Dela Cruz, yareniel Pru Compressor - a machine which is used to increase the pressure of a gas by decreasing its volum | Figure 1 shows the layout of a reciprocating compressor typically for supplying a workshop. i SAFETY COOLING VALVE sarety WATER OUT VALVE + AFTERCOOLER COOLING WATER IN WATER TRAP: Figure 1 SrARATOR Re igure WATER AIR COMPRESSO! Tie IDEAL RECIPROCATING COMPRESSOR COMPRESSOR WITHOUT CLEARANCE Ca Figure 2 shows the pressure - volume diagram for: | ideal reciprocating compressor. The piston reciprocates drawing in gas,compressing it = and expelling it. Ifthe piston expels all the air and there is no restriction at the valves, the pressure - volume cycle is as shown. Gas is induced from 4 to 1 at the inlet pressure, It is then trapped inside the cylinder and compressed according the law pVn = C. At point 2 the pressure reaches the same level as that in the delivery pipe and the outlet valve pops open. Airis then expelled. at the dejjvery pressure. The delivery pres- sure might rise very slightly during expulsion if the gas is being compacted into a fixed storage volume. This is how pressure bullds up from switch on. 0 ‘Volume, eu ft Fig.2ro (Classification of alr compressors: 4.Reciprocating Compressor K (high pressure, low capacity) \1.POSITIVE DISPLACEMENT TYPE: a solid object such as @ piston, lobe, vane, or gear pushes he gas towards the discharge. The compressor has a fixed displacement. 2. Rotary Compressor (medium pressure, low capacity) VANE TYPE ‘The vanes fit in slots in the rotor. The rotor is eccentric to the bore of the cylinder. When the rotor is turned, centrifugal force throws the vanes out against the wall of the cylinder. The space between the vanes grows and shrinks as” [the rotor turns so if inlet and out- let passages are cut in the cylin- {der at the appropriate point, air is. drawn in,squeezed and expelled. l2 ROTODYNAMIC OR KINETIC TYPE : The gas fon the speed of its driver. 4. Centrifugal Compressor laction of the impeller or blades (kinetic or dynamic action). Compressor displacement is dependent is pushed away from the center by the whirling 2. Axial Compressor CENTRIFUGAL TYPE The rotor has a set of vanes shaped as shown im the diagram. When the rotor spins, the air between the vanes is thrown outivards by cen- trifugal force and gathered inside the casing. As the air slows down in the casing, the kinetic energy is converted into pressure. The shape of the casing is important and is basically an eccentric passage surrounding the rotor edge. Fresh air is drawn in from the front of the rator:These types of compressor are suitable for medium and large flow rates. Pressure up to 25 bar may be obtained by using several stages or using them as the second stage ofan axial flow type. AXIAL FLOW TYPE The axial flow compressor is basically many rows of fan blades arranged along the axis. Each row gives the air kinetic energy. Not shown on the diagram are fixed vanes in between each row that slows the air down again and raises the pressure. In this way the pressure gradually increases as the air flows along the axis from inlet to outlet. Often a cen trifugal stage is situated at the end in order to give ita boost and change the direction of flow to the side. Typical industrial compressors can provide 70 mis at1S bar. They are not suit- able for small flow rates (below 15 ms).WORKED EXAMPLE No. 1A single stage reciprocating compressor draws in air at atmospheric pressure of 1.01 bar and delivers it at 9.5 bar. The polytropic index is 1.18 for the compression and expansion.he swept volume is 1.5 dm3 and the clearance vol- ume is 0.10 dm3. The speed is 500 rev/min. Determine the isothermal efficiency. A.80% B.84% C.73% D.89% o-e4 4.Compression Process: (1 - 2) speed, rev / sec x cylinders Aon He KE PqV4= PpV2" lex em where : n = polytropic exponent =k for isentropic process (k = 1.4 for air ) = 1 for isothermal process | 2,Piston Displacement(Swept volume) , Vp, Vp = (wi4) D2 LN m3/ sec [cfm] where: D = bore, m [ft] L = stroke, m [ft] i | | 3. Free AirCapacity of Compressor (Free air discharge), V1" When a gas such as air flows in a pipe, the mass of the air depends upon the pressure and tem- perature. It would be meaningless to talk about the volume of the air unless the pressure and tem. perature are considered, For this reason the volume of air is usually stated as FREE AIR DELIV- ERY or FAD. In other words FAD refers to the volume the air would have if let out of the pipe and returned to atmospheric pressure and temperature. The FAD is also the volume of air drawn into a compressor from the atmosphere. After compres- sion and cooling the air is returned to the original temperature but it is at a higher pressure. PyVy"= mRT i SCREW TYPES : Two rotors have helical lobes cut on them in such a way that when they mesh and rotate in oppe site directions, air is drawn along the fage of the lobes from input to output. Oil is used liberally seal the air, The oll also acts as a coolant and the diagram shows how the oil and alr are separate and then cooled in a radiator. The oils re-circulated. LOBE TYPES Lobe compressors are commonly used as superchargers on large engines.CONVENTIONAL COMPRESSOR or COMPRESSOR WITH CLEARANCE In reality, the piston cannot expel all the gas and a clearance volume is needed between the piston and the cylinder head. This means that a small volume ofcompressed gas is trapped in the cylinder at point 3. When the piston moves away from the cylinder head, the compressed gas expands by the law pV" = C until the pres- sure falls to the level of the inlet pressure. At point 4 the inlet valve opens and gas is drawn in. The volume drawn in from 4 to 1 is smaller than the swept volume because of this expansion. Piston rings The volumetric efficiency is defined by the following equation. _ Induced Volume Swept Volume It may be shown that this reduces to . nis efficiency is made worse if leaks occur past the valves or piston. The clearance ratio i is defined as c = Clearance volume/Swept volume. Ideally the process 2 to 3 and 4 to 1 are isothermal. That is to say, there is no temperature change during induction and expulsion. WORKED EXAMPLE No2 Gas is compressed in a reciprocating compressor from 1 bar to 6 bar. The FAD is 13 dm3/s. The clearance ratio is 0.05. The expansion part of the cycle follows the law-p¥2 G. The crank speed is 360 rev/min. Calculate the volumetric efficiency. A828.% /. B88.2 .% C.76.5.% D.80.6.%Double-Acting, Single-Stage Reciprocating Compressor Piston Displacement, Vp= Ane + A ce a. Piston rod neglected: Vp = 2 ( t_D*? LN) 4 b. Piston rod considered: Vo= _D*LN+2(0?-d?)LN 4 4 . _-— Compressor Work ( Power) 41. ISOTHERMAL POWER Piston rings P4V4' In Pd/ Ps) 2. ISENTROPIC OR IDEAL POWER KPAV4' [( Pd / Ps )(K-A)K 4 ke Pi=Ps 3. POLYTROPIC or INDICATED POWER v,° nP4qV4'[(Pd/ Ps 1) Ge aance m4 volume where : Ps = suction pressure Pd = discharge pressureCOMP 1 A single-acting air compressor operates at 200 rpm with an initial condition of air at 98 kPa and 27°-C and discharges the air at 380 kPa to cylindrical tank. The bore and stroke are 350 mm and 376 mm respectively with a percentage clearance of 6%. If the surrounding air is at 100 kPa and 25°C while the compression and expansion processes are PV1-3 = constant, determine the required if compressor A167 KW kW C. 26.7KW D. 10.7 kW COMP 2 single-acting compressor has a volumetric efficiency of 87%, operates at 500 rpm. It takes in air at 100 kPa and 30 C and discharges it at 600 kPa. The air handled is 6 cu.m/min measured at discharge condition. If the compression is isentropic, find the mean effective pressure inkPa | We =e YO a A.230.6 kPa 8203.6 kPa C.302.6kPa D. 103.6 kPa COMP 3 The piston displacement of a double-acting compressor is 0.358 cu.m/s and delivers gas 101.325 kPa and 300 K to 675 kPa at the tate of 0.166 cu.m/s at 150 rom, Value of n for ~-mpression and expansion is 1.33. Find the bore and stroke assuming bore = stroke, and dis- placement of crank end and head end are the same. ° A054m 8.0.45m C.0.65m D.0.75m COMP 4 A\single stage air compressor handles 0.454 m®/sec of atmospheric pressure, 27°C air, and delivers it to a receiver at 652.75 KPa. Its volumetric efficiency is 0 72, its compression effi- ciency on an isothermal basis is 0.85 and its mechanical efficiency is 0.90. If it rotates at 350 rpm, what power in. kW is required to drive it? AS #80112 C. 120°). 