REFRIGERATION COMPRESSORS

Refrigeration Compressor
✓A mechanical machine that pumps vapors or
compresses the refrigerant suction pressure of
the evaporator to its condenser pressure.
✓Considered as the heart of all cooling units
except absorption refrigeration.
✓Transforms saturated liquid into superheated
gas in refrigeration processes.
 Type of Compressors
➢ Positive displacement machines which ensure positive
admission preventing undesired reversal of refrigerant
flow within in the machine as achieved by the use of
valves.
a. Reciprocating Compressors
b. Rotary Compressors
c. Scroll Compressors
d. Screw Compressors
➢ Non-positive displacement machines have no means to
prevent the reversal of refrigerant flow.
a. Centrifugal Compressors
 Reciprocating Compressors
✓Built in sizes ranging from fractional kilowatt
to hundreds of kilowatts refrigeration capacity.
✓Can be a single-acting or double-acting
cylinder compressor.
Reciprocating Compressors
Semi-Hermetic Type
 Compression Cycle

3 4 1 2
Piston at top Suction valve Piston at bottom Discharge Valve
Dead center open Dead center Open
 Pressure Volume Diagram

Discharge

Pd
3 2

Re-expansion
Compression

Intake
Ps
Clearance
4 1
Volume,
Vc
Volume of Cylinder
filled with suction vapor., Vs
Volume of Re-expanded
vapor
Piston Displacement, Vp

V V4 V1
 𝑝2 3 2
I.D.C. = Inner Dead Center
O.D.C. = Outer Dead Center = 𝑉1
𝑉𝑐 = Clearance Volume
p
𝑉𝑐 = 𝑉3
𝑝1 4 1 𝜋𝐷2 𝐿
PD = 𝑉𝑃 = 4
= 𝑉1 - 𝑉3
𝑉𝑃

PD = Swept Volume or Piston

𝑉𝑐 𝑉𝑆
v Connecting Displacement
Rod
2
D

1 D
S Crank

L
I.D.C Piston Cylinder O.D.C

Cylinder and Piston mechanism and p – V diagram of a reciprocating compressor

 Performance of Reciprocating Compressor
𝐼𝑠𝑜𝑡ℎ𝑒𝑟𝑚𝑎𝑙 𝑊𝑜𝑟𝑘
Isothermal Efficiency = 𝑛 𝑇 =
𝐴𝑐𝑡𝑢𝑎𝑙 𝑊𝑜𝑟𝑘

𝐼𝑠𝑒𝑛𝑡𝑟𝑜𝑝𝑖𝑐 𝑊𝑜𝑟𝑘
Adiabatic Efficiency = 𝑛𝑎 = 𝐴𝑐𝑡𝑢𝑎𝑙 𝑊𝑜𝑟𝑘

𝑉
Volumetric Efficiency = 𝑛𝑣 = 𝑉𝑠
𝑝

where, 𝑉𝑠 = Volume of the Suction Vapor sucked and pumped

𝑉𝑝 = Displacement or Swept Volume

Clearance = (0.005L + 0.5)mm

𝑉
Clearance factor = C = 𝑉𝐶
𝑃

𝑉𝑐 = Clearance Volume

C ≤ 5%
 Performance of Reciprocating Compressor

𝑉1 − 𝑉4 𝑉𝑃 − 𝑉𝐶 −𝑉4
Clearance Volumetric Efficiency = 𝑛𝑐𝑣 = =
𝑉𝑃 𝑉𝑃

𝑃2 𝑦1
𝑛𝑐𝑣 = 1 + 𝐶 − 𝐶( )
𝑃1
𝑉 𝑉
𝑛𝑣 = 1 + C - C(𝑉4 ) = 1 + c - c(𝑉 𝑠𝑢𝑐𝑡𝑖𝑜𝑛 )
𝐶 𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒

𝑄
𝑉𝑆 = Suction Volume = 𝑞𝑜 𝑣1 = 𝑛𝑣 𝑉𝑝
𝑜

𝑉𝑝 𝑉𝑝
m = 𝑣 𝑛𝑣 𝑄𝑜 = m𝑞𝑜 = 𝑛𝑣 𝑣 (ℎ1 - ℎ4 )
1 1
 Dimensions of Reciprocating Compressors
𝑄
𝑉𝑆 = Suction Volume = 𝑞𝑜 𝑣1 = 𝑛𝑣 𝑉𝑝
𝑜
D = Bore
𝜋𝐷2 𝑉𝑝
𝑉𝑝 = LN60 m = 𝑣 𝑛𝑣 L = Stroke
4 1
N = RPM
3 𝑉𝑆 𝑉𝑆
D = 0.277 = 0.0266 Cm = Mean Piston Speed
𝜃𝑁𝑛𝑣 𝐶𝑚 𝑛𝑣
2𝐿𝑁
𝜋𝐷2
Cm =
60
𝐹𝑃 = Piston Force = 𝑃𝑑
4
𝐶𝑚 ≈ 1.5 to 5 m/s
𝐿
𝜃= 𝐷

