Compressors

A compressor is the most important and often the costliest component (typically 30 to 40 percent of
total cost) of any vapour compression refrigeration system (VCRS).

The function of a compressor in a VCRS is to continuously draw the refrigerant vapour from the
evaporator, so that a low pressure and low temperature can be maintained in the evaporator at
which the refrigerant can boil extracting heat from the refrigerated space. The compressor then has
to raise the pressure of the refrigerant to a level at which it can condense by rejecting heat to the
cooling medium in the condenser.

Classification of compressors

Compressors used in refrigeration systems can be classified in several ways:

a) Based on the working principle:

i. Positive displacement type

When the pressure rises to a level that is slightly higher than the condensing pressure, then
it is expelled from the enclosed space and a fresh charge of low-pressure refrigerant is
drawn in and the cycle continues.

Since the flow of refrigerant to the compressor is not steady, the positive displacement type
compressor is a pulsating flow device. However, since the operating speeds are normally
very high the flow appears to be almost steady on macroscopic time scale.

Since the flow is pulsating on a microscopic time scale, positive displacement type
compressors are prone to high wear, vibration and noise level.
Depending upon the construction, positive displacement type compressors used in
refrigeration and air conditioning can be classified into:

i. Reciprocating type

ii. Rotary type with sliding vanes (rolling piston type or multiple vane type)

iii. Rotary screw type (single screw or twin-screw type)

iv. Orbital compressors, and

v. Acoustic compressors
In roto-dynamic compressors, the pressure rise of refrigerant is achieved by imparting kinetic
energy to a steadily flowing stream of refrigerant by a rotating mechanical element and then
converting into pressure as the refrigerant flows through a diverging passage.

Unlike positive displacement type, the roto-dynamic type compressors are steady flow devices,
hence are subjected to less wear and vibration.

Depending upon the construction, roto-dynamic type compressors can be classified into:

i. Radial flow type, or

ii. Axial flow type

Centrifugal compressors (also known as turbo-compressors) are radial flow type, roto-dynamic
compressors. These compressors are widely used in large capacity refrigeration and air
conditioning systems. Axial flow compressors are normally used in gas liquefaction applications
b) Based on arrangement of compressor motor or external drive:

i. Open type

ii. Hermetic (or sealed) type

iii. Semi-hermetic (or semi-sealed) type

In open type compressors the rotating shaft of the compressor extends through a seal in the
crankcase for an external drive. The external drive may be an electrical motor or an engine (e.g.
diesel engine). The compressor may be belt driven or gear driven.

Open type compressors are normally used in medium to large capacity refrigeration system for all
refrigerants and for ammonia (due to its incompatibility with hermetic motor materials).

Open type compressors are characterized by high efficiency, flexibility, better compressor cooling
and serviceability.
 However, since the shaft has to extend through the seal, refrigerant leakage from the
system cannot be eliminated completely.

Hence refrigeration systems using open type compressors require a refrigerant reservoir to
take care of the refrigerant leakage for some time, and then regular maintenance for
charging the system with refrigerant, changing of seals, gaskets etc.

In hermetic compressors, the motor and the compressor are enclosed in the same housing
to prevent refrigerant leakage. The housing has welded connections for refrigerant inlet and
outlet and for power input socket. As a result of this, there is virtually no possibility of
refrigerant leakage from the compressor.
All motors reject a part of the power supplied to it due to eddy currents and friction, that is,
inefficiencies. Similarly the compressor also gets heated-up due to friction and also due to
temperature rise of the vapor during compression.

In Open type, both the compressor and the motor normally reject heat to the surrounding air for
efficient operation. In hermetic compressors heat cannot be rejected to the surrounding air since
both are enclosed in a shell.

Hence, the cold suction gas is made to flow over the motor and the compressor before entering the
compressor. This keeps the motor cool. But the efficiency falls because the heat generated by
motor act as additional load to the refrigerant.

The cooling rate depends upon the flow rate of the refrigerant, its temperature and the thermal
properties of the refrigerant. If flow rate is not sufficient and/or if the temperature is not low enough
the insulation on the winding of the motor can burn out and short-circuiting may occur.

Hence, hermetically sealed compressors give satisfactory and safe performance over a very
narrow range of design temperature and should not be used for off-design conditions
The COP of the hermetic compressor based systems is lower than that of the open compressor
based systems since a part of the refrigeration effect is lost in cooling the motor and the
compressor.

However, hermetic compressors are almost universally used in small systems such as domestic
refrigerators, water coolers, air conditioners etc, where efficiency is not as important as customer
convenience (due to absence of continuous maintenance).

In addition to this, the use of hermetic compressors is ideal in systems, which use capillary tubes
as expansion devices and are critically charged systems. Hermetic compressors are normally not
serviceable. They are not very flexible as it is difficult to vary their speed to control the cooling
capacity.

