Compressed Air Production CONTROL ENGINEERING

COMPRESSED AIR
PRODUCTION
ME 3219- CONTROL ENGINEERING
JANEN MARIE C. CALOTES

BSME 3-B
TABLE OF CONTENTS
• Production Plant
• Types of Compressors
• Criteria for the Selection of a Compressor

PRODUCTION PLANT
• Compressed air is a vital utility in

various industries, powering pneumatic
drives and controls efficiently.
• Compressors are required to compress
the air to the desired working pressure.

• Portable compressors cater to dynamic
needs, especially in industry sectors
which change site frequently, like in
construction.
Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

PRODUCTION PLANT
In planning, you have to consider the following:
• Allocate for expansion and new equipment acquisitions to prevent overloading of the production plant.
Designing generously initially saves costs associated with later expansion.
• Clean air is important to prolonged the compressor life.
• Select the appropriate compressor type to ensure optimal performance and longevity.

ME 3219 - CONTROL ENGINEERING
TWO GROUPS OF COMPRESSORS
Piston Compressor Turbine

Operates based on “Displacement Operates based on “Air-flow Principle.”
Principle.”

TYPES OF COMPRESSOR
Reciprocating Piston Rotary Piston Flow Compressor

Compressor Compressor
Piston Compressor Diaphragm Radial- Flow Axial-Flow

Compressor Compressor Compressor
Sliding vane rotary Two - axle screw

Compressor Roots Blower
Compressor

PISTON COMPRESSORS
Reciprocating Piston Compressor
• It is the most widely used compressor because it can be used
not only for low to medium pressure, but also to high pressure.
Reciprocating piston compressors are made as air-cooled
designs and also as water-cooled designs.
The optimum ranges for reciprocating

compressors are
up to 400 Kpa (4 bar/ 58 psi) single-stage
up to 1500 Kpa (15 bar/ 217.5 psi) double-stage
up to 1500 Kpa (15 bar/ 217.5 psi) multi-stage
Possible, but not always economical
up to 1200 Kpa (12 bar/ 174 psi) single-stage

up to 3000 Kpa (30 bar/ 435 psi) double-stage
up to 22000 Kpa (200 bar/ 3190 psi) multi-stage
RECIPROCATING PISTON COMPRESSOR
X. M. (2021, September 23). Reciprocating Piston Air Compressor Animation. YouTube. https://www.youtube.com/watch?v=TgcFXQUjr3M
RECIPROCATING PISTON COMPRESSOR

PISTON COMPRESSORS
Diaphragm Compressor
• This type of compressor belongs to piston
compressor group. The piston is separated from
the sanction chamber by a diaphragm, i.e. the air
does not come into contact with the reciprocating
parts. Thus, the air is always kept free of oil.

DIAPHRAGM COMPRESSOR
P. (2011, May 20). Diaphragm Pump Animation. YouTube. https://www.youtube.com/watch?v=Ljb7R09f-8k

PISTON COMPRESSOR
Rotary Piston Compressor
• The rotary piston compressor is a compressor with

rotating pistons. At the same time, chambers are
compacted and the air in these chambers are
compressed.

ROTARY PISTON COMPRESSOR

PISTON COMPRESSORS
Sliding Vane Rotary Compressor
• An eccentrically-mounted rotor rotates in a
cylindrical housing having inlet and outlet slots.
Sliding vanes are contained in slots in the rotor and
form chambers with the cylindrical wall.

SLIDING VANE ROTARY COMPRESSOR
J. C. (2022, August 3). Types of Compressors and how they work - Positive Displacement - Dynamic - Piston - Centrifugal. YouTube. Van Dyke, M., & Van Dyke, M. (1982). An album of fluid motion (Vol. 176). Stanford: Parabolic Press.
PISTON COMPRESSORS
Two-axle Screw Compressor
• Two intermeshing rotors, one having a convex

profile and the other concave profile, displace the
axial entering air to the other side.

TWO-AXLE SCREW COMPRESSOR
H. (2017, August 14). Screw Compressor animation | Howden. YouTube. Van Dyke, M., & Van Dyke, M. (1982). An album of fluid motion (Vol. 176). Stanford: Parabolic Press.
PISTON COMPRESSORS
Roots Blower
• In these compressors, the air is conveyed

from one side to the other without any
change in volume. It is also called as “Lobe”
compressor.

ROOTS BLOWER
TURBINE
Flow Compressor
• These work on the air-flow principle and are
especially suitable for large delivery volumes. The
air state is converted in one or more turbine wheels
to flow velocity. It is also called as “turbo”
compressor.

TURBINE
Axial-Flow Compressor
• The air is accelerated by the blades in an

axial direction of flow.

AXIAL-FLOW COMPRESSOR
M. E. S. (2014, January 27). 3D animation of axial flow compressor working principle. YouTube. https://www.youtube.com/watch?v=Il27VvHu-s0
TURBINE
Radial-Flow Compressor
• Acceleration from chamber to chamber radially

outwards, reversal of the flowing air and return to
the shaft. From there, again acceleration outwards.
• Also called as “centrifugal” compressor.

RADIAL-FLOW COMPRESSOR
CRITERIA FOR THE SELECTION OF A COMPRESSOR

DELIVERY VOLUME
• It is the amount of air which the compressor delivers.
• Delivery volume is given in or in .
DELIVERY VOLUMES ARE SPECIFIED IN TWO DIFFERENT

WAYS:
• theoretical delivery volume
• The theoretical delivery volume for reciprocating piston compressors is the product swept-
volume - no. of revolutions.
2. effective delivery volume
• The effective delivery volume depends on the type of compressor and the pressure. It is a
affected by the volumetric eficiency.