Vacuum Pumps or High Speed Air Compressor 𝜃 ≤ 0.5

Fluorocarbon Compressor 𝜃 ≈ 0.8
Ammonia Compressor 𝜃 ≈ 1.0
High Pressure Compressor 𝜃= 4.6
 PISTON DISPLACEMENT
Reciprocating compression is the total cylinder
volume swept through by the piston in any
given time interval:
Vp = π D2 L N n / 1000 For Single Acting Cylinder
Where:
Vp = Piston Displacement in liters per second
L = Stroke or Length of Stroke
D = Bore or diameter of cylinder
N = Revolution of crankshaft per second
n = Number of Cylinders.
 REFRIGERATING CAPACITY
Qo = m qo
Qa = Qo Пv/100
Пv = Va 100/Vp
m = Vp ρ = Vp/v

R= Absolute Discharge Pressure

Absolute Suction Pressure
 REFRIGERATING CAPACITY
Where:
Qo = Theoretical refrigerating capacity in KW
Qa = Actual refrigerating capacity in KW
Пv = Total volumetric efficiency in percent
Va = Actual volume of suction vapor compressed
per unit time.
qo = Refrigerating effect in kJ/kg.
m = Mass flow rate in kg per second.
v = Specific volume in liters per kg.
ρ = Density of suction vapor in kg per liter
R = Compression Ratio
 COMPRESSOR POWER

Pt = Qa P
Ps = Pi + Pf
Ps = 100 Pt / Пo
Ps = Pt / Пc Пm
Pi = Pt / Пc
Пo = 100 Pt / Ps
 COMPRESSOR POWER
Pt = Theoretical Power required to drive the compressor in
kW
Ps = Power supplied to the shaft of the compressor in kW
Pi = Indicated power or the power required to offset
the losses resulting from the derivation of an actual
compression cycle, kW
Pf = Friction power necessary to overcome the mechanical
friction in the compressor kW
P = Theoretical Power required per unit capacity in kW/kW
of refrigeration capacity
Пo = Overall Efficiency in percent
Пc = Compression Efficiency in percent
Пm = Mechanical Efficiency in percent
 Classification of Reciprocating Compressors

• Hermetic Compressor – Sealed Type (Single Housing

for both motor and compressor)
Fully Hermetically Sealed - Non Serviceable
Semi-Hermetically Sealed - Serviceable
• Open Type Compressor – Motor is exposed to the
atmosphere. Higher Capacity
 Method of Reciprocating Compressor Control

➢ On and Off Control

▪ Cycling the compressor start-stop in conjunction
with the thermostat setting
▪ Use for small capacity; refrigerators, window air-
conditioners, small split and unitary units.
➢ Back pressure regulation
▪ Throttles the suction gas between the evaporator
and the compressor
▪ Keep the evaporation pressure constant
▪ Gives good control of the evaporator temperature
but it is inefficient
 Refrigeration Cycle
Simple Vapor Compression System

CONDENSER

Capacity of the Evaporator = m (h1 – h4)

EXPANSION
DEVICE Suction line

EVAPORATOR
COMPRESSOR
 Method of Reciprocating Compressor Control
➢Hot Gas Bypass
▪ Bypassing the Compressor discharge gas back to
the suction line
▪ Initially the evaporator pressure drop
▪ Maintains constant suction pressure
▪ Suction Temperature tends to increase
▪ The compressor often runs hot.
▪ Resulting to higher compressor work making it
inefficient
 Refrigeration Cycle
Simple Vapor Compression System

CONDENSER

EXPANSION
DEVICE

EVAPORATOR
COMPRESSOR
 Method of Reciprocating Compressor Control
➢Compressor Multi-Cylinder unloading
▪ Holding the Valves Open
▪ Diverting the discharge gas from a cylinder back to
the suction line before compression
▪ By means of step controls, more and more
cylinders are unloaded.
▪ Used for intermittent unloading requiring short
period of idling.
Compression Cycle
 Method of Reciprocating Compressor Control

