UNIT-5

Air Compressors

Review of equations
Work done in a single stage compressor

 P  
n 1

n n
n
 P1V1  2   1  mR  T2  T1 
n 1  P1   n 1
 
Work done in a two stage compressor for perfect inter cooling

 P  2 n 
n 1

2n
 P1V1  3   1
n 1  P1  
 
Work done in a two stage compressor

PT   P n 
1

  1 a 1  c  c 2  
PaT1   P1  


Volumetric Efficiency
 P    P  
n 1 n 1

n n
n n

 P1V1  2   1  P2V2  2   1
n 1  P1   n 1  P2  
   

Problem 1
A single stage acting air compressor 30 cm bore and 40 cm stroke is running at a speed of
100 RPM. It takes in air at 1 bar and 20ºC and drive it when the compresses it to a
pressure of 5 bar. Find the power required to drive it when compression is (i) isothermal
(ii) PV1.2 = C and (iii) adiabatic. Also find the isothermal efficiencies for the cases (ii)
and (iii) Neglect clearance.
N1  100 RPM , d  30cm
L  40cm P1  1 bar
 20C
T1  
P  5 bar
Vs  2
d L 0.32  0.4 2
4 4
 0.028 m / cycle
3

100
V1  Vs  0.028   0.047 m 3 / s
60
PV 1x102 x0.047
m 1 1   0.055 kg/s
RT1 0.287 x 293
(i ) Isothermal PV  C
P2 P
Power  P1V1 Ln  mRT1 Ln 2
P1 P1
5
 0.055 x0.287 x 293Ln  7.56kW
1

(i ) PV1.2  C
n 1 1.21
P 
 293 
n
5 1.2
T2  T1  2   383.14 K
 P1  1

n
Power   P2V2  P1V1   n x mR T2  T1 
n 1 n 1
1. 2
 x 0.055 x 0.287 383.14  293  8.53 kW
1.2  1

Isothermal Power
Isothermaleffiency 
Actualpower
7.56
  0.8854
8.53
 Isothermal  88.54 %
(iii ) Adiabatic PV1.4  C
 1 1.4 1
P  5 1.4
 293 

T2  T1  2   464 K
 P1  1
 Isothermal Power
Isothermaleffiency 
Actualpower
7.56
  0.8854
8.53
 Isothermal  88.54 %
(iii ) Adiabatic PV1.4  C
 1 1.4 1
P  5 1.4
 293 

T2  T1  2   464 K
 P1  1


Power  x mR T2  T1 
 1
1. 4
 x 0.055 x 0.287 464  293  9.45 kW
1. 4  1

7.56
 Isothermal   0.80
9.45
 80 %

Problem 2
A single acting stage acting air compressor with clearance running at 360 rpm has a bore
of 10 cm. The compression and expansion are polytrophic with n = 1.25 for each. The
clearance volume is 80cm3 . If the suction and delivery pressures are 98.1 kPa and
706.32 kPa absolute, find the free air at 101 kPa and 15ºCdelivered per minute. What is
the work done per cycle? The temperature at the beginning of compression may be taken
as 30ºC.Find also the power required to drive the compressor.

Ta  15C , d  10cm
L  8.5cm P1  98.1kPa
T1  30C P  706.32kPa
2
Ps  
V  d101
2 
L  kPa0.12  0.85
a 4 4
 6.675 x 10-4 m 3
Vc  80cm  0.8 x 10-4 m 3
 Vc 0.8 x 10-4
Clearance ratio C    0.12
Vs 6.675 x 10-4
Volumetric efficiency

PT   P n 
1

  1 a 1  c  c 2  
PaT1   P1  
 
98.1 x 288   706.32 1.25   0.496
1

 1  0.12  0.12  
101 x 303 
  98.1   

PaTa 101 x 0.1193

m 
RTa 0.287 x 288
 0.1457 kg/min

Va
 
Vs
 Volume of free air Va  0.496 x 6.675 x 10-4
 0.0003314 m 3 / cycle
 0.0003314 x 360  0.1193 m 3 / min

0.1457
m  0.00242kg / sec
60
n 1 1.251
P  n 706.32  1.25
T2  T1  2   303   449.67 K
 P1   98.1 
n 
Power    x mR  T2  T1 
 n  1
1.25 
   x 0.00242 x 0.287 449.67  303
 1.25  1 
 0.5 kJ/s or kW

0.5
Workdone / cycle   0.0084kJ / cycle
360 60
 Problem 3
A single stage double acting air compressor is required to deal with 17 m3/min of air
measured at 1 bar and 15°C. the pressure and temperature at the end of suction is 0.98 bar
and 30°C. The delivery pressure is 6.3bar. The rpm of the compressor is 500.assuming a
clearance volume of 5% of the stroke volume, laws of the compression and expansion as
PV1.32 =C, calculate the necessary stroke of volume, temperature of the air delivered and
power of the compressor.