100 COMP § An air compressor is to compress 8.5 cu. m. per min. from 98.56 KPa to 985.6 KPa, Assuming conditions ideal, ad with n = 1.3, what will be the saving in work due to two staging? _ A. zero B. 4.6 kW e3 KW DL 3.5 Kw Meo NESE TES a : COMPE In’a single stage-air compressor the diameter of the cylinder is 250 mm, the stroke of the | piston is 360 mm; and the clearance volume is 900 cm, Air is drawn in at a pressure of 0.986 bar and delivered at 4.1 bar. Taking the law of compression p\V1-25 = C, calculate the distance trav- ‘d by the piston from the beginning of its compression Stroke when the delivery valves open. +» 260.8mm B.265.0mm C.205.5mm D. 250.5 mm COMP 7'The internal volume of an air-storage vessel is 666 liters. Find the mass of air stored in it when the pressure is 40 atmospheres and the témperatiure is 26°C Note: The mass of 1m? of air at atmospheric pressure and at O°C is. 1.293 kg. Ans. 26.73kg v1 = eHRY COMP 8 A single-stage air compressor takes in 0.9 kg of air per minute at atmospheric pressure and 24°C and compresses it to 10 atmospheres of pressure, the law of compression being pV12=C. Calculate the volume of air drawn in per minute. Take the specific volume of air at atmospheric pressure and 0°C as 0.7734 m3/kg [0.7571 m3] COMP 9 A certain gas at 101.32 kPa and 16 C whose volume is 2.83 m3 are compressed into a storage vessel of 0.31 m3 capacity. Before admission the storage vessel contained the gas at a Pressure and temperature of 137.8 kPa and 24 C; after admission the pressure has increased to 1171.8 kPa. What should be the final temperature of the gas in the vessel in Kelvin.COMP 10 “The volume of air in a single-stage compressor at the beginning of compression is 0.0424 m3 and its pressure is 1 bar. The clearance volume in the cylinder is 1230 cm? and the discharge pressure is 8 bar. Calculate the volume of air delivered per stroke, ir liters, if its compressed (i) isothermally, (il) adiabatically, taking = 1.4. Ans. 4.071 liters ; 8.371 liters COMP 11 The diameter of a cylinder of a single-acting air compressor is 250 mm and the strokeo | the piston is 400 mm. It runs at 2.5 rev/s taking in air at 1.01 bar and delivering it at 5.5 bar. Neglecting clearance, calculate the indicated power when the law of compression i pvi2 = aconstant, Calculate also the percentage increase in power if the index of the law of compression increased to 1.3 without change of speed. Ans. 9.69 kW ; 6.088% COMP 12 “The presstire and temperature of the air at the beginning of compression in a single- stage double-acting air compressor are 0.98 bar and 24°C, the pressure ratio is 4.55 an — the index of compression and expansion is 1.25. The stroke is 1.2 x cylinder diameter, clearance equal to 5% of the stroke, and the compressor runs at 8 rev/s. If it takes from the atmosphere at 1.013 bar, 16°C, at the rate of 5 m/min, calculate (i) the compressor power, (ii) volumetric efficiency, (iii) the dimensions of the cylinder. Ans: 15.36 KW ; 0.8819 iii) Dia. = 188.1 mm, Stroke = 225.7 mm COMP 13 Ina single acting air compressor, the clearance volume is 364 om, diameter of cylinder 200 mm, stroke 230 mm, and it runs at 2 rev/s. It receives air at 1 bar and delivers it at 5 bar, the index of compression” and expansion being 1.28, Calculate the indicated power, the mean indicated pressure, and the volumetric efficiency. Ans: 2.432 kW; 1.683 bar ; 87.32% COMP 14 The free air delivery of a single stage, double acting, reciprocating air com- pressor is 0.6083 m3/s meastired at 1.013 bar and 15°C. Compressor suction condi- tions are 0.97 bar and 27°C, deliverypressure is 4.85 bar. Clearance volume is 6% of stroke volume, stroke and bore are equal. If the index of compression and expansion is 1.32 and the machine runs at § rev/s R = 287 J/kg oK determine: a) the required cylinder diménsions [0.463 m] ° b) the isothermal efficiency of the compressor.