➢Multiple Units
▪ When unloading of compressor requires long
period
▪ Use of multiple units or multiple compressors
▪ By means of step/stage controls of compressors,
the unit capacity is controlled.
▪ Unit compressor may serve as standby unit
▪ Allows partial load operation in case of breakdown
Multi-Compressors
 Problem
A R 22 hermetic (directly-coupled motor), 2 cylinder
reciprocating compressor with 4 percent clearance is to be
designed for 7.5 TR Capacity at 4°C evaporating and 40°C
condensing temperature. The compression index 1.15, mean
piston speed Cm as 3 m/s and stroke to bore ratio for
fluorocarbons is 0.8. Pressure drops at suction and discharge
valve is 0.2 and 0.4 bar respectively. The compression work is
26.6 kJ/kg and volumetric efficiency is 85.85%. Determine
(a) Suction & Discharge pressures in bar
(b) Refrigerating effect kJ/kg
(c) Mass flow of refrigerant in kg/s
(d) Power consumption in kW
(e) Coefficient of Performance
(f) Piston displacement m3/min.
(g) Bore and stroke in mm
(h) RPM
 p-h diagram
tk

Subcooled
Region
Tk = 40 C
pk to 3 2

v1 = 0.0431 m3/kg
p

To = 4 C
po
4 1

h1 = 406.8 kJ/kg
h4 = 249.1 kJ/kg h2 = 439.3 kJ/kg
 Solution
(a) At 4°C evaporating and 40°C condensing temps.
po = 5.657 bar pk = 15.335 bar
ps = 5.657 – 0.2 = 5.457 bar (Suction pressure)
pk = 15.335 + 0.4 = 15.735 bar (Discharge pressure)
(b) Refrigerating Effect
qo = 406.8 – 249.1 = 157.7 kJ/kg
(c) Mass Flow rate
m = 7.5 x 3.5167/157.7 = 0.1673 kg/s
(d) Power Consumption
W = 0.1673 x (26.6) = 4.45 kW
(e) Coefficient of Performance
COP = 157.7 /26.6 = 5.9
(f) Piston displacement per cylinder
Vp = ½ (mv1/nv) = 0.1673 x 0.0431 x 60 / 2 x 0.8585
= 0.252 m3 / min
(g) Vp = πD2LN/4 = (πD2L/4) (30Cm/L)
D = √4Vp/π 30 Cm = √(4) (0.252) / π (30) (3)
= 0.06 m or 60 mm
L = 0.8 x 0.06 = 0.048 m or 48 mm
(h) N = 30 Cm / L = 30 x 3 / 0.048 = 1875 rpm
 Problem - Heat Pumps
A 1 ½ ton Freon 22 air conditioner operates on a simple
saturation cycle between an evaporator temperature of
4°C and a condenser temperature of 54.5°C.
(a) Find the theoretical COP for cooling, piston
displacement and horsepower of the compressor
motor.
(b) If the same air conditioner is used as a heat pump
for a winter heating with evaporator and condenser
temperatures of -5°C and 60.4°C respectively, find
the theoretical COP for heating and the capacity of
the compressor for heating in kW.
(c) What should be the horsepower of the motor so
that it is adequate for both summer and winter air
conditioning.
 p-h diagram
tk

Subcooled
Region
Tk = 54.5 C
pk to 3 2

v1 = 0.0416 m3/kg
p

To = 4 C
po
4 1

h1 = 406.8 kJ/kg
h4 = 268.3 kJ/kg h2 = 439.3 kJ/kg
 Solution
(a) Refrigeration Cycle
h1 = 406.8 kJ/kg, s1 = 1.746 kJ/kg K = s2
h2 = 439.3 kJ/kg t2 = 74°C
h3 = h4 = 268.3 kJ/kg
Solution:
kJ
q = h
1
− h 4 = 406 − 268 .3 = 138 .5
o kg
 kJ
W = h 2
− h 1
= 439 . 5 − 406 .8 = 33
kg

q 138 . 5
E c
= o
= = 4 .2
W 33
1 . 5  211 kg
m = = 2 . 2852
138 . 5 min
3
V = 2 . 2852  0 .0416 = 0 . 095 m
min
W = 2 .2852  33 = 1 . 27 kW
1 .27  1000
HP = = 1 .7 hp
746
 p-h diagram
tk