Ta  15C , Va  17 m 3 / min
P  1bar P1  .98bar
a
T1  30C P  6.3bar
2
N  5500rpm
C  0.05
100
PT   P n 
1

  1 a 1  C  C  2  
PaT1   P1  


98.1 x 288   6.3 1.32   0.8452

1

  1  0.05  0.05  
1 x 303 
  0.98  
V
  a
Vs
17
Vs  StrokeVolu me   20.11 m3 / min
0.8452
20.11
Vs   0.0402m 3 / min
500

n 1 1.321
P  n 6.3  1.32
T2  T1  2   303 
 P1   0.98 
Temperatur e of air delivered  475.71 K

PaTa 1 x 100 x 17
m   20.56kg/min
RTa 0.287 x 288
20.56
  0.3427 kg/sec
60
 n 
Power    x mR  T2  T1 
 n  1
1.32 
   x 0.3427 x 0.287 495.71  303
 1.32  1 
 70 kJ/s or kW

Problem 4
A single stage double acting air compressor delivers 15 m3 of air per min of air measured
at 1.013 bar and 27°C. delivers at 7bar.The condition at the end of the suction stroke are
pressure 0.98 bar and temperature 4°C. The a clearance volume is 4% of the swept
volume, and stroke to bore ration is 1.3:1 and compressor runs at 300rpm. calculate the
Volumetric efficiency of the compressor. Assume the index of compression and
expansion to be 1.3.

Ta  27C , Va  15m3 / min

P  1.013bar P1  .98bar
a
T1  40C P  7bar
2
N  300rpm, Clearanceratio  0.04
L / dP
T 1.3 P  
1
n

  1 a
1  C  C  2  
PaT1   P1  


98.1 x 300   7 1.3   0.796

1

  1  0.04  0.04  
1.013 x 313 
  0.98  
 79.6%
Va
 
Vs
15
Vs  Swept Volume   18.84 m3 / min
0.796

But for double acting compressor


Vs  d 2 x L 2NL  1.3d
4

18.8 4  d 2 x 1.3d x 2 x 300
4
1 8.8 x 44
d  3  0.313m  31.3cm
 x 1 .3 x 2 x 3 00
L  1.3 x 3 1.3  4 0.72cm
 PaTa 1.013 x 100 x 15
m   17.6kg/min
RTa 0.287 x 300
17.6
  0.294 kg/s
60
n 1 1.31
P  7  1 .3
 313
n

T2  T1  2     492.7 K
 P1   0.98 

n 
Power    x mR  T2  T1 
 n  1
1.3 
Power    x 0.294 x 0.287 492.71  313
 1.3  1 
 65.7 kJ/s or kW

P2 P
Isothermal Power  P1V1 Ln  mRT1 Ln 2
P1 P1
7
 0.294 x 0.287 x313Ln  51.92kW
0.98
51.92
Isothermal efficiency  x100  79%
65.7

Problem 5
A two-stage compressor compresses 1kg/min of air from 1bar to 42.18 bar. Initial
temperature is 15ºC. At the intermediate pressure the intercooling is perfect. The
compression takes place according to PV1.35 =C. Neglecting the effect of clearance,
determine the minimum power required to run the compressor. Also find the mass of
cooling water required in the intercooler , if the temperature rise of water is limited to
5°C.

1
M  1kg / min   0.0166kg / s
60
P1  1bar T1  15C P3  42.18bar
For perfect intercooling
P2  P1P3  1x42.18  6.48bar
n 1 1.351
P  6.49  1.35
 288
n

T2  T1  2    467.7 K
 P1   1 
  n 
Maximum Power    x mR  T2  T1 
 n 1

 2x1.35 
  x 0.0166 x 0.287 467.7  288
 1.35  1 
 6.6 kJ/s or kW
Heat rejected in the intercooler Q  mCp  T2  T1 
 0.0166 x1.005 467.7  288
 2.99kJ/Sec

But Q is also  m xC p x temperature rise

299  m x 4.187 x 5
m  0.1432kg / sec

Problem 6
A two stage reciprocating compressor delivers 150 m3/hr of free air measured at 1.03 bar
and15ºC. The final pressure 18bar. The pressure and temperature of the air in LP cylinder
before compression is 1 bar and 30°C. the diameter of the LP cylinder is twice that of HP
cylinder and air enters the HP cylinder at 40ºC. If compression follows the law
PV1.22=C, determine
(i) Intermediate pressure and power required if the intercooler is imperfect.
(ii) Ration of cylinder diameter and minimum power required for perfect intercooling.

