COMPARATIVE STUDY ON AIR COMPRESSOR

CHAPTER NO 1.
INTRODUCTION
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 . By one of several methods,
an air compressor forces more and more air into a storage tank, increasing the pressure. When
tank pressure reaches its engineered upper limit, the air compressor shuts off. The compressed
air, then, is held in the tank until called into use. The energy contained in the compressed air can
be used for a variety of applications, utilizing the kinetic energy of the air as it is released and the
tank depressurizes. When tank pressure reaches its lower limit, the air compressor turns on again
and re-pressurizes the tank. An air compressor must be differentiated from a pump because it
works for any gas/air, while pumps work on a liquid. A compressor is a mechanical device that
increases the pressure of a gas by reducing its volume. An air compressor is a specific type of
gas compressor.

Figure No. 1.1 Air Compressor

Air Compressor System provides high pressure compressed air with subsequent reduction
in volume for a range of industrial and domestic applications. They have become imperative
equipment in almost every industry.

The primary objective of this report is to understand the construction and working of air
compressor systems. In addition, the report covers the construction and working principle of
rotary and reciprocating The different types of compressors, along with their merits and
demerits, applications have been delineated.

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CHAPTER NO.2

CLASSIFICATION OF COMPRESSOR
Compressors are classified in many ways out of which the common one is the
classification based on the principle of operation. So the classification of compressor is as
following,

A. Positive Displacement compressor

1. Reciprocating compressor:-

1. In-line compressors,
2. “V"-shaped compressors,
3. Tandem Piston compressors.
4. Single-acting compressors,
5. Double-acting compressors,
6. Diaphragm compressors.

2. Rotarycompressor:-

1. Screw compressors,
2. Vane type compressors,
3. Lobe and scroll compressors and other types.

B. Roto-dynamic compressors

1. Centrifugal compressors, and the

2. Axial flow compressors.

C. Other compressor

1. Number of stages (single-stage, 2-stage and multi-stage),

2. Cooling method and medium (Air cooled, water cooled and oil-cooled),
3. Drive types ( Engine driven, Motor driven, Turbine driven, Belt, chain, gear or direct
coupling drives),
4. Lubrication method (Splash lubricated or forced lubrication or oil-free compressors).
5. Service Pressure (Low, Medium, High)

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CHAPTER NO. 3

CONSTRUCTION AND WORKING

1. Reciprocating compressor
1. Single Acting Compressor:-

Construction :-

They are the reciprocating compressor which has piston working only in one direction.
The other end of the piston is often free or open from which no work is performed. There is only
one side compression or the upper part of the piston is used to compress the air. The bottom part
is open to crankcase and is not utilized for the compression of air.

Figure No. 3.1 Single Stage Compressor

Working:-

In single stage reciprocating air compressor, the entire compression is carried out in a single
cylinder. The opening & closing of a simple check valve (plate or spring valve) depends upon
the difference in pressure, if mechanically operated valves are used for suction & discharge then
their functioning is controlled by cams. The weight of air in the cylinder will be zero when the
piston is at top dead center. At this position, you have to neglect clearance volume. When piston
starts moving downwards, the pressure inside the cylinder falls below atmospheric pressure&
suction valve/inlet valve opens. The air is drawn into the cylinder through a suction filter
element. This operation is known as suction stroke. When the piston moves upwards, compresses

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the air in cylinder & inlet valve closes when the pressure reaches atmospheric pressure. Further
compression follows as the piston moves towards the top of its stroke. Until when the pressure in
the cylinder exceeds that in the receiver. This is compression stroke of a compressor. At the end
of this stroke discharge/delivery valve opens & air is delivered to a receiver.

2. Double acting compressor :-

Construction:-

As from its name it uses its both sides to compress the air. Thesetype of compressors
have two sets of suction/intake and delivery/exhaust valve 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 exhaust valve operates corresponding to the movement of the piston or with the stroke of the
compressor. The air is compressed accordingly and delivered continuously as compared to
single-acting air compressor.