Subcooled
Region
Tk = 60.4 C
pk to 3 2
Superheat
Region
p

To = - 5 C
po
4 1

h1 = 403.5 kJ/kg
h4 = 276.6 kJ/kg h2 = 448 kJ/kg
v1 = 0.0554 m3/kg
 Solution

(b) Heat Pump Cycle

h1 = 403.5 kJ/kg t2 = 82°C
h2 = 448.0 kJ/kg v = 0.0554 m3/ kg
h3 = h4 = 276.6 kJ/kg
kJ
q = h
1
− h 4 = 403 .5 − 276 .6 = 126 .9
o kg
 kJ
W = h 2
− h 1
= 488 − 403 .5 = 44 .5
kg
kJ
q = h 2
− h 3
= 488 − 276 .6 = 171 .4
k kg

q 171 .4
E h
= k
= = 3 .85
W 44 .5
 Solution
• Coefficient of Performance

h − h3 448 − 276 .6
COP = 2
= = 3 .8517
h 2
− h1 448 − 403 .5
• Mass flow in the compressor(piston displacement = 0.095 m3/min)
V 0 . 095 kg
m = = = 1 .715
v1 0 .0554 min
• Capacity for heating of the compressor

1 .715  171 .4
Q = mq = = 4 .9 kW
k k 60
 Solution

(c) Horsepower requirement

1 .715  44 .5 1000
HP =  = 1 .71 hp
60 746
 Rotary Compressors
▪ Positive displacement direct drive machine
▪ Two designs
• Rolling Piston Type
• Rotating Vane Type (Multiple Vane)
▪ High volumetric efficiency
▪ Negligible clearance
▪ Used in a single stage
▪ Up to a capacity of 5 Tons
▪ Mostly used for domestic refrigerators,
freezers, and air conditioners
Rotary Compressors
 Volume Displacement
Rolling Piston Compressors

π𝐻(𝐴2 −𝐵2 )
• 𝑉𝑝 =
4
• 𝑉𝑝 is the theoretical piston displacement
• H is the height of the cylinder
• A and B are the diameters of the cylinder and
rolling piston, respectively
 Rotary Screw Compressor
▪ Positive Displacement Compressor
▪ Large capacity low temperature application
▪ Application in food refrigeration
▪ Application in large capacity central air conditioning
plants
▪ No surging problems
▪ Uses R-134a or R-22 refrigerants
▪ Consist of two helically-grooved rotors
▪ Rotors are geared to each other
▪ No lubrication between the rotors
▪ Male rotor consists of lobes and is the driving motor.
▪ Female rotor has gullies and is the driven rotor
▪ It is a high speed rotary machine
▪ It can be used on high-pressure refrigerants
▪ High Compression Efficiency
Rotary Screw Compressor
 Screw Compressor
• Positive displacement compressors.
• The machine essentially consists of two helically-
grooved rotors which rotate in a housing.
• The red color symbolizes the compressed
refrigerant.
Rotary Screw Compressor
Rotary Screw Compressor
Rotary Screw Compressor
 Scroll Compressor

• Valve-less positive displacement machines like

rotary and screw compressors.
• Compression achieved by two inter-fitting spiral-
shaped ‘scroll members’ one of which is a ‘fixed
scroll’ and the other an ‘orbiting scroll’.
Scroll Compressor
 Scroll Compressor Process
▪ The outermost pockets are sealed off.
Suction gas is trapped just before
compression begins.
▪ The orbiting motion of the orbiting scroll will
move the gas to the center. Pocket volume
progressively reduces and pressure rises.
▪ The gas reaches the discharge port at the
center, and discharge takes place.
Simultaneously, suction begin at the outer
periphery.
 Capacity Control Scroll Compressor
▪ Variable Speed Control – uses an inverter drive
to convert a fixed frequency AC current into
adjustable voltage and frequency which
permits varying the speed of the induction
motor.
▪ Variable Displacement Scroll Compressor – the
control mechanisms connects or disconnects
the compression chamber to suction side by
closing and opening the porting holes
• When all porting holes are closed, the
compressor runs at full capacity
• When all porting holes are open to suction
side, the compressor runs at lowest capacity
Scroll Compressor
Scroll Compressors
Scroll Plate
 Centrifugal Compressor
▪ First commercial refrigeration compressor
▪ Capacity Range - 200 to 10,000 KW
▪ Evaporating temperature extend down to
the -50 to 100 0C range for multi-stage
system
Centrifugal Compressor
 Centrifugal Compressor
▪ Inlet Casing – accelerate the fluid to the
impeller inlet.
▪ Impeller – transfer energy fluid increasing
static pressure and kinetic energy.
▪ Diffuser – convert the kinetic energy at the
impeller outlet resulting into pressure rise.
▪ Volute Casing – collect fluid and covert the
kinetic energy resulting to further pressure
rise.
Centrifugal Compressor Capacity Control

