INTRODUCTION

Air compressors produce compressed air and they have many applications. The process is
used in manufacturing oxygen cylinders, spray cans, etc. Due to these wide applications, let
us study the working of air compressors, various types, their advantages, and disadvantages.

An air compressor is an essential piece of equipment that transforms power into compressed
air, making it a crucial tool across various industries. By increasing the pressure of air, these
devices enable a wide range of applications, from powering pneumatic tools to serving as a
vital component in manufacturing processes and HVAC systems. Air compressorscome in
different types, including positive displacement and dynamic compressors, each designed for
specific uses based on required pressure and airflow.

The versatility of air compressors extends to fields such as construction, automotive repair,
and food processing, where they provide reliable power and efficiency. As technology
advances, modern air compressors have become more energy- efficient, contributing to
sustainability efforts while maintaining high performance. Understanding the principles and
applications of air compressors is vital for optimizing their use in both industrial and
commercial environments.

An air compressor is a machine that takes ambient air from the surroundings and discharges it
at a higher pressure. It is an application of a gas compressor anda pneumatic device that
converts mechanical power (from an electric motor, diesel or gasolineengine, etc.) into
potential energy stored in compressed air, which has many uses. A common application is to
compress air into a storage tank, for immediate or later use. When the deliverypressure
reaches its set upper limit, the compressor is shut off, or the excess air is released through an
overpressure valve.

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  Air compressors: -
Compression is a process of increasing the pressure of any state of matter. Aircompression is
the process of increasing the air pressure above the atmospheric pressure. The value of
atmospheric pressure is given as ‘1 atm’ or ‘101,325 Pa (Pascals)’.

The mechanical device used to compress air is called an ‘Air compressor’. Thus, the air
compressor is a mechanical pneumatic device powered by IC engines or electric motors to
convert the kinetic energy of air to potential energy.

The compressed air from the air compressors is usually stored in a high-pressurevessel. An
example is shown in the images below.

Air compressors are usually run by steam engines, IC engines, or electric motors. There is an
upper limit provided by engineers to each type of compressor manufactured, crossing which
it gets shut down. The pressurized compressed air in the cylinders has kinetic energy when
released and can be used in various applications, which arediscussed below.

An air compressor cannot be considered a pump as the former works with only gas or air
while the latter works with liquids only. Let us now learn the basic principle behind the
working of these mechanical devices.

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  A general working principle of these compressors is listedbelow: -
1. The compressor, usually a piston-cylinder arrangement or other types as discussed
below, is a work-absorbing device.

2. The air from the atmosphere is sucked into the device.

3. The working element compresses the air to high pressure increasing its volume.

4. According to Boyle’s Law, the temperature is also increased in this process.

5. Then, the compressed air from the compressor is delivered to the high-pressure vessel
to store the potential energy in the form of air.

6. The compressor draws in air and creates a vacuum to reduce its volume.

7. To force it into a smaller space and as a result bringing the molecules closer to each
other.

8. A compressor is a mechanical flowing device designed to increase the pressure of a

gas by reducing its volume.

9. They are powered by an energy-variable motor converted from electrical to kinetic

energy.

10. A positive displacement air compressor will force air into a chamber with decreasing
volume to compress the air.

This is represented mathematically and diagrammatically in the image below.

Here,
P1P1 and P2P2 = Inlet and outlet pressure respectively,
V1V1 and V2V2 = Inlet and outlet velocity respectively.
Let us study the types and then the working principle of each type in detail.

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  Working of Air Compressors: -

Air compressors work by forcing atmospheric air under pressure to create potential energy
that can be stored in a tank for later use. Just like an open balloon, the pressurebuilds up
when the compressed air is deliberately released, converting the potential energy intousable
kinetic energy. From there, this energy transfer can be harnessed to power various
pneumatic tools.

Industrial air compressors work similarly to combustion engines. Generally,air compressor

operation requires a pump cylinder, piston and crankshaft to transfer energy fora wide
variety of tasks. These basic components can help supply air for filling up objects like tires
or inflatable pool toys, or they can supply power for operating tools such as drills, nail guns,
grinders, sanders and spray guns.

From impact wrenches to AC units, many versatile air-powered tools andmachines are
responsible for the comfort, shelter, automation and efficiency of everyday life. The
compressors themselves are more compact and lightweight than other centralized power
sources. They are also long-lasting, require less maintenance and are easier to move than other
old-fashioned machinery.

Mathematically, PV𝖺TPV𝖺T.

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 Classification of Air Compressor

Again these compressor are classified as:-

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 1. Positive Displacement Air Compressor: -
The compression here follows a process of trapping the air, and then compressing it. This
reduces the volume while increasing the pressure. The air above the condensing pressure after
the rise in pressure level is expelled from the enclosed chamber. A fresh supply of air is then
drawn, and the cycle continues.

These type of compressors forces air into the chamber. The air is displacedcontinuously by a
rotating mechanical component. Air cavities are formed when the componentmoves from
one place to another.

In this article, we shall discuss the two types based on the requirement of AE/JE Mechanical
examination: Reciprocating and Rotary type air compressors.

