Compressed Air Systems II - Compressor Types

Transcript

Slide 1: Compressed Air Systems II: Compressor Types

Welcome to Compressed Air Systems II: Compressor Types.

This is the second in a series of compressed air system courses offered by Energy University. If you have not
already done so, it is recommended that you participate in Compressed Air Systems I: An Introduction before
taking this course.

Compressor imagery used with permission from Atlas Copco Group

Slide 2: Many Thanks to the US Department of Energy & the Compressed Air Challenge
This course was produced using material from the US Department of Energy’s “Improving Compressed Air
System Performance”. The source book is free and available for download from the Compressed Air
Challenge website: www.compressedairchallenge.org.

Slide 3: Welcome
For best viewing results, we recommend that you maximize your browser window now. The screen controls
allow you to navigate through the eLearning experience. Using your browser controls may disrupt the
normal play of the course. Click ATTACHMENTS to download important supplemental information for this
course. Click the Notes tab to read a transcript of the narration.

Slide 4: Objectives
At the completion of the course, you will be able to:

List the main types of compressors and identify the differences in their function
Compare the capacity and efficiency of different types of compressors
Identify appropriate compressor types for an application

Slide 5: Introduction
Compressed air is one of the most expensive utilities. There are many different types and designs of air
compressors. Each is suited for different applications in buildings and industry. In this course, we will
explore the main types of compressors and identify their differences, compare the capacity and efficiency of
different types of compressors and we will identify appropriate compressor types for an application.

Compressor imagery used with permission from Atlas Copco Group

Slide 6: Introduction
Let’s continue our investigation into the supply side system. Here we see some of the main components of
the supply-side of the system: Compressors; Receivers; Dryers; and Filters. Also depicted are some of the
typical demand-side components of the system such as distribution piping, hoses, and end use filters,
regulators, lubricators, and tools. In this class, we’ll focus on the compressor itself.

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 Compressed Air Systems II - Compressor Types
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Diagram used with permission from the US Department of Energy and the Compressed Air Challenge

Slide 7: Two Compressor Types

There are two basic compressor types: positive-displacement and dynamic.

In positive-displacement types, a given quantity of air or gas is trapped in a compression chamber and the
volume it occupies is mechanically reduced, causing a corresponding rise in pressure prior to discharge. At
constant speed, the average air flow remains essentially constant with some minor pulsing or variations in
discharge pressure.

Dynamic compressors impart velocity energy to continuously flowing air or gas by means of impellers rotating
at very high speeds. The velocity energy is changed into static-pressure energy in the impeller and in
discharge diffusers and volutes. In the centrifugal-type dynamic compressors, the shape of the impeller
blades determines the relationship between air flow and pressure. Pressure is referred to as “head”.

Compressor imagery used with permission from Atlas Copco Group

Slide 8: Selection Criteria

Selecting the right compressor depends on requirements for:
Capacity;
Pressure;

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 Compressed Air Systems II - Compressor Types
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Efficiency at full, partial and no load;

Noise level;
Physical size;
Oil carry-over;
Vibration; and
Maintenance

The choice of the type of compressor, whether axial, centrifugal, reciprocating, or rotary, depends primarily on
the required flow to be compressed, the compression ratio, and the duty which has to be performed.

Slide 9: Positive Displacement Compressors

There are two basic sub-types of positive displacement compressors:
Reciprocating; and
Rotary, which includes
Liquid Ring
Sliding Vane
Rotary Screw
Lobe Type

Slide 10: Reciprocating Compressors

Reciprocating compressors resemble a bicycle pump or piston, driven by a rod from a crankshaft. They may
be air-cooled or liquid-cooled. Air-cooled versions rely on fins, and fans to blow air over the fins to reject
heat of compression. Liquid cooled versions have a jacket around the cylinder and heads, and a heat
exchanger to reject heat of compression. These compressors may require lubricants within the compression
chamber and the piston rings, or sometimes are designed to exclude lubricant from the compression
chamber, and instead use non-lubricated components.

Compressor imagery used with permission from Atlas Copco Group

Slide 11: Operating Cycle of a Reciprocating Compressor

The operating cycle of a reciprocating compressor takes place in four stages as shown in this
Pressure-Volume indicator cycle:

Suction occurs as the piston withdraws, increasing the available volume in the compression chamber and
bringing in air from the inlet. The inlet valve closes.

