Compressor Operation

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Introduction to Compression
The purpose of Compressors is to move gases from one place to other place. Following machine are used Compressors Move air or gas in higher differential pressure ranges from 35 psi to as high as 65,000 psi in extreme cases. Blowers Move large volume of air or gas at pressure up to 50 psi. Fans

Move air or gas at a sufficient pressure to overcome static forces. Discharge pressure range from a few inches of water to about 1 psi.

Purpose of Compression
In chemical process industry some reaction take place at certain pressure and temperature condition. The compression of gases for liquefying them for storage purpose. The compression and subsequent expansion of gases for the purpose of cooling. Pressurized air is used for measuring and control system.

Compression
Molecules are always travel at high speed, they strike against walls of enclosed vessel and produce pressure. Temperature affects average molecules speed. When heat is added in fixed volume of gas, the molecule travel faster, and hit the containing walls of vessel more often and with greater force. If the enclosed vessel is fitted with a piston so that the gas can squeezed into smaller space, the molecule travel is now restricted and pressure increased.

Confined Gas before and after heating

Volume Reduces and pressure Increases

What is a compressors
Before discussing the types of compressors and how they work, it will be helpful to consider some of basic gas laws and the manner in which they effect compressors.

State of working Fluid

Working fluid is the matter contained within boundaries of a system. Matter can be in solid, liquid, vapor or gaseous phase.

State of working Fluid

The state of the working fluid is defined by certain characteristics known as properties. Some of the properties which are important in thermodynamic problems are
Pressure(P) Temperature(T) Specific enthalpy(h) Specific entropy(s) Specific volume(v) Specific internal energy(u)

Gas and vapor

Gas is a compressible fluid having neither specific shape or form A vapor is a gasified liquid or solid; a substance in gaseous form. All gases can be liquefied under specific temperature and pressure conditions there for they can also be called as vapor. The term gas is used more generally when condition are such that return of the vapor to liquid phase is not possible with in operation scope.

CRITICAL CONDITIONS
There is one temperature above which a gas will not liquefy with pressure increase is critical temperature. The pressure require to compress and condense a gas at this critical temperature is critical pressure. Tcr Vcr = 374.14C = 0.003155 m3/kg Pcr = 220.48 bar, 3206 lb/inch2

GAS LAWS
Boyles Law Charles Law Amontons Law Daltons law Amagats Law Avogadros Law Ideal Gas Equation

Boyles Law
In 1662 Robert Boyle (1627-91) an English man, observed during his experiment with a vacuum chamber that the pressure is inversely proportional to their volume at constant temperature. PV = Constant

Charles Law and Gay Lussae Law

In 1810 J.A.C. Charles and J. Gay Lussac, Frenchman, experimentally determined that at low pressure the volume of a gas is proportional to its temperature. V/T = Constant

Amontons Law

At constant volume, the pressure of an ideal gas varies directly with absolute temperature

P2/P1= T2/T1

V= constant

Daltons law
Total pressure of a mixture of ideal gases is equal to the sum of partial pressure of the constituent gases Partial pressure is the pressure each gas will exert if it alone occupied the volume of the mixture at the mixture temperature P=pa+pb+pc+pd+.. But it is experimentally observed that normally the pressure is higher than the calculated pressure. However the error is minimum

Amagats Law
Total volume of a mixture of ideal gases is equal to the sum of partial volume of the constituent gases Partial volume is the volume each gas will occupy if it alone is under same pressure temperature condition of mixture V=va+vb+vc+vd+..

Avogadros Law
Avogadro states that equal volumes of all gases, under the same conditions of pressure and temperature, contain the same number of molecules.

Ideal Gas Equations

Any equation that relates the pressure, temperature and specific volume of a substance is called an equation of state. There are several equations, some simple and others very complex. The simplest and best known equation of state for substances in the gas phase is ideal gas equation. This equation predicts the P-V-T behavior of gas quit accurately with in some properly selected region. P1V1/T1 = P2V2/T2 PV = RT

Ideal Gas Constant

R = 8.314 = 8.314 = 0.08314 = 1.986 = 10.73 = 1545

KJ / (Kmo1 oK) K Pa. M3/Kmol oK) Bar. M3/(Kmol oK) Btu/(Ibmol oR) Psia ft3 /(Ibmol oR) ft Ibf /(Ibmol oR)

Deviation from Ideal Gas Behavior

Practically it was observed that gases follow the ideal gas behavior under certain conditions.

At low pressure qAt high temperature. qLow density gasses

q

Kinetic Theory of Gases

No momentum or time is lost during collisions with the wall of the containing vessel. The volume occupied by the molecules is negligible compared with total volume. The attractive forces between adjacent molecules are negligible.