 Advantages of Positive Displacement Air Compressor: -

o High reliability.
o Excellent quality.

 Disadvantages of Positive Displacement Air Compressor: -

o Require incredibly high maintenance.
o Costly.
 Application of Positive Displacement Air Compressor:-
o Fertilizer industries.
o LPG plants.
o Chemical plants.

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 2. Single Acting Reciprocating Air Compressors
Let us refer to the image below as we learn more about the type. These are commonly
known as single stage reciprocating air compressors.

Fig : Single Stage Reciprocating Air Compressor Schematic

In this type, one end of the piston is used for suction and compression. The first stroke draws
the air inside the compressor chamber followed by the compression in the second stroke.
The other end of the piston is free and is not open for work.

As seen from the image above, the induction (suction) valve intakes the air at atmospheric
pressure. The work is done by only one end of the piston, usually the upper part, in the
compressor. Water jacket maintains the temperature well below the operating temperature of
the air, which may increase according to Boyle’s law.

The other side of the piston indirectly helps the stroke by aiding the openingand closing of
the crankcase. The piston works by the air pushing it down in one direction, andthe spring
action by the crankshaft brings the piston back to its normal position. This increasesthe
pressure above the atmospheric pressure of air.

This is supplied through the delivery valve. Thus, the work is done by only one piston in these
types of air compressors for the supply of compressed air.

 Advantages of Single Acting Reciprocating Compressors:

o The compressor has a simple working.
o It is Easier to repair.
 Disadvantages of Single Acting Reciprocating Compressors:
o The system should run at full potential even for a small amount of work output.
 Application of Single Acting Reciprocating Compressors:
o Commonly used in woodworking, food production in the bakery, and metalwork.

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 3. Double Acting Reciprocating Air Compressors: -
A schematic diagram of a typical double acting reciprocating air compressor is shown below.
These are usually categorized under multi-stage reciprocating air compressors, but let us
restrict the study to double acting/stage compressors concerned with the AE/JE mechanical
engineering exams.

Fig: Double Acting Reciprocating Air Compressor Schematic

This is a well-known type of positive displacement compressor. Here, unlike single
acting, both sides of the piston are used to intake and compress the air. The piston
movesdownward and draws the air. It then moves upward by compressing the air and
pushing it towards the delivery (exhaust) valve.

Here, both sides of the piston are used in the compressor chamber for the total work of air
compression. The volume of the air is reduced by the end of the process. Water jackets
are provided to maintain the temperature of the air while the compressor is working.

The operation of the induction and delivery valve depends on the piston movement of the air
compressor.

 Advantages of Double Acting Reciprocating Compressors:

o Greater control over the compression process.
o Only the first stage could be used to produce energy.
 Disadvantages of Double Acting Reciprocating Compressors:
o Higher capital investment.
o Complicated repair process.
 Applications of Double Acting Reciprocating Compressors:
o It is well-known to be used in various air force applications in the military.

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 4. Diaphragm Reciprocating Air Compressors: -
The diaphragm type of air compressor is a classic of the positive displacement category. It
has piston rings and a seal with backup as shown in the imagebelow. In this type, a moving
membrane (just like a human diaphragm) is driven by therod and crankshaft to intake the air.

Fig: Diaphragm Type Reciprocating Air Compressors Schematic

The membrane and the plate are in contact with the air, unlike the other typeswhere the piston
is in contact. Usually, the diaphragm or the membrane is manufacturedto withstand the stress
of the compressing action.

As these are commonly used with toxic gases as operating gases, the diaphragm should be
non-reactive. The oil space is used to maintain the system temperature while the perforated
plates let the oil lubricate the piston-cylinder arrangement.

This concludes the discussion on the reciprocating type.

 Advantages of Diaphragm Reciprocating Compressors:
o No air leakage and contamination during the process
o Low vibration
 Disadvantages of Double Acting Reciprocating Compressors:
o Requires a large area to install.
 Applications of Double Acting Reciprocating Compressors:
o Widely used for compressing toxic gases and rare gases such as hydrogen, nitrogen,
etc.

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5. Rotary Air Compressors: -
Unlike other types of compressors that use piston-cylinder movement, Rotary air
compressors use the action of gears to compress air. These compressors involve the
rotating element developing a liquid seal. This creates a suction at the inlet.

The air is displaced positively by the mechanical component in this type of

compressor. There are three major types of this compressor: Lobe type or Roots
Blower, Screw type, and Vane type.

6. Lobe Type or Roots Blower Rotary Air Compressors: -

A typical roots blower with two lobes is shown in the image below.

Fig: Roots Blower Rotary Air Compressor

There are two rotors in the compressor, and generally one of them is connected to the
external drive that drives the other rotor. The shape, technically known as the lobe,
of these rotors, follows a cycloid or involute profile.

The mating between these two imparts accurate sealing to the delivery side. Low-
pressure air is compressed by the action converting it to high-pressure air by the end of
the process.

