the compressor compress the air from point 1
to 2, the suction valves immediately closed, shutting off the suction line of the
cylinder. At point 2, the discharge valves opens and compressed air is pushed out of
the cylinder into the discharge line of the cylinder.
The discharge stroke is completed at point 3. At this point, the piston returns to
point 4, where the pressure drops and closing the discharge valve. The clearance
between the end of the cylinder and the top dead center (TDC) is known as the
“clearance volume”.
The piston expands from point 3 to 4. And the intake stroke occurs from point 4
to 1, which is also known as the “compressor capacity”. The complete cycle is shown
in the P-v diagram in figure 2.
Piston Speed, v
Piston speed is measured as the total distance travel by the piston
multiplied by the angular speed.
Where;
N v = piston speed, m/s
𝑣=2 L
60
L = length of stroke
N = compressor angular speed, rpm

Volume Displacement, VD
Where;
V D=V 1 −V 3 D = piston diameter, m
N L = stroke, m
V D= AL
60
N = compressor angular speed, rpm
No. of piston action = 1 for single-acting;
( )( )
2
D ln
V D= π (No . of Cylinder)(No . of pistons) 2 for double-acting
4 60
 Double-Acting Reciprocating
Compressor
Double-acting compressors as shown in the figure 3, compresses gas in both sides
of the piston. For the same motor speed, double-acting compressors deliver twice of
that single-acting compressors. They are water-cooled and mostly used in large capacity
applications.
The P-v diagram of a double-acting reciprocating
compressor is shown in Figure 4. The cycle occurs
at the opposite side of the piston.

Fig 3. Schematic view of double-acting reciprocating

Fig 4. Double-acting Reciprocating Air compressor and
compressor
P-v diagram
COMPRESSOR
FUNDAMENTALS
Compressor Work, WC

a) Work for Polytropic Compression

[( ) ]
n −1
nP1 V 1′ P 2
WC= n
−1
n −1 P1

b) Work for Isentropic Compression

[( ) ]
k −1
kP1V 1′ P 2
WC= k
−1
k −1 P 1

c) Work for Isothermal Compression

′
W C =P 1V 1 ln ( )
P2
P1
Note: Pressure must be in absolute values
COMPRESSOR
FUNDAMENTALS
Compressor Capacity, V1’

Compressor capacity is the actual volume of air drawn in by the compressor

as measured at the intake pressure and temperature

′
Where;
V 1 =V 1− V 4
R = ideal gas constant,

m a RT 1 Rair = 0.287 KJ/kg-K for air

′
V 1=
P1

PVT Relationship
Where;

( ) ( )
n−1 n −1
T 2 P2 V1
= n
= 1 ˂ n ˂ 1.4 = polytropic compression
T 1 P1 V2
n = k = 1.4 = isentropic compression
n = 1 =isothermal compression
COMPRESSOR
FUNDAMENTALS
Volumetric Efficiency, ƞV
Volumetric efficiency describes how efficient air is being drawn into
the cylinder of the air-compressor. It is the ratio of the amount of air
drawn into the cylinder of the air-compressor. It is the ratio of the
amount of air drawn in divided by the volume displacement or the
maximum possible amount of air can be drawn in.

actual volume
ƞV = x 100 %
volume displacement
COMPRESSOR
FUNDAMENTALS
Volumetric Efficiency, ƞV
actual volume
Analysis: ƞV = x 100 %
volume displacement

V 1′ V 1− V 4
ƞV = ∗ 100 %= ∗100 %
VD VD

Where;
V 1=V 3+VD =cVD+VD
c = percent clearance ranges 3% to 10%

( ) ( )
n −1 n −1
V4 P3
= n
; P 3=P 2 P 4=P 1
V3 P4

V 4=V 3 ( ) =cVD ( )
1 1
P2 P2 n n
P1 P1
COMPRESSOR
FUNDAMENTALS
Volumetric Efficiency, ƞV

Substituting;

( ) ∗ 100 %
1
P2
( cV D+VD ) −cV D n
V 1′ P1
ƞV = ∗ 100 %=
VD VD

Therefore;
V 1′
ƞV = ∗ 100 %
VD

ƞ V =1+c − c
P1 ( )
P 2 1n
∗100 %

It is evident that as the clearance becomes smaller, the volumetric

efficiency increases.
COMPRESSOR
FUNDAMENTALS
Compressor Efficiency

The compressor efficiency is the ratio of the compressor power output over the
brake power input to the compressor. Consider the compressor shown in Figure 5.