Compression takes place as the piston drives inward, decreasing the available volume in the compression
chamber and compressing the captured air. This increases the pressure in the chamber.

Discharge takes place when the outlet valve opens. This will happen when the pressure in the cylinder is
slightly greater than the pressure in the receiver. The piston continues to drive inward and the compressed air
is expelled from the chamber above the immediate downstream pressure. The pressure remains constant as
this takes place.

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As the piston moves back, the outlet valve closes when the pressure starts to fall and the piston returns to its
original position. Clearance expansion takes place as the residual air expands and the pressure in the
chamber drops. When the pressure in the chamber falls below atmospheric pressure, the pressure
difference will make the inlet valve open, and the cycle repeats.

Slide 12: Heat of Compression

As air is compressed heat results due to the compression ratio between suction pressure and discharge
pressure. This can be damaging to compressor components. To improve compressor efficiency and limit
internal temperature, the compressor package may contain more than one stage of compression. Air may be
compressed in stages to reach the final required pressure with cooling between stages to remove heat,
moisture, and improve efficiency.

Slide 13: Two Stage Compressor

This chart shows the compression cycle broken into two stages. If this was done as one stage, the process
would start with suction, at G, and proceed through the rest of the cycle to C, B, and F1. The system would
then reset to G for the next cycle .

With the cycle in two stages, the first stage will proceed G, C, A to F.

The second stage will take over at G1, and proceed through C1, A1 to F1.

Because the compression second stage is presented with air that is already compressed to G1, and cooled,
the piston in the second stage receives cooled, dried, air at an intermediate pressure at its suction.
Therefore at the end of suction it is at stage C1 and it can accomplish the compression with less work. The
energy saved is represented by the area of A – B –A1 – C1, which is the difference in profile between the

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single compression cycle and the two-stage approach.

 

Slide 14: Multi Stage Savings

Air pressures at or above 10 bar g or 150 psig usually dictate the use of two stages of compression -
inter-cooling is economical for savings and also to extend the life of the compressor components.

Click to view the US customary version or the Metric version of a corresponding chart.

This chart shows power and savings of two-stage and three-stage compression compared to single-stage of
compression at various discharge pressures.

Slide 15: Double Acting Compressor

Reciprocating compressors may be single acting, or double acting. Double acting means that both sides of
the piston are used for compression, giving twice the capacity for a given cylinder size. These images show
various images of small single-stage and multi-stage, single-acting and double acting reciprocating
compressors.

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 Compressed Air Systems II - Compressor Types
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Diagrams adapted from compressionjobs.com

Compressor imagery used with permission from Atlas Copco Group

Slide 16: Rotary Compressor

Let’s move on to rotary compressors. These are positive displacement devices which rely on rotating
positive-displacement components rather than a piston arrangement.

The liquid ring compressor is one of several types. The impeller rotates within the casing, and water is fed into
the space. The water is subject to centrifugal forces and forms a moving cylinder around the inside of the
casing. The liquid layer seals the space between the impeller blades, creating a series of pockets that trap the
air. The impeller is not centered in the casing, but is offset. As a result as the impeller turns, the blades are
dipped further into the water layer. The air pockets are compressed, and the compressed air is discharged
from the cylinder.
 

Liquid ring compressor with elongated casing and schematic section at inlet and discharge sectors

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Adapted from Nash Engineering Company, Norwalk, CT

Slide 17: Sliding Vane Compressor

The sliding vane compressor has a rotor with blades that fit inside radial slots. The rotor is fitted within the
casing at an offset. When the rotor turns the blades slide in and out of the slots but remain in contact with the
cylinder wall. Air is trapped in the space between the blades and the wall. Since the rotor is offset, as the
rotor turns, the blades slide into the slots and the air pocket volume gets smaller. The air trapped in the
volume is thus compressed.

Imagery credit: James Parker

Slide 18: Screw Compressor

A screw compressor uses a pair of meshed helical screws to force the gas into a smaller space. Air is first
drawn in by suction to the lobe spaces between the screws. As the screw rotates, the lobe spaces are cut off
from the suction port. The lobe on one screw fits into a groove in the other screw and so the spaces are
reduced as the air is forced down the screw; this creates the compression. This continues until the lobe
space becomes exposed to the discharge port. Then the compressed air flows smoothly out of the
compressor.