Figure No. 3.2 Double Acting Compressor

Working :-

Double acting reciprocating air compressor is similar to double acting reciprocating

pump. It is comprised of following parts: 1) Cylinder 2) Piston and piston rod and connecting
rod. 3) Crank and crank case 4) Two suction valves and two delivery valves. 5) One inlet port
and one outlet port It uses four bar mechanism. There are 4 valves (2 suction valves and 2
delivery valves). There are cooling fans similar to single acting compressors. The crank rotates
on electric motor/engine/turbine. In this compressor, compression of air takes place on both side
of the piston. When crank rotates, the piston starts reciprocating. When piston comes down and
attains, ‘Bottom dead center piston’ the air comes in through port due to vacuum created due to
downward movement. When piston starts moving upward, the air starts compressing. When
piston attains, ‘Top dead center piston’, the stroke is complete and air is fully compressed which
goes out through delivery valve to air receiver. During this upward movement the vacuum is
created on other side (Piston rod side) of piston. Suction valve opens and air comes in. When
piston starting comes down, this air which came through valve, gets compressed and compressed
air goes out through delivery valve to air receiver. In this downward movement air comes in
through valve and entire cycle repeats.

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3. In line Compressor :-

Construction: -their names clarify the design of the compressor. The cylinders of various stages
are found in a straight line when seen from the top that’s why they are called in line compressors.
These are most commonly used compressors in the area where there is a need of varying
pressure. They have simple design and commonly driven by electric motors or diesel engines.

Figure No. 3.3 Inline Compressor

Working: - In single stage reciprocating air compressor, the entire compression is carried out
in a single cylinder. The opening & closing of a simple check valve (plate or spring valve)
depends upon the difference in pressure, if mechanically operated valves are used for suction &
discharge then their functioning is controlled by cams. The weight of air in the cylinder will be
zero when the piston is at top dead center. At this position, you have to neglect clearance
volume. When piston starts moving downwards, the pressure inside the cylinder falls below
atmospheric pressure& suction valve/inlet valve opens. The air is drawn into the cylinder
through a suction filter element. This operation is known as suction stroke. When the piston
moves upwards, compresses the air in cylinder & inlet valve closes when the pressure reaches
atmospheric pressure. Further compression follows as the piston moves towards the top of its
stroke. Until when the pressure in the cylinder exceeds that in the receiver. This is compression
stroke of a compressor. At the end of this stroke discharge/delivery valve opens & air is
delivered to a receiver

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4. V-shaped compressors:-

Construction:-

They are come under air cooled compressors with concentric valves mounted on each
cylinder head unit which are placed in V-shaped i.e. at the angle of 90 degrees from each other
and may or may not be connected to same crank pin on the crank shaft.

They are compressors of higher capacity so the cooling is required. The v-shaped is given
to such compressor for achieving better torque and balancing by displacing different units at
some angle.

Figure No. 3.4 V- Type Compressor

Working :-

This compressor type uses a piston, which moves inside a cylinder, to compress the air.
Reciprocating simply means ‘moving back-and-forth’. Usually it’s a piston that moves back-and-
forth, but it can also be a rubber membrane (membrane compressor).Two sets of valves take care
of the air intake and exhaust. Piston compressors are available as lubricated and oil-free, and
most of the time with 2 cylinders in V-shape. Very small piston compressors use only 1 cylinder.
And after the compression stork the compress air is out from out late.

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2. ROTARY COMPRESSOR

1. Vane Type Rotary Compressor

Construction: -This is another type of rotary compressor. There is a fixed casing in Vane type
compressor in which a rotary rotor disc is placed which has slots that are used for holding the
sliding plates.