Compressibility
Gases deviate from ideal gas behavior significantly at states near the saturation region and the critical point: This deviation from ideal-gas behavior at a given temperature and pressure can accurately be accounted for by the introduction of correction factor called the compressibility factor Z.

Compressibility
PV= ZRT Z = PV/RT Z = Vactual / Videal For Ideal Gas For real Gas Z=1 Z = >1 or < 1

(The farther away Z is from unity, the more the gas deviates from ideal gas behavior)

Reduced Pressure & Temperature

Gases behave differently at given temperature and pressure, but they behave very much the same at temperature and pressure normalized with respect to their critical temperature and pressures. PR = P/Pcr TR = T/Tcr PR = Reduced Pressure TR = Reduced temperature

Comparison of Z Factors

Principle of Corresponding State

The compressibility factor for all gases is approximately the same at same reduced pressure and temperature.

Generalized Compressibility Chart.

At very low pressure (PR << 1), the gases behavior as an ideal gas regardless of temperature. At high temperature (TR > 2), ideal gas behavior can be assumed with good accuracy regardless of pressure (except when PR >> 1) The deviation of a gas from ideal gas behavior is greatest in the vicinity of critical point.

Observation of Generalized Compressibility Chart.

Partial pressure is used to determine the moisture removed in intercooler and after cooler. The practical application of partial pressure in compression problem is the determination of mixture volume or weight to be handled at the intake of the each stage of compression The determination of molecular weight, specific gravity, and the actual or proportional weight of the components.

Application of Partial pressure in case of compression

Temperature rise due to compression

Temperature rise due to compression

Compression (Multistage)
The compression of gases to higher pressures results in higher temperatures, creating problems in compressor design. All basic compressor elements, regardless of type, have certain design limiting operating conditions. When any limitation is involved, it becomes necessary to perform the work in more than one step of compression process. This is termed multistage.

Compression (Multi stages)

Important limitation in single stage compression are.
1. 2.

Discharge pressure ---- in all types. Differential pressure ----dynamic units and most displacement types. Compression ratio----- dynamic units. Effect of clearance --------reciprocating units. Desirability of saving power---- in all types.

3. 4. 5.

Methods of Compression
1.

Trap quantities of gas, reduce the volume, push the compressed gas out of the enclosure. Trap gas, carry it without volume change to the discharge opening. Compress the gas by backflow from discharge system, then push the compressed gas out of the enclosure Compress by the mechanical action rotating impellers or bladed rotors that impart velocity and pressure Entrain the gas in a high velocity jet of the same or another gas and convert the high velocity of the mixture into pressure in a diffuser.

2.

3.

4.

COMPRESSOR
INTERMITTENT FLOW CONTINOUS FLOW

POSTIVE DISPLACEMNT

DYNAMIC

EJECTOR

ROTARY

RECIPROCATING

RADIAL

MIXED
FLOW

FLOW
SLIDING VANE LIQUID PISTON HELICAL LOBE STRIEGHT LOBE MECHANICA L PISTON

AXIAL FLOW

CENTRIFUGAL

MIXED FLOW

AXIAL

Types of compressor
Positive Displacement Units are those in which successive volumes of gas are confined within a closed space and elevated to a higher pressure. Dynamic compressors Dynamic compressors are rotary continuous flow machines in which the rapidly rotating element through the element, converting the velocity head into pressure. This occurs partially in the rotating element and partially in stationary diffusers or blades.

Types of Compressors

Application of Compressors

psia

Compressor Definitions
Volumetric efficiency is the ratio of the actual capacity of compressors to displacement and is expressed as a percentage. Compression efficiency is the ratio of the theoretical horsepower to the actual indicated horsepower required to compress a definite amount of gas. Mechanical efficiency is the ratio of the indicated horsepower in the compressing cylinders to the brake horsepower delivered to the shaft. It is expressed as a percentage.

Compressor Definitions
Overall efficiency is the product of the compression efficiency and the mechanical efficiency. Compression ratio is the ratio of the absolute discharge pressure (psia) and the absolute inlet pressure (14, 696). Thus, a compressor operating at sea level on plant air service with a 100 psi discharge pressure would have a compression ratio of 7.8.

Compressor Definitions
Adiabatic compression occurs when no heat is transferred to or from the gas during compression (PVk = C). Isothermal compression occurs when the temperature of the gas remains constant during compression (PV = C). Polytropic compression occurs when heat is transferred to or from the gas at a precise rating and where the compression and expansion lines follow the general law (PVn = C).

CURVE OF DIFFERENT COMPRESSORS

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