Ta  15C , Va  150m 3 / min

Pa  1.03bar P1  1bar
T1  30C P3  18bar
T2  40C
(Neglet theintercooli
i ) Imperfect effect ofng clearance
d LP  2d HP
P1V11.22  P2V21.22
1.22 1.22
P2  V1    / 4 xd LP
2
xL 
    
P1  V2    / 4 xd 2
HP xL 

2 x1.22
P2  d LP 
 
P1  d HP 

P2  1x( 2) 2.44
Intercooling pressure P2  5.426bar
 P1V1 PV
 a a
T1 Ta
PaVaT1 1.03 x10 2 x 0.02916 x303
V1  
Ta P1 1x10 2 x 288
 0.045m3 / sec
 n 1 
n  P 
 1
n
WLP  P1V1 
 P 
2
 
n 1  1 

 


 1.22 1 
1.22  5.426  1.22
WLP  2
1x10 x 0.045    1
1.22  1  1  

 

 8.89 kW
Air enters HP cylinder at T2  40C
P2V2 PV
 1 1
T2 T1
P1V1T2 1x10 2 x0.045 x313
V2  
T1 P2 5.426 x10 2 x303
 0.008567m3 / sec

 n 1 
n  P3  n 
WHP  P2V2 
P    1
n 1  2 

 


 1.221 
1.22  18  1.22
WHP  2
5.426 x10 x 0.008567    1
1.22  1  5.426  

 

 6.12 kW
Total Power  8.89  6.12
 15.01 kW

Problem 7
A multi stage compressor compressing air is to be designed to elevate the pressure from
1 bar to 120bar such that the stage pressure ratio should not exceed 4. Determine
(i) The number of stages
(ii) Exact stage pressure ratio
(iii) Intermediate pressure

Solution:
 P1  1bar PN 1  120bar
P2 P P P P
Stage pressure ratio   2  3  4  N 1  4
P1 P1 P2 P3 PN
Assuming the intercooling to be perfect we have
1
PN 1  PN 1  N
  
PN  P1 
1
 120  N
4 
 1 

Ln120
N  3.453
Ln 4
 Number of stages  4
PN 1 1
Exact stage pressure ratio   120 4  3.31
PN
P5 120
 3.31, P4   36.25 bar
P4 3.310
P4 36.25
 3.31, P3   10.95 bar
P3 3.31

P3 10.95
 3.31, P2   3.308 bar
P2 3.31
 Intermediat pressure are 36.25 bar, 10.95 bar
and 3.308 bar

Problem 8
A two-stage compressor delivers air at pressure of 19 bar. The free air conditions are
1.03 bar and 25ºC. The pressure of the air before compression is 0.98bar. The
intermediate pressure is 4.5bar. The temperature of the air entering each cylinder is 35°C.
The law of compression and expansion being PV1.25 =C. The clearance volume is 5% of
the swept volume. Determine the volumetric efficiency and the work done per kg of air.

Ta  25C , P2  4.5bar
Pa  1bar P1  0.98bar
T1  35C P3  19bar
Clearance ratio C  0.05
  1 
P1Ta   P2  n 
  1  C  C
 P  
PaT1   1 

 

 1

98.1 x 298   4.5  1.25 
  1  0.05  0.05   0.835
1 x 308   0.98  

 

 83. 5%

Even through the temperature of air entering

each cylinder is same, work is not saem in
both cylinder since P2  P1 P3

n 1 1.251
 P2  n  4.5  1.25
T2  T1 
P 
  308   416.1K
 1   0.98 

n 1.25
WLP  R  T2  T1   x 0.287 416.1  308
n 1 1.25  1
 155.12 kJ/kg
Temperatur e of air entering HP cylinder T5  35C

n 1 1.25 1
P  n  19  1.25
T6  T5  6   308   410.82 K
 P5   4.5 

n 1.25
WHP  R  T6  T5   0.287 410.82  308
n 1 1.25  1
 147.55kJ/kg
Total work  155.12  147.55
 302.75kJ/kg of air

Problem 9
A two-stage double acting air compressor takes in air at 1 bar and 25°C. It runs at 200
rpm. The diameter of LP cylinder is 35cm. The stroke of both LP and HP cylinders are
40cm. The clearance volume of both the cylinders is 4%. The index of compression is
1.3. The LP cylinder discharges air at a pressure of 4 bar. The air passes through the
intercooler so that it enters the HP cylinder at 27°C and 3.6 bar, finally it is discharged
from the compressor at 14.4 bar.
 Calculate