Figure No. 3.5 Vane Type Compressor

Whenever rotor rotates the disc also rotates thus allowing the sliding plates to slide as the
inner surface of casing is eccentric. Whenever the plates moves away from the center a huge
amount of air get trapped inside it and with the rotation the sliding plates converge due to its
shape and the trapped air get compressed. This results in compression of air.

Working: - When the rotor rotates, vanes are driven out of the rotor towards the casing due to
centrifugal force. The space between the two adjacent vanes, rotor and the casing increases
creating vacuum. Thus, the gas is drawn in, from the suction opening. When the rotor crosses the
point just opposite to its eccentricity, suction starts. As the rotor continues to rotate, the
entrapped gas is compressed due to reduction in volume.

The high pressure gas is then discharged through delivery opening. Usually, half of the total
pressure rise is developed during the internal reversible compression and the remaining pressure
rise occurs irreversibly when the entrapped gas is released to the delivery side, due to back flow
of high pressure air from the receiver.

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2. Lobe Type Air Compressor

Construction:-

This is one of the simpler compressor type. In this there is no complicated moving part.
There are two lobes attached to the driving shaft by the prime mover. These lobes are displaced
with 90 degrees to one another. Thus if one of the lobe is in horizontal direction the other lobes
will be exactly positioned at 90 degree i.e. in vertical direction.

The air gets trapped from one end and as the lobes rotate the air gets compressed as
shown in image. The compressed air is then delivered to delivery line.

Working:-

Lobe type air compressor: it is a rotary type of compressor consisting of two rotors which
are driven externally. One rotor is connected to drive and second is connected to gear. These two
rotors have two or three lobes having epicycloids, hypocycloid or involutes profiles. In the figure
two lobes compressor is shown with a inlet arrangement and receiver.

Figure No. 3.6 Lobe Type Compressor

A very small clearance is maintained between surfaces so that wear is prevented. Air leakage
through this clearance decreases efficiency of this compressor. During rotation a volume of air V
at atmospheric pressure is trapped between left hand rotor and casing .this air is positively
displaced with change in volume until space is opened to high pressure region. At this instant
some high pressure air rushes back from the receiver and mixed with the blower air until both
pressure are equalized.

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3. Screw Compressor
Construction:-Screw compressor consists of two rotors meshing with each other closely. Each
rotor is helical with large pitch. The male rotor has three or four lobes while the female rotor has
four, five or six recesses. The entrapped air is continuously compressed as it flows axially, due to
narrowing of passages formed by the rotors.

Figure No. 3.7 Screw Compressor

Working:-
The cycle of working of screw compressor consists of four processes namely:
(i) Suction:
When the meshing rotors begin to disengage near the suction opening, gas is drawn in due to low
pressure created. This is continuous so long as rotors unmesh.

(ii) Transportation:
As the rotation of the rotor continues, the space filled with gas isolates from suction opening.
This space is then gradually transported around the outer periphery’ at constant pressure until the
male lobe starts meshing with the space being transported.

(iii) Compression:
When rotors remesh from suction end gradually, the entrapped gas is compressed.

(iv) Delivery:
Soon after the space filled with entrapped gas is exposed to discharge opening, the gas is driven
out into the delivery line due to continuous penetration of male rotor into the space.

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CHAPTER NO. 4

ADVANTAGES AND DISADVANTAGES

Advantages and disadvantages of any compressor are based on its characteristics and
application. Advantages and disadvantages listed below are for a typical compressed air system
in an industrial plant. The estimated full load bhp requirement of each compressor type at 100
psig discharge pressure at the compressor, a main drive motor typical efficiency of 92 percent
and 0.746 kilowatts (kW)/bhp, the approximate operating costs of operation are obtained.

1. Single Acting, Air Cooled Reciprocating Air Compressors

Advantages include:-
• Small size and weight
• Generally can be located close to point‐of‐use avoiding lengthy piping runs and pressure drops
• Do not require separate cooling systems
• Simple maintenance procedures.