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 Advantages of Double Acting Reciprocating Compressors:

o Simple in design compared with other rotary air compressors.

o Efficiency in operating at lower rpm.

 Disadvantages of Double Acting Reciprocating Compressors:

o Extremely susceptible to the wear of internal components

 Applications of Double Acting Reciprocating Compressors:

o They are commonly used in the pulp and paper industry.

o It is also used in pharmaceutical industries.

7. Screw Type Rotary Air Compressors: -

The screw type rotary air compressor uses a rotary type positive displacementmechanism.
The explanation is understood with the reference to the image below.

Fig: Screw Type Rotary Air Compressor

The compressor comprises closely meshing rotors of spiral shape to compress the air.
In practical scenarios, while running the system dry, a pair of timing gears are used
to ensure precise alignment. This also ensures resistance to rapid wear.

The lubricating oil forms a connection in the space between the rotors in an oil-
flooded rotary screw air compressor. This oil acts as a transfer medium of mechanical
energy between the rotors to aid in the rotation of one powered by the other.

 Advantages of Double Acting Reciprocating Compressors:

o Less noisy while under operation.
o Outlet air temperature would be comparatively low.

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 Disadvantages of Double Acting Reciprocating Compressors:
o This compressor has to be used frequently to avoid rust.
o Needs excessive maintenance.
 Applications of Double Acting Reciprocating Compressors:
o Small air compressors or mini air compressors of this type are used as mobile units to
fill the air.
o They are also used in the food packaging industry.

8. Vane Type Rotary Air Compressors: -

The vane type compressor consists of a set of vanes mounted on a rotor as shown in the
image below.

Fig: Vane Type Rotary Air Compressors

The vanes on the rotor inside the chamber are of variable length. They are in contact
with the walls of the casing as the rotor rotates. The air from the inlet is drawn and
compressed with this action.

This completes our discussion on the first category of air compressors. Let us move
ahead with the next major category.

 Advantages of Double Acting Reciprocating Compressors:

1) Easy to maintain
2) Simple design
 Disadvantages of Double Acting Reciprocating Compressors:
o Lubricant may contaminate the air
 Applications of Double Acting Reciprocating Compressors:
o Used in the agricultural industry to supply compressed air to operate farm equipment.

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  Dynamic Displacement Air Compressors: -
A steadily flowing air is impacted by kinetic energy bythe mechanical elements in a
compressor of this type, which increases the pressure of the flowing air. There are two types:
Centrifugal and Axial Compressors.

9. Centrifugal Air Compressors: -

The rotational energy is imparted to the air by centrifugal air compressors in the possessof
compression.

Fig 10: Centrifugal Compressor

The rotational energy by the vanes is converted into a centrifugal force that pushes the air
towards the discharge side. The airflow is normal to the axis ofthe rotating shaft in this type.
The vanes are of two types: Diffuser and Impeller.

Impeller vanes are curved which aids the flow of air. Diffuser vanes arefixed and are used to
aid in the conversion of the rotational kinetic energy of air comingfrom impeller vanes to
pressure energy. The components in figure 10 are the main components of a centrifugal air
compressor.

 Advantages of Double Acting Reciprocating Compressors:

1) Reliable and less expensive

2) Ability to handle high-pressure operations.
 Disadvantages of Double Acting Reciprocating Compressors:
1) Less flexible and stable at higher compressions
2) Generates more vibrations.
 Applications of Double Acting Reciprocating Compressors:
Mainly used by gas turbines and refrigeration compressors
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 10.Axial Air Compressors: -

The axial air compressor, a widely known dynamic compressor, is a mechanical device
employed to increase the pressure of the air continuously in the system. In comparison with the
centrifugal compressor, the axial compressors are smallin size and lightweight.

Let us have an idea of these types of compressors using the image below.

The compressor has a drum on which the rotating blades are mounted. The fixed blades are to
direct the flow and achieve high speeds. The air radially entersthe impeller and is discharged
axially from the compressor.

In this system, the air is allowed to pass through in a parallel direction due to the rotating
blades. When the axial flow compressors are combined with gas turbines, they can generate
electricity.

 Advantages of Double Acting Reciprocating Compressors:

o Higher flow rate and greater pressure ratio.
o Higher thrust and fuel efficiency.
 Disadvantages of Double Acting Reciprocating Compressors:
o Bulky construction
o High starting power
 Applications of Double Acting Reciprocating Compressors:
These compressors are used in the construction of jet engines, high-speed ship
engines,and small-scale power stations.

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 Conclusion

An air compressor is a necessity across diverse sectors,

from manufacturing and construction to automotive and healthcare. From
powering pneumatic tools to providing clean and compressed air, air
compressors have become vital components of everyday operations.

Air compressors work by forcing atmospheric air under

pressure to create potential energy that can be stored in a tank for later use.
Just like an open balloon, the pressure builds up when the compressed air is
deliberately released, converting the potential energy into usable kinetic
energy.

Compressors and pumps have only one thing in

common: they increase the fluid pressure necessary for transporting
fluid from one point to another via different operations. However,
compressors only work with gases while pumps work with gases

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