PRESSURE
Working Pressure
• It is the compressor outlet pressure, or the pressure in the receiver and the pressure in the
pipelines to the user.
Operation Pressure
• Is the pressure which is required at the operation position. In most cases, the operation
pressure is 600 kPa (6 bar/87 psi).
Important:
Constant pressure is essential for reliable and accurate operation. The following are related to the
constant pressure:
• The speed
• The forces
• The time sequences of the working elements
DRIVE
• Depending on the operational requirements, compressors are driven either by electric motor or by an
internal combustion engine. If the compressor Plant is not stationary, the drive is mostly by means of
internal combustion engines (Petrol and Diesel).
Electric Motors Internal Combustion Engine

REGULATION
• In order to delivery volume of the compressor to the fluctuating consumption, it is necessary to regulate
the compressor. Various types of regulation are regulation for this purpose. The delivery volume is
regulated between the adjustable limiting values of maximum pressure and minimum pressure.
Different Types of Regulation:
No load regulation Low-speed regulation On-off regulation

a. Exhaust regulation a. Speed regulation
b. Shut-off regulation b. Suction throttle regulation
c. Grip-arm regulation

NO LOAD REGULATION
Exhaust Regulation Shut-off Regulation

• in this simplest type of regulation, the • With this type of regulation, the suction valve is
compressor works against a pressure relief shut off. The compressor intake is closed. The
valve. When the pressure in the receiver has compressor cannot draw air in and continuous
reached the set value, the safety valves opens to run in the vacuum range.
and exhausts to atmosphere.
Grip-arm Regulation
• The suction valve is kept open by means of a grip
arm, and the compressor cannot compress any
air.

LOW SPEED REGULATION
Speed Regulation
The speed regulator of the I.C. engine is regulated via an adjusting link. The speed adjustment can be made by hand
or automatically - controlled by the working pressure.
Suction Throttle Regulation

Regulation is effected by simply throttling the air intake. Specific partial load ranges can thus be set. This type of
regulation is used on rotary piston compressors and on turbocompressors.

ON-OFF REGULATION
With this type of regulation, the compressor has 2 operating conditions(full load or stand still). The drive motor of
the compressor is switched off on reaching . When the pressure has dropped the , the motor is switched
on again and the compressor starts up again.

COOLING
When compressing air in the compressor, heat is generated and must be removed. The most suitable type of cooling
for the compressor depends on the amount of heat generated. Cooling fins on smaller compressors allow the heat to
be removed by radiation. Larger are equipped with an additional fan to remove heat.
Air Cooling Water Cooling

INSTALLATION SITE
• The compressor station

should be installed in a room
on its own and sound-
proofed towards the outside.
• The room should be well
ventilated, and the free air

should be as cool, dust free,
and dry as possible.

COMPRESSED AIR RECEIVER

• The compressed air receiver serves to stabilized the compressed air supply. It smoothens pressure fluctuations in
the network when air is consumed.

• The large surface area of the receiver cools the air.

COMPRESSED AIR RECEIVER

The size of a compressed air receiver depends on:
• delivery volume of the compressor air consumption
• network (whether additional volume)
• type of regulation
• permissible pressure difference in the network
Example:
Delivery volume
Switching cycle/h
Pressure difference
Receiver size
Result:
Receiver size
RECEIVER SIZE CHART

SAMPLE PROBLEMS
SAMPLE PROBLEMS
SAMPLE PROBLEMS

Compressed Air Production CONTROL ENGINEERING

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COMPRESSED AIR

JANEN MARIE C. CALOTES

• Criteria for the Selection of a Compressor

• Compressed air is a vital utility in

• Compressors are required to compress

the air to the desired working pressure.

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Designing generously initially saves costs associated with later expansion.

• Clean air is important to prolonged the compressor life.

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

TWO GROUPS OF COMPRESSORS

Piston Compressor Turbine

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Reciprocating Piston Rotary Piston Flow Compressor

Piston Compressor Diaphragm Radial- Flow Axial-Flow

Sliding vane rotary Two - axle screw

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

The optimum ranges for reciprocating

Possible, but not always economical

up to 1200 Kpa (12 bar/ 174 psi) single-stage

RECIPROCATING PISTON COMPRESSOR

RECIPROCATING PISTON COMPRESSOR

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

P. (2011, May 20). Diaphragm Pump Animation. YouTube. https://www.youtube.com/watch?v=Ljb7R09f-8k

• The rotary piston compressor is a compressor with

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

ROTARY PISTON COMPRESSOR

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

SLIDING VANE ROTARY COMPRESSOR

• Two intermeshing rotors, one having a convex

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

TWO-AXLE SCREW COMPRESSOR

• In these compressors, the air is conveyed

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

• The air is accelerated by the blades in an

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

• Acceleration from chamber to chamber radially

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

CRITERIA FOR THE SELECTION OF A COMPRESSOR

• Delivery volume is given in or in .

DELIVERY VOLUMES ARE SPECIFIED IN TWO DIFFERENT

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Electric Motors Internal Combustion Engine

Different Types of Regulation:

No load regulation Low-speed regulation On-off regulation

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Exhaust Regulation Shut-off Regulation

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

LOW SPEED REGULATION

Suction Throttle Regulation

regulation is used on rotary piston compressors and on turbocompressors.

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

Air Cooling Water Cooling

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

• The compressor station

ventilated, and the free air

Meixner, H., & Kobler, R. (1989). Introduction to pneumatics. (3rd ed.)

COMPRESSED AIR RECEIVER

the network when air is consumed.