▪ Varying of Compressor Speed

• Speed Reduction Gear
• Qo = m (h1 – h4)
▪ Variable Inlet Vane
• Vary inlet vane opening
Centrifugal vs. Reciprocating Compressor
Variation of Evaporator Temperatures
Centrifugal vs. Reciprocating Compressor
Variation of Condenser Temperatures
Comparison of Compressors
 Compressor Efficiencies in kW per ton
Water Cooled System

• H E Centrifugal Compressor - 0.5 - 0.65

• Screw Compressor - 0.75
• Rotary Compressor - 0.75
• Reciprocating Compressor - 0.80 – 0.85
 Compressor Comparisons
Compressor Capacity,
System Type tons Refrigerant kW per ton Remarks
Rotary Scroll 10-390 R-410A 1.25
Air-Cooled Rotary Screw 80-500 R-134a 1.05-1.15
Reciprocating
Chillers 60-410 1.25
Screw Chillers 0.7 Standard
Variable Speed &
Water- Screw Chillers 0.57-0.64 Soft Start
Cooled High Eff. Screw
Chillers 0.49-0.58 Constant Speed
Centrifugal
Chillers 200-3000 0.54-0.58
 Operating Cost For Centrifugal
Compressor

kW Demand = 500 Tons x 0.6 kW/ton = 300 kW

kWh/year = 300 kW x 10 h/day x 365 days/year
= 1,095,000 kWh per year
Cost of electricity
Energy = 1,095,000 kWh x P12/kWh
= P13,140,000 per year
Demand = 300 kW x P 440/kW x 12 months
= P1,584,000 per year
Total = P14,724,000 per year
 Operating Cost For Reciprocating
Compressor

kW Demand = 500 Tons x 0.9 kW/ton = 450 kW

kWh/year = 450 kW x 10 h/day x 365 days/year
= 1,642,500 kWh per year
Cost of electricity
Energy = 1,641,500 kWh x P12/kWh
= P19,710,000 per year
Demand = 450 kW x P 440/kW x 12 months
= P2,376,000 per year
Total = P22,086,000 per year
Operating Cost For Scroll Compressor
Air-cooled System
kW Demand = 500 Tons x 1.25 kW/ton = 625 kW
kWh/year = 625 kW x 10 h/day x 365 days/year
= 2,281,250 kWh per year
Cost of electricity
Energy = 2,281,250 kWh x P12/kWh
= P27,375,000 per year
Demand = 625 kW x P 440/kW x 12 months
= P3,300,000 per year
Total = P30,675,000 per year
 Problems
1. An ammonia compressor has a 5 % clearance volume and a
displacement rate of 60 L/sec. and pumps against a condensing
temp. of 40˚C. For the two different evaporating temp. of -10˚C
and 10˚C. Compute the refrigerant flow rate assuming that the
clearance volumetric efficiency applies.

2. The catalog for a refrigerant 22, four-cylinder hermetic

compressor operating at 29 r/sec with a condensing temperature
of 40 ˚C and evaporating temperature of -4 ˚C develops a
refrigerating capacity of 115 kW. At this point the motor draws
34.5 hp with an efficiency 90%. The bore of the cylinder is 87
mm and the piston stroke is 70 mm. The performance data are
based on 8˚C of sub cooling of the liquid leaving the
condenser. Determine the following:
a) Draw the ph diagram indicating the pressures &
enthalpies
b) Piston displacement in m3/sec
c) Mass of refrigerant in kgs/sec
d) Volume flow in m3/sec
e) Actual volumetric efficiency
f) Compression efficiency
 Problems
3. Compute the maximum displacement of two vane compressor
having a cylinder diameter a 190mm and a rotor 80mm long with
a diameter of 170mm. The compressor operates at 29r/sec.

4. A refrigerant 12-twin cylinder compressor with equal bore and

stroke of 2.5 centimeter, rotating at 1750 rpm has an evaporating
and condensing temperature of 10C and 35C respectively. The
volumetric efficiency is 80%, mechanical efficiency is 95% and
overall efficiency is 85%. If the theoretical power is 2 Kilowatts,
determine the following:
a. Draw the PH Diagram showing the discharge temperature
of the compressor, the enthalpies and specific volume in
liters per kg.
b. Discharge temp. of the compressor in degree C.
c. Piston Displacement in liters per second
d. Mass flow rate of refrigerant in kilograms per second.
 Problem
e. Theoretical refrigerating capacity in Kilowatts.
f. Actual Piston Displacement in liters per second.
g. Actual Refrigerating Capacity in Kilowatts.
h. Compression Ratio
i. Shaft power in kilowatts
j. Compression Efficiency