(i) Diameter of HP cylinder

(ii) The heat rejected in the intercooler
(iii) The power required to drive the HP cylinder

Volumatric effiency referred to the suction condition 1

1
P n
  1  C  C  2 
 P1 

Volume of air referred to condition 1

V1  0.9238 x0.2822  0.26071m 3 / S
P1V1 1x10 2 x0.26071
Mass of air m  
RT1 0.287 x 298
 0.30483 kg/s

n 1 1.31
P  n 4 1 .3
T2  T1  2   298   410.34 K
 P1  1

Heat rejected in the intercooler

 mC p  T2  T1   0.30483x1.005 410.34  298
 34.14kJ/s
Volume of air draw to HP cylinder
mRT5 0.30483x0.287x298
V5   2
 0.0724m3 / s
P5 3.6x10

Pressure ratio in LP cylinder = 4

Pressure ratio in HP cylinder =14.4/3.6=4
Since the pressure ratio and clearance percentage in both HP and LP cylinders are the
same, the volumetric efficiency of the cylinders referred to the condition at the start of
compression is same.

V5 0.0724
Swept volume of HP cylinder  
 0.9238
 0.07837 m 3 / s

 2 2 x 200
D HP xLHP x  0.7837
4 60
 2 2 x 200
D HP x 0.4 x  0.1934 m
4 60
 19.34 cm
Since pressure ratio is same T6  T2

Power required for HP cylinder

 n 
  x mR  T6  T5 
 n 1
 n 
  x mR  T2  T1 
 n 1 
 1.3 
  x 0.30483x0.287 410.34  298
 1.3  1 
 42.58 kW

Problem 10
A two stage air compressor compresses air from 170C and 1 bar to 63 bar. The air is
cooled in the intercooler to 300C and intermediate pressure is steady at 7.7 bar. The
low pressure cylinder is 10 cm diameter and the stroke for both cylinders is 11.25 cm.
Assuming a compression law of PV 1.35 = constant, and that the volume of air at
atmospheric conditions drawn in per stroke is equal to the low pressure cylinder
 swept volume, find the power of the compressor while running at 250 rpm. Find also
the diameter of HP cylinder.

Solution:
dLP = 10cm L = 11.25cm
P1 = 1 bar P2 = 7.7 bar T1 = 170C
P3= 63 bar
Volume of LP cylinder
V1 = /4 X 0.12 X 0.1125 = 0.00088 m3
m = P1V1/R T1 = (1 X 100 X 0.00088)/(0.287 X 290) = 0.00106 kg

T2 = 300C
Volume of air entering the HP cylinder

V2 = mR T2/ P2 = (0.00106 X 0.283 X 303)/ (7.7 X 102) = 0.0001198 m3

V2 = /4 X d22 X L
0.0001198 = /4 X d22 X 0.1125
d2 = diameter of HP cylinder
= 0.0368 m
Diameter of HP cylinder = 3.68 cm

Work required/cycle = (n/n-1) P1V1( P2 / P1)n-1/n – 1+ P2V2( P3 / P2)n-1/n – 1 

W = (1.35/1.35-1)  1 X 102 X 0.00088 (7.7/1)1.35-1/1.35 - 1 + 7.7 X 102 X 0.0001198

(63/7.7)1.35-1/1.35 - 1

= 0.49456 kJ/cycle

Power = 0.49456 X Number of cycles/sec

= 0.49456 X 250/60
Power = 2.06 kW

Problem 11

A three stage air compressor draws 8 m 3/min of air at 1 bar and 18 0C and delivers the
same at 55 bar and 200C. The index of compression is 1.32. The air while passing through
the intercoolers and aftercoolers suffers a pressure loss of 4% and is cooled to the intial
temperature. Determine the shaft power required to drive the compressor if mechanical
efficiency is 85%.

Solution:
V1 = 8 m3/min = 8/60 = 0.133 m3/sec
P1 = 1 bar T1 = 180C P4 = 55 bar
The pressure drop of 4% in the intercooler is accounted for by the factor C = 0.96

For 3 stage compressor,

Power = 3(n/n-1) X P1V1 P4/C3P1n-1/3n - 1

= 3 (1.32/1.32-1) X 1 X 102 X 0.133 55/0.963 X 11.32-1/1.32 - 1

= 283.kW

Actual shaft power required = Power/mech = 283.32/0.85 = 333.32kW