In some (usually larger) hermetic units, the cylinder head is usually removable so that the valves
and the piston can be serviced. This type of unit is called a semi-hermetic (or semi-sealed)
compressor.
Reciprocating compressors

Reciprocating compressor is the workhorse of the refrigeration and air conditioning industry. It is the
most widely used compressor with cooling capacities ranging from a few Watts to hundreds of
kilowatts. Modern day reciprocating compressors are high speed (≈ 3000 to 3600 rpm), single
acting, single or multi-cylinder (upto 16 cylinders) type.
Reciprocating compressors consist of a piston moving back and forth in a cylinder, with suction and
discharge valves to achieve suction and compression of the refrigerant vapor.

Its construction and working are somewhat similar to a two-stroke engine, as suction and
compression of the refrigerant vapor are completed in one revolution of the crank.

The suction side of the compressor is connected to the exit of the evaporator, while the discharge
side of the compressor is connected to the condenser inlet.

The suction (inlet) and the discharge (outlet) valves open and close due to pressure differences
between the cylinder and inlet or outlet manifolds respectively. The pressure in the inlet manifold is
equal to or slightly less than the evaporator pressure.

Similarly the pressure in the outlet manifold is equal to or slightly greater than the condenser
pressure. The purpose of the manifolds is to provide stable inlet and outlet pressures for the
smooth operation of the valves and also provide a space for mounting the valves.
Rolling piston (fixed vane) type compressors:

Rolling piston or fixed vane type compressors are used in small refrigeration systems (upto 2 kW
capacity) such as domestic refrigerators or air conditioners.

These compressors belong to the class of positive displacement type as compression is achieved
by reducing the volume of the refrigerant. In this type of compressors, the rotating shaft of the roller
has its axis of rotation that matches with the centerline of the cylinder, however, it is eccentric with
respect to the roller.

This eccentricity of the shaft with respect to the roller creates suction and compression of the
refrigerant. A single vane or blade is positioned in the non-rotating cylindrical block. The rotating
motion of the roller causes a reciprocating motion of the single vane.
 This type of compressor does not require a suction valve but requires a discharge valve. The
sealing between the high and low pressure sides has to be provided:

- Along the line of contact between roller and cylinder block

- Along the line of contact between vane and roller, and

- between the roller and end-pates

The leakage is controlled through hydrodynamic sealing and matching between the mating
components. The effectiveness of the sealing depends on the clearance, compressor speed,
surface finish and oil viscosity. Close tolerances and good surface finishing is required to minimize
internal leakage. Unlike in reciprocating compressors, the small clearance volume filled with
high-pressure refrigerant does not expand, but simply mixes with the suction refrigerant in the
suction space. As a result, the volumetric efficiency does not reduce drastically with increasing
pressure ratio, indicating small re-expansion losses. The compressor runs smoothly and is
relatively quiet as the refrigerant flow is continuous.
Centrifugal Compressor

This compressor increases the pressure of low-pressure vapour refrigerant to a high pressure by
centrifugal force. The centrifugal compressor is generally used forrefrigerants that require large
displacement and low condensing pressure, such as R-11 and R- 113.

A single stage centrifugal compressor, in its simplest form, consists of an impeller to which a
number of curved vanes are fitted symmetrically.

The impeller rotates in an airtight volute casing with inlet and outlet points. The impeller draws in
low pressure vapour refrigerant from the evaporator.

When the impeller rotates, it pushes the vapour refrigerant from the centre of the impeller to its
periphery by centrifugal force. The high speed of the impeller leaves the vapour refrigerant at a
high velocity at the vane tips of the impeller.
The kinetic energy thus attained at the impeller
outlet is converted into pressure energy when the
high velocity vapour refrigerant passes over the
diffuser. The diffuser is normally a vaneless type
as it permits more efficient part load operation
which is quite usual in any air conditioning plant.

The volute casing collects the refrigerant from the

Following are the advantages and disadvantages of centrifugal compressors over reciprocating
compressors :

Advantages

1. Since the centrifugal compressors have no valves, pistons, cylinders, connecting rod etc.,
therefore the working life of these compressors is more as compared to reciprocating compressors.

2. These compressors operate with little or no vibration as there are no unbalanced masses.

3. The operation of centrifugal compressors is quiet and calm.

4. The centrifugal compressors run at high speeds (3000 rpm. and above), therefore these can be
directly connected to electric motors or steam turbines.
5. Because of the high speed, these compressors can handle large volume of vapour refrigerant,
as compared to reciprocating compressors.

6. The centrifugal compressors are especially adapted for systems ranging from 50 to 5000
tonnes. They are also used for temperature ranges between — 90°C and + 10°C.

7. The efficiency of these compressors is considerably high.

8. The large size centrifugal compressors require less floor area as compared to reciprocating
compressors.

Disadvantages

I. The main disadvantage in centrifugal compressors is surging. It occurs when the refrigeration
load decreases to below 35 per cent of the rated capacity and causes severe stress conditions in
the compressor.

2. The increase in pressure per stage is less as compared to reciprocating compressors

4. The refrigerants used with these compressors should have high specific volume.