['81.8%] COMP 15The stroke of a compressor piston is 380 mm and clearance volume is equal tc 7% of the stroke volume, The pressure of the air at the beginning of the compression stroke is 0.99 bar. The delivery valves open when the piston has travelled 260 mm from the beginning of the compression stroke and the pressure of the air is then 4 bar. Ifcom- pression follows the law pVn=C, find the value of n. Ans. 1.37REAL COMPRESSOR (Se = Fig 3 In real compressors the warm cylinder causes a slight temperature rise over the induction from 4 to 4, The gas is restricted by the valves and py is slightly less than p4. The valves also tend fo move so the real cycle looks more like figure 3 INDICATED POWER Entra work to force charge out of cylinders -Excess pressure to open valves 2 ‘and slat flow Receiver pressure Reduction in wrk ue to “eaing, This maybe rules by poor cooling and ‘excess friction Extra work since clesrance does not return all energy put into it The indicated work per cycle is the area enclosed by the p - V diagram. The easiest way to find this is by integrating wiih respect to the pressure axis. Py delivery __| pressure inlet pressure — Ideal Indicated Power =Pmi Yb where : Pm = indicated mean effective pressureBrake Power = power required to drive the compressor = Compressor Power Compressor Efficiency Piston Speed = 2Ln, m/min [fpr] EFFICIENCY TERMS Adiabatic Compression Efficiency isentropic Work Indicated Work Isothermal Compression Efficiency tsothermal Work Indicated Work Compressor Mechanical Efficiency Indicated Work Brake Work Motor Efficiency _ Brake Work Electrical Input Two-Stage Reciprocating Compressor {2 STAGE RECIPROCATING COMPRESSOR Fig2 4. Induction box and silencer on 8. After cooler outside of building with 9, Pressure gauge. course screen. 10, Aicreceiver. 2. Induction filter. 11. Safety pressure relief valve. 3. Low pressure stage. 12. Stop valve 4. Intercooler. 5, _ High pressure stage, 6. Silencer. a Drain trap.The main advantage to compressing the air in stages is that the air may be cooled between each stage and the overall compression is nearer to being isothermal. This reduces the power requirement and allows removal of water from the air. Two stage com- pressions are common but when very high pressure is required, more stages may be used. 3.4 THE EFFECT OF INTER-COOLING ON THE INDICATED WORK Intercooler ih ra Consider the p - V diagram for a com- pressor with two stages. The cycle 1 to 4 is a normal cycle conducted between pL and pM. The air is expelled during process 3 to 4 at pM and constant temperature. The air is then cooled at the intermediate pressure and this causes a contrac- tion in the volume so that the induced volume V8 to V5 is smaller than the expelled volume V2 to V3. The high pressure cycle is then a normal cycle conducted between pM and pH.The shaded area of the diagram represents the work saved by using the intercooler. The optimal saving is obtained iby choosing the correct intermediate pressure. Ideal (optimum) Conditions: 1.No pressure drop in intercooler 2.Perfect intercooling 3.Work in 1st stage = Work in 2nd stage 5, COOLERS Coolers are used for the following reasons. To reduce the indicated work in multiple stage compressors. To condense water from the air. For reciprocating compressors, the cooling takes place in the following places. COOLING WATER Heat tet INTER-COOLER ~The cylinder, -Between stages. -After final compression. cooLING WATER Heatiass | et The cylinders may