Compressor imagery used with permission from Atlas Copco Group

Slide 19: Oil Lubricated Screw Compressor

Oil-lubricated screw compressors have complicated oil filtering, cooling, injection and removal systems
included on the compressor package. This depiction shows how oil passes through the compressor and is
removed in the air-oil separator immediately before the compressor discharge to the compressor after cooler.
 

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Complete oil-lubricated compressor packages look like those shown in these images.

Diagrams and compressor imagery used with permission from Atlas Copco Group

Slide 20: Lobe Compressor

The rotary lobe blower is another rotating positive-displacement machine. It incorporates two or more
lobes that trap air and carry it around to the discharge end of the blower and then exhausts the air to the
system. This unit is referred to as a blower rather than a compressor because technically it moves volumes
of a gas with moderate increase in pressure.

Imagery used with permission from Atlas Copco Group

Slide 21: Dynamic Compressors

The other predominant type of compressor is the dynamic compressor. This category is sub-divided into
centrifugal blowers and compressors, and axial compressors.

Slide 22: Centrifugal Compressor

Centrifugal machines include single-stage and multi-stage blowers and compressors. Centrifugal
compressors use one or more spinning impellers to transfer kinetic energy to a continuously flowing air
stream. Speeds can exceed 50,000 revolutions per minute. About 50% of the pressure energy comes from
the impeller and the rest results from the velocity energy changing into pressure energy when the air exits the
chamber and enters a space known as a volute.

Centrifugal compressors may have one to four stages (or more for high pressure applications). Each stage
further compresses the air from the previous stage. Between each stage there is an intercooler and separator
to reduce the air temperature back to ambient levels and eliminate condensation before passing to the next
stage.

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 Compressed Air Systems II - Compressor Types
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Compressor imagery used with permission from Atlas Copco Group

Slide 23: Regenerative Blower

Regenerative blowers are a type of dynamic centrifugal blower that can be very useful at times for
point-of-use savings. The impeller blades draw air into the chamber through the inlet port. Centrifugal forces
accelerate the air forward and outward. The air is “reflected”, or “regenerated,” by the wall of the chamber and
directed to the base of subsequent impeller blades, where it is again projected outward. With each
“regeneration” the air is pressurized more. There may be one or two impellers.

A “stripper section” is designed into the shape of the chamber. In this area the wall fits closely around the
impeller blades, and the air is directed out of the blower. (It is located between the inlet and the outlet where
the annulus is reduced in size to fit closely to the sides and tips of the impeller blades.)

Compressor imagery used with permission from Atlas Copco Group

Slide 24: Axial Compressor

Axial compressors contain a rotor and a motionless stator with airfoils that work together to raise air pressure
through each stage of compression. The rotor has multiple airfoil blades, while the stator has rows of
stationary airfoil vanes.

As the rotor turns, the airfoil blades accelerate the air, giving it kinetic energy. Air enters one rotor stage
gaining kinetic energy as it is pushed along the through the compressor. This air is then funneled into the
subsequent stator blades which convert the kinetic energy back into pressure energy. This process repeats
in the next stage - combination of rotor blades then stator blades. Eventually, air passes along the full length
of the rotor through all stages and is discharged from the compressor.

Axial compressors generally have multiple stages (without inter-cooling at each stage). The first few stages
may or may not have variable geometry enabling some capacity control. This means that the pitch or angle
of the stator blades can be adjusted to capture smaller or larger volumes of air. These compressors are
normally used for very high-volume high-power applications in refineries, and wind tunnels.

Reference for photography: Boyce, M. P. 2006.

http://www.netl.doe.gov/technologies/coalpower/turbines/refshelf/handbook/2.0.pdf

Reference for drawing : Falck, N. 2008.

http://www.tpe.energy.lth.se/fileadmin/tpe/Axial_Flow_Compressor_Mean_Line_Design.pdf

Animated axial compressor image source: http://www.grc.nasa.gov/WWW/K-12/airplane/caxial.html

Slide 25: Compressor Comparison

Click Attachments for a detailed comparison of the advantages and disadvantages of each compressor type.

Slide 26: Compressor Comparison

This chart shows the most common ranges of compressors by type and size. Single acting reciprocating

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compressors cover a wide range of sizes, but do not normally cover the largest applications. Double acting
reciprocating compressors cover an even wider range. Normally the smallest ones are one stage, with the
medium and large applications covered by two stage designs. Rotary compressors are generally rotary screw
types, although at the smaller end of the scale lobe types are also found. Dynamic compressors are usually
only manufactured for larger applications.

