AIR COMPRESSOR

Introduction

By
SANDEEP KUMAR
SENIOR DEPUTY MANAGER
(MOLDING MAINTENANCE)
Definition
• An air compressor is a device that converts power (using an electric motor,
diesel or gasoline engine, etc.) into potential energy stored in pressurized
air (i.e., compressed air).

OR
The function of a compressor
• The function of a compressor is to take a definite quantity of fluid
• (usually a gas, often air) and deliver it at a required pressure.
• Reciprocating type – low mass flow rate (kg/s) and high pressure ratio
• Rotary type – high mass rate but low pressure ratio.
TYPES OF COMPRESSORS
• Positive Displacement Type compression
• Dynamic(Centrifugal) Type compression
• Positive displacement compressors cab be further divided into
Reciprocating Compressor and
• rotary compressors.
Classification of Reciprocating Compressor
• In-line compressors,
• “V"-shaped compressors,
• Tandem Piston compressors.
• Single-acting compressors,
• Double-acting compressors,
• Diaphragm compressors.
Classification of Rotary Compressor
• Screw compressors,
• Vane type compressors,
• Lobe and scroll type compressors
Classification of Dynamic Compressor
• Centrifugal compressors
• Axial Compressors
The compressors are also classified based on
other aspects like
• Number of stages (single-stage, 2-stage and multi-stage),
• Cooling method and medium (Air cooled, water cooled and oil-
cooled),
• Drive types ( Engine driven, Motor driven, Turbine driven, Belt, chain,
gear or direct coupling drives),
• Lubrication method (Splash lubricated or forced lubrication or oil-free
compressors).
• Service Pressure (Low, Medium, High)
Positive Displacement Compressor
• In positive displacement compression, the air is drawn into one or
more compression chambers, which are then closed from the inlet.
Gradually the volume of each chamber decreases and the air is
compressed internally. When the pressure has reached the designed
build-in pressure ratio, a port or valve is opened and the air is
discharged into the outlet system due to continued reduction of the
compression chamber’s volume.
Single stage, single acting piston compressor.
Dynamic Compressor
• In dynamic compression, air is drawn between the blades on a rapidly
rotating compression impeller and accelerates to a high velocity. The
gas is then discharged through a diffuser, where the kinetic energy is
transformed into static pressure.
Dynamic Compressor (Radial Turbo
Compressor)
V"-Shaped Compressors:

• These are usually air cooled compressors with concentric valves

mounted on each cylinder head unit. The compressor has different
units displaced usually by 90 degrees, may or may not be connected
to same crank pin on the crank shaft. Higher capacity compressors are
water cooled. Better torque and balancing is achieved by displacing
the units by certain angle.
Single-Acting Compressors:

• These are usually reciprocating compressors, which has piston

working on air only in one direction. The other end of the piston is
often free or open which does not perform any work. The air is
compressed only on the top part of the piston. The bottom of the
piston is open to crankcase and not utilized for the compression of air.
Double-Acting Compressors:

• These compressors are having two sets of suction/intake and delivery

valves on both sides of the piston. As the piston moves up and down,
both sides of the piston is utilized in compressing the air. The intake
and delivery valves operate corresponding to the stroke of the
compressor. The compressed air delivery is comparatively continuous
when compared to a single-acting air compressor. Thus both sides of
the pistons are effectively used in compressing the air.
•
Rotary Compressors:

• These compressors are not of reciprocating nature, therefore does

not have any pistons and crankshaft. Instead, these compressors have
screws, vanes, scrolls, and other devices which rotate and thus
compress air. The rotary compressors are classified into screw type,
vane type-lobe type, scroll type and other types.
Screw Compressors
• The screw compressors are efficient in low air pressure requirements.
Two screws rotate intermeshing with each other, thus trapping air
between the screws and the compressor casing, forming pockets
which progressively travel and gets squeezed and delivering it at a
higher pressure which opens the delivery valve. The compressed air
delivery is continuous and quiet in operation than a reciprocating
compressor.
Vane Compressors
• The Vane type Air Compressor is having a fixed casing and a rotary
rotor disc which has slots for holding the sliding plates as shown in
the figure. As the rotor rotates, the disc also rotates, thus allowing the
sliding plates to slide as the inner surface of the casing is eccentric.
Thus the sliding plates moves away from the center, huge quantities
of air will be trapped in, thus as the plates converge, the air gets
compressed and thus results in compressed air.
Scroll Type COMPRESSOR
• The Scroll type compressors are having scrolls driven by the prime
mover. The scrolls outer edges trap air and then as they rotate, the air
travel from outwards to inwards thus getting compressed due to the
reduction in the area. Thus the compressed air is delivered through
the central space of the scroll to the delivery air line.
Lobe Type Compressors
• The Lobe type air compressor is very simpler type with no
complicated moving parts. There are single or twin lobes attached to
the drive shaft driven by the prime mover. The lobes are displaced by
90 degrees. Thus if one of the lobes is in horizontal position, the other
at that particular instant will be in vertical position. Thus the air gets
trapped in between these lobes and as they rotate they get
compressed and delivered to the delivery line.
 AIR COMPRESSOR

ZT 75
Description
• The Z 75/90 VSD (variable Speed Driver) are two-stage screw
compressors driven by electric motor.
• The compressors deliver oil free, pulsation-free air
• By continuously matching the speed of the drive motor to the air
demand, the VSD compressor optimizes energy consumption and
reduce the operating pressure band.
• ZR 75/90 VSD are water-cooled compressors.
• ZT 75/90 VSD are air-cooled compressors.
• Full-future compressors are additionally provided with an air dryer
which removes moisture from compressed air.
Compressor ZT 75 Main Parts
• Air Filter (AF)
• Load/No-load Valve ()
• Low-pressure compressor element (EI)
• Intercooler (Ci)
• Hig-pressure compressor element (Eh)
• Aftercooler (Ca)
• Electric Motor (MI)
• Drive Coupling
• Gear Casing
• Electronic Regulator
• Variable speed Drive Unit
• Safety Valves (SVh,SVI)