be cooled with air and are designed with cooling fins on the outside, Circulating water through a cooling jacket produces more effective cooling Consider the energy balance over the first stage. Balancing the energy we have HA + P(in) = HB + Q (out) Q (out) = P(in) - mOp(T - Ta) B AR Poverls ° Assuming that no heat is lost to the sur- roundings, the SFEE may be applied to. the air and water side Q= mg Cg ATa = My Cy AT mais the mass flow rate of air. ‘My is the mass flow rate of water. Tg is the temperature change of the air. |AT is the temperature change of the water. Ica is the specific heat capacity of air. 5.3 AFTER COOLING ‘The only purpose of an after cooler is to cool the air to around ambient conditions and condense water from the air. This is usually another water-cooled heat exchanger and the same heat balanceThree-Stage Reciprocating Compressor For ideal Conditions, pressure ratios are equal + from which: Px = (P42Po) V3 CompressorWork = uy (2): -1 n-1 [\Pt Heat rejected in intercooler = 2m &p (Ty -T4) Summary of Multi-Stage Compressor No. of Stages Px = interstage pressure Compressor Work 2 Px = (PyPa) V2 ee (E)e-1 n-l Pi 3 Px = (P42Pq) 18 4 Px = (P43Pq ) 4 General Formula Px = (P41 Pp) 1isCOMP16 Asingle-acting, two-stage air compressor with 3% clearance is required to compress isentropically 0.05 cu.m. free air per second from 100 kPa to.300 kPa.The compressor has a mean piston speed of 140 m/min and that each piston has the same stroke. Take free air condition to be the same as suction stroke and for perfect intercooling, calculate: A)Piston area for minimum power B)Total power required C) Heat loss in the intercooler Ans. A) 0.025104 m2; B) 5.947 kW; C) 2.96 kJ/sec COMP 17 In a two-stage compressor, 0.05 kg of air is taken in per stroke at 0.97 bar and 17°C and com- pressed in the first stage to 2.91 bar. Itis then passed through the intercooler where it is cooled at constant pressure to its initial temperature . In the second stage, the air is further compressed to 7.3 bar and passed through the after-cooler where it is cooled at constant pressure to the initial temperature . Calculate (i) the % decrease in volume due to cooling at the end of each stage, (ii) the percentage decrease in volume if the air had been compressed in a single-stage from 0.97 to 7.3 bar and then finally cooled to its initial temperature of 170C. Take R for air = 0.287 kJ/kg-K and compression to follow the law pVn = constant where n = 1.3 in each stage. Ans. (1) 22.42% , 19.12% ; (ii) 37.24% COMP 18 Ina single-acting three stage tandem air compressor, the diameters of the high pressure and the low pressure pistons are 80 mm and 270 mm respectively, the stroke is 250 mm and it runs at 110 revimin. Taking atmospheric pressure as 1 bar and the volumetric efficiency as 0.9, Find the time taken to pump up three air bottles from atmospheric pressure to 40 bars gauge. The bottles have hemispherical ends and the internal dimensions of each are 450 mm diameter and 2.25 m long overall. Ans. 31 min. COMP19 A multi-stage air compressor is fitted with perfect intercoolers and is designed for mini- mum work. It takes in air at 1 bar, 35°C and delivers it at 100 bar. If the maximum temperature at any point.during compression is fiot to exceed 950C and the compression and expansion in each stage obeys the law pV1.3 = C. Take R = 0.287 kuikg-K for air, determine: a)The minimum number of stages required. 6 stages b)The indicated power input required for a mass flow rate of 0.1 kg/s 44.7 KW COMP20 ‘A single acting two stage air compressor delivers air at 16 bar. Inlet conditions are 1 bar, 33°C and free air delivery is 17 m/min, If the compressor is designed for minimum work and complete intercooling, determine if the compression law is pV1.3=C: a) the power required to drive the first stage b) the heat rejected in the intercooler per minute Note: Cp = 1005 J/kg-K and R = 287 J/kg-K. Ans: 46.73 KW ; 2.25 Md/min. bey, i cv