𝐖𝐂
ƞ 𝐂= ∗ 𝟏𝟎𝟎%
𝐏 𝐁𝐫𝐚𝐤𝐞

FIGURE 5. The compressor as the system

 Sample Problems:
1. A single-acting reciprocating air compressor with a clearance of 5% receives air at 100
kPa and 30°C and is delivered at 450 kPa. The bore and stroke are 350 mm and 390 mm,
respectively when operating at 1000 rpm. Determine:
a) Volume displacement, in m3/s
b) Volumetric efficiency, in percent
c) Compressor capacity, in m3/s
d) Compressor work, in kW
e) Compressor efficiency, in percent, if the brake power input to the compressor is 120
kW.
f) Temperature of air at the discharge, in °C

Assume no pressure drop in the intake and discharge port of compressor and take the
compression and expansion process to be PV1.3 = C.
Solving for the volume displacement, VD Solving for the volumetric efficiency, ƞv

( )( ) ( )
P 2 1n
2
D ln
V D= π (No . of Cylinder)(No . of pistons) ƞ V =1+c − c ∗100 %
4 60 P1

( )
1
( 0.350 m )2 1000 rpm 450 kPa
V D= π
4
(0.390 m)(
60
)(1)(1) ƞ V =1+0.05 − ( 0.05 ) 1.3
∗ 100 %
100 kPa
𝐦𝟑
𝐕 𝐃=𝟎 . 𝟔𝟐𝟓𝟒
𝐬 ƞ 𝐕=𝟖𝟗 . 𝟏𝟎%
Solving for the compressor capacity, V1’
V 1′
ƞV = ∗ 100 %
VD
V 1′
0 .8910=
m3
0.6254
s
′ m3
V 1 =0.5572
s

Solving for the compressor work, in kW

[( ) ]
n −1
nP1 V 1′ P 2
WC= n
−1
n −1 P1

(
( 1.3 ) ( 100 kPa ) 0.5572
m3
)
s
[( ) ]
1.3 − 1
450 kPa 1.3
WC= −1
1.3 − 1 100 kPa

𝐖 𝐂=𝟏𝟎𝟎. 𝟏𝟗𝟏𝟐𝐤𝐖
Solving for the compressor efficiency,
WC
ƞ C= ∗ 100 %
P Brake

100.1912 kW
ƞ C= ∗ 100 %
120 kW

ƞ C=8 3.49 %

Solving for the temperature of air at the discharge, in °C

( )
n−1
T2 P2
= n
T1 P1

=(
100 kPa )
1.3 −1
T2 450 kPa 1.3
( 30+273 ) K
T 2=428.7301 K − 273 K

𝐓 𝟐=𝟏𝟓𝟓 .𝟕𝟑 ℃
COMPRESSOR
FUNDAMENTALS
Actual Compressor Cycle

An increase in area occurs in actual

compressor cycle because of the fluid
losses thru the inlet and discharge ports of
the compressor which cause pressure drops
in the cycle. Other contributors to the
pressure drop in the compressor are the
friction losses and fluid slippage past the
piston rings, intake and discharge valve. A
larger area covered by the cycle in the P-v
diagram, as shown in Figure 6, means
larger horsepower input required to the
compressor.
FIGURE 6. Actual Compressor P-v
diagram as given by an indicator card
 Sample Problems:
A single acting reciprocating compressor
receives air at 100 kPa and 30°C and delivered at
700 kPa. The clearance volume is taken to be
10% and the compression and expansion process
to have a polytropic exponent of 1.3. The
compressor piston displacement is 450 cm3 and
operating at a speed of 850 rpm. Determine the
mass of air compressed, in kg/hr and the required
compressor power, in kilowatts when the
pressure drop at the suction and discharge port
are 10 kPa and 15 kPa, respectively.
Solving for the mass of air compressed, in kg/hr

P 1V 1=mairR T 1

P 1 V 1′
m a=
RT 1

Solving for V1’, from volumetric efficiency, ƞV;

( )
1
V 1′ P2
ƞV = =1+c− c n
VD P1
Solving for the volume displacement, VD, in m3/s

N
V D= AL
60

V D=( 4.5 x 10 m 3)
−4
( 850 rpm
60 )
−3 m3
V D=6.375 x 10
s
Substituting to solve for the actual volume of air taken in by the
compressor, V1’;

( )
1
V 1′ 715 kPa
3
=1+0.1 −( 0.1) 1.3

−3 m 90 kPa
6.375 x 10
s
′
(
V 1 = 3.8732 x 10
−3 m3
s )( 3600 s
1hr )
′ 𝐦𝟑
𝐕 𝟏 =𝟏𝟑 . 𝟗𝟒𝟑𝟒
𝐡𝐫

For mass of air;