Slide 27: Compressor Specific Efficiency

The most practical way to express compressor efficiency is the specific power consumption. This is the kW
or horsepower per volume flow rate. This allows us to compare different compressors that would provide
identical duty.

Compressor imagery used with permission from Atlas Copco Group

Slide 28: Comparing Lubricated & Oil Free Compressors

These charts show how different sizes of compressors perform at full-rated load. The x axis is a logarithmic
scale of the rated power of the compressor. The y axis is a linear scale of the power per unit volume at full
load.

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Click to explore the Metric versions and the US Customary versions.

Slide 29: Metric Lubricated Graph

For example, here is the profile for a single-stage, single acting reciprocating compressor. It is only
designed for use in the range up to approximately 25 kW. This means that it will absorb approximately 25
kW at the motor shaft when at full load. The y-axis shows you the efficiency of making compressed air at
that power consumption. 100 CMH will require 11 to 13 kW.

The profile for a two-stage double-acting reciprocating compressor is more efficient than a single-stage
single-acting compressor.

You can see this because the line for the two stage compressor is lower down the chart. It uses fewer kW to
make 100 CMH of air. It also has a wider range.

In the 400kW range, the only lubricated compressors typically available are two-stage double-acting
reciprocating compressors and rotary screw compressors.
 

Slide 30: Metric Oil-Free Graph

Oil free compressors have similar profiles comparing available compressors but now we can see centrifugal
compressors as well. Notice that centrifugal compressors are normally seen in high volume applications.
Axial fan compressors are normally seen in very high volume applications that are beyond our scope and not
shown on this chart.

A centrifugal compressor may be somewhat more efficient than a lubricated, single stage single-acting
reciprocating compressor. However the centrifugal compressor would not be able to operate at the lower
volumes that the single stage compressor can support.
 

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Click to explore the US Customary versions or click Continue.

Slide 31: US Customary Lubricated Graph

For example, here is the profile for a single-stage, single acting reciprocating compressor. It is only
designed for use in the range up to 30 hp. This means that it will absorb 30 hp at the motor shaft when at full
load. The y-axis shows you the efficiency of making compressed air at that power consumption. 100 CFM
will require 25 to 30 horsepower.

The profile for a two-stage double-acting reciprocating compressor is more efficient than a single-stage
single-acting compressor.

You can see this because the line for the two stage compressor is lower down the chart. It uses less
horsepower to make 100 CFM of air. It also has a wider range.

In the 500 hp range, the only lubricated compressors typically available are two-stage double-acting
reciprocating compressors and rotary screw compressors.
 

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Slide 32: US Customary Oil-Free Graph

Oil free compressors have similar profiles comparing available compressors but now we can see centrifugal
compressors as well. Notice that centrifugal compressors are normally seen in high volume applications.
Axial fan compressors are normally seen in very high volume applications that are beyond our scope and not
shown on this chart.

A centrifugal compressor may be somewhat more efficient than a lubricated, single stage single-acting
reciprocating compressor. However the centrifugal compressor would not be able to operate at the lower
volumes that the single stage compressor can support.
 

Click to explore the Metric versions or click Continue.

Slide 33: Compressor Comparison

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For the purposes of normal compressed air applications, specific power consumption is a suitable
comparison between compressors and systems. Example efficiency performance numbers include kW per
100 CMH, and kW per CFM.

For practical analysis, energy used per air produced is most important to the end user. There are other
measures of compressor efficiency: volumetric efficiency, adiabatic efficiency, isothermal efficiency and
mechanical efficiency. These measures are not practical for the average consumer and beyond the scope of
this training class.

Compressor imagery used with permission from Atlas Copco Group

Slide 34: Summary

Let’s summarize some of the information that we have discussed in this course.

In this class, you learned the main types of compressors and identified the differences in their functions. We
discussed comparisons of the capacity and efficiency of different types of compressors, and we identified
appropriate compressor types for an application.

In the following classes in this series we’ll look at compressor control methods, other supply-side and
demand-side equipment in more detail, and action plans for best efficiency.

Slide 35: Thank You!

Thank you for participating in this course.

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