Disadvantages include:-
• Lubricant carryover as piston rings wear, which should be avoided
• Relatively high noise
• Relatively high cost of compression
• Generally are designed to run not more than 50 percent of the time, although some can be at 80
percent
• Generally compress and store the air in a receiver at a pressure higher than required at the point
of use. The pressure then is reduced to the required operating pressure but without recovery of
the energy used to compress to the higher pressure.

2. Double Acting ,Water Cooled Reciprocating Air Compressors

Advantages include:-
• Efficient compression, particularly with multistage compressors
allowing efficient part load operation
• Relatively routine maintenance procedures.

Disadvantages include:-
• Relatively high first cost compared with equivalent rotary air compressors
• Relatively high space requirements
• Lubricant carryover on lubricant cooled units
Relatively high vibrations require high foundation costs
Seldom sold as complete independent packages
Require flywheel mass to overcome torque and current pulsations in motor driver
• Repair procedures require some training and skills.
Operating Efficiency: 15 to 16 kW/100 cfm

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3. Lubricant Injected Rotary Screw Compressors

Advantages include:
• Compact size and complete package
• Economic first cost
• Vibration free operation does not require special foundation
• Part load capacity control systems can match system demand
• Routine maintenance includes lubricant and filter changes.

Disadvantages include:
• Less efficient full and part load operation compared with water cooled reciprocating air
compressors
• Lubricant carryover into delivered air requires proper maintenance of air/lubricant separator
and the lubricant itself.

4. Lubricant Free Rotary Screw Air Compressors

Advantages include:
• Completely packaged
• Designed to deliver lubricant free air
• Do not require any special foundations.

Disadvantages include:
• Significant premium over lubricant injected type
• Less efficient than lubricant injected type
• Limited to load/unload capacity control and VSD
• Higher maintenance costs than lubricant injected type over the life of the machine.
Operating Efficiency: 18 to 22 kW/100 cfm

5. Centrifugal Air Compressors

Advantages include:
• Completely packaged for plant or instrument air up through 500 hp
• Relative first cost improves as size increases
• Designed to deliver lubricant‐free air
• Do not require any special foundations.

Disadvantages include:
• Limited capacity control modulation, requiring unloading for reduced capacities
• High rotational speeds require special bearings, sophisticated monitoring of vibrations and
clearances
• Specialized maintenance considerations.

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CHAPTER NO. 5

APPLICATIONS OF AIR COMPRESSOR

Air compressor use in small size businesses:

 Painting vehicles in an auto body shop

 Sanding in an auto body shop or in woodworking
 Making snow at ski hills or for entertainment uses
 Using pneumatic nail guns for roofing
 Providing dental and medical services
 Using pneumatic drills and hammers on construction sites
 Powering various air tools in an automotive repair shop
 Using an air blowgun to clean machinery
 Sandblasting in a machine shop and manufacturing facilities

Air compressor use in Agriculture/Farming

 Moving feed and grain to and from silos with conveyors

 Glasshouse ventilation systems
 Spraying crops
 Powering dairy machines
 Operating pneumatic material handling equipment

Air compressor use in Manufacturing

 Operating air tools on production lines

 Cutting and welding equipment
 Ejecting pieces from production molds
 Monitoring production
 Adjusting roller and feed machinery
 Blowing a molded gas tank or plastic bottle
 Efficiently performing basic tasks such as driving screws and turning nuts
 Increasing production efficiency with air cylinders that power positioners, clamps, air
chucks, and air knives
 Finishing and packaging with pneumatic devices used for liquid padding, carton stapling,
appliance sanding, dry powder transporting and fluidizing
 Sandblasting and finishing metal
 Operating automated machinery

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References :-

1. Text book of refrigeration and air conditioning – P. N ANANTHANARAYAN

2. Text book of air compressor troubleshooting-S.D. Amedakar
3. Text book pump and compressor –S.S. Agrawal

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