P 1V 1′
m a=
RT 1

m a=
(
( 90 kPa ) 13.9434
m3
hr )
( 0.287
kJ
kg ∙ K )
( 30+ 273 ) K

𝐤𝐠
𝐦 𝐚=𝟏𝟒 .𝟒𝟑𝟎𝟕
𝐡𝐫
Solving for the compressor power required, in kW

[( ) ]
n −1
nP1 V 1′ P 2
WC= n
−1
n −1 P1

(
( 1.3 )( 90 kPa ) 3.872 x 10 −3 m3
)
s
[( ) ]
1.3 −1
715 kPa
WC= 1.3
−1
1.3 −1 90 kPa

𝐖 𝐂=𝟎.𝟗𝟐𝟔𝟒 𝐤𝐖

Note: In general, single compressors are generally used for pressures from 35 to 100
psig, and a two-stage compressor are used from 100 to 250 psig.
Multi-Stage Reciprocating
Compressor
Two-stage compressor
In multistage compressor, the gas is delivered by the low pressure cylinder at
intercooler pressure to succeeding stages. In this way, the low pressure cylinder
determines the volumetric efficiency of the whole machine because whatever the low
pressure cylinder passes to the succeeding stages must be discharged. Figure 7 shows
the P-v diagram of a two-stage compressor.

Fig 7. Two-stage reciprocating compressor

By using multistage compressor, the power input to the compressor is lessen, the gas
discharge temperature and pressure differential are decreased. Intermediate pressure,
PHX, for two-stage compressor can be theoretically approximated by:

Where;
P HX=√ P1P 4 P1 = pressure intake at the first stage
P4 = pressure at the second stage discharge
The compressor work for two-stage, WC 1-2 is given by;

[( ) ]
n −1
2 nP 1 V 1 ′ P HX
W C 1 −2= n
−1
n −1 P1

For Isentropic Compression;

[( ) ] [( ) ]
k− 1 k −1
k P 1V 1′ P 2 kmRT 1 P 2
W C 1−2= k
−1 W C 1 −2= k
−1
k− 1 P1 k −1 P1
For Isothermal Process;
′
W C 1 −2=P 1 V 1 ln ( )
P2
P1
W C 1 −2=m RT 1 ln ( )
P2
P1

Compressor Efficiency;
Compressor Efficiency
e c=
Brake Power

Ideal Indicated Power;

P∈¿(P me)V D

The heat rejected by the intercooler;

Q HX=mai rCpai r (T 1 −THX )

Multi-Stage Reciprocating
Compressor
Three-stage compressor

Figure 8 shows the P-v diagram of a three-stage compressor.

Fig 8. Two-stage reciprocating compressor

For two stage compressor, intermediate pressure, PHX and PHY, can be theoretically
approximated by:

P HX=√(P 1) P 6
3 2 Where;
P1 = pressure intake at the first stage
P HY =√ P 1(P 6)
3 2
P6 = pressure at the third stage discharge

The compressor work for three-stage, WC1-2-3 is given by;

[( ) ]
n− 1
3 nP 1V 1 ′ P HX
W C 1 −2 −3 = n
−1
n− 1 P1

For ideal conditions: For Heat Rejected in Intercoolers:

P HX P HY P 6 Q=2 mCp(TX −T 1)
= =
P 1 P HX P HY
Multi-Stage Compressor (GENERAL FORMULA)

Compressor Work:

[( ) ]
n−1
s nP1 V 1′ P HX
W C 1 −2 −3 = n
−1
n −1 P1
S = no. of stages

Intercooler Pressure

PX= √ ( P i )
s s−1
(Pf )
Air Receivers
It is necessary for all reciprocating compressor to have an air receiver to
eliminate the pulsation of air delivered. It is also used to store compressed
air, and to condense some of its moisture content by cooling it down.

Air receiver size, VT, can be theoretically calculated from;

V 1′ P1
V T=
P2

Air receiver size depends on the capacity of the compressor, pipeline

network and pressure drop, air consumption of the plant and switching
cycle per unit-time of the compressor operation.
Assignment:
1. A rotary compressor receives 8 m3/min of a gas ( R = 0.410
kJ/kg-K, Cp = 1.03 kJ/kg-K) @ 108 kPa, 27 degC and
delivers it at 650 kPa. Find the work if compression is
polytropic with PV1.3 = C.

2. A single stage air compressor handles 0.454 m3/s of

atmospheric pressure, 27 degC, and delivers it to a receiver
@ 652.75 kPa. Its volumetric efficiency is 0.72, its
compression efficiency on an isothermal basis is 0.85 and its
mechanical efficiency is 0.9. If it rotates @ 350 rpm, what
power in hp is required to drive it?