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MECHANICAL DEPARTMENT USNIVERSITY OF ENGINEERING & TECHNOLOGY TAXILA

Goal
Describe the basic types of compressors and their typical applications used in industry.

Definition of Compressor
Compressors are described as mechanical device that takes in a gas and increases its pressure by squeezing volume of it into a smaller volume

A Brief History of Compressors

Compressor History
1933 Danfoss founded 1952 "Pancake" compressor 1956 PW compressor 1956 Danfoss Flensburg founded 1958 Start of production in Flensburg 1960 Synthetic materials and oils 1970 SC compressor and PTC starting device 1972 FR compressor 1977 TL and BD compressor 1988 Concentration of production in Flensburg 1989 100,000,000 compressors produced 1990 NL and TLES compressor 1992 PL compressor 1992 Compressors for R134a 1993 Compressors for R600a 1993 Danfoss Compressors d.o.o (Slovenia)

1995 Danfoss Compressors S.A. de C.V. (Mexico) 1996 NLY compressor 1997 150,000,000 compressors 1998 Introduction BD35F (DC) 1998 Variable speed drive compressor TLV 1999 Introduction BD50F (DC) 1999 Compressors for R290 2000 Variable speed drive compressor NLV 2000 TLX compressor 2001 ePTC-Electronically controlled PTC starting device 2001 200,000,000 compressors produced 2002 Danfoss Compressors spol. s.r.o. 2002 Compressor for mobile refrigeration BD150F 2003 BD35F & BD35K (DC) for solar applications 2003 CO2 compressor (carbon dioxide) 2003 X-treme Series: NLX-KK & TLX-KK.3 compressors 2004 Introduction BD80F (DC) 2005 GS compressor 2006 TN (CO2) compressor 2006 SLV variable speed drive compressor

Introduction

Compressors used to increase the pressure of a gas (compressible fluid) Examples Increase the pressure for instrument air systems (to get control valves to operate), transport gases such as hydrogen, nitrogen, fuel gas, etc. in a chemical plant

OR
Working fluid enters compressor as a low pressure gas near room temperature Compressor does work on fluid Pushes gas inward as the gas moves inward Gas temperature rises (first law) Ordered energy becomes disordered energy Fluid leaves compressor as hot, high pressure gas

Compressors used to compress air from inlet pressure (atm) to a higher pressure (PV

R T) Classified according to:

Type of displacement Staging Type of Drive (prime mover) Operating Pressure Capacity

Types of Compressors

Compressors

Positive Displacement

Dynamic

Ejector

Reciprocating

Rotary

Centrifugal (Radial Flow) Mixed Flow Axial Flow

Mechanical Piston

Sliding Vane Liquid Piston Helical Lobe Straight Lobe Scroll

Types of Compressors

Positive Displacement (PD) : Operate by trapping a specific volume of gas and forcing it into a smaller volume

2 Basic Designs for PD Compressors

Rotary Reciprocating
Centrifugal : Operate by accelerating the gas and converting the energy to pressure

2 Basic Designs for Centrifugal Compressors

Centrifugal Axial

Positive Displacement Compressors: Rotary Design

Rotary compressors (get their name from the rotating motion of the transfer element) compress gases with lobes, screws, and vanes into smaller volumes. 4 Primary Types of Rotary Compressors:

Rotary Screw Scroll Sliding Vane Lobe Liquid Ring

Rotary Compressors
Higher efficiency, lower noise and vibration Cylinder rotating eccentrically in side housing Double-acting

Rotary Screw Compressors

Commonly used in industry. It operates with 2 helical rotors that rotate toward each other, causing the teeth to mesh. As the left rotor turns clockwise, the right rotor rotates counterclockwise. This forces the gases to become trapped in the central cavity. The 2 rotors are attached to a drive shaft and drive that provide energy to operate the compressor. Have an inlet suction line and outlet discharge port

Very common in plants Good mid-range size (25 hp 300 hp) Models include oil flooded or oil free Oil flooded units offer best efficiency

Example:
Screw compressor traps the refrigerant vapor and compresses it by gradually shrinking the volume of the refrigerant. This particular screw compressor design uses two mating screw-like rotors (male and female rotors) to perform the compression process. Only the male rotor is driven by the compressor motor. The lobes of the male rotor engage and drive the female rotor, so that the two parts counter-rotate.

Rotating meshed screws One or two screws

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Screw Compressor Advantages / Disadvantages

Advantages

Good efficiency for oil flooded models (continuous intercooling) Low maintenance costs Not usually noisy Can run fully loaded for extended periods of time Good for heat recovery for space heating

Disadvantages

Can use 40%-90% of full load power when unloaded Not good for very small or very large loads

Scroll compressors
It works on the principle of trapping the refrigerant vapor and compressing it by gradually shrinking the volume of the refrigerant. The scroll compressor uses two scrolls to perform this compression process. The stationary scroll contains a discharge port. The driven scroll is connected to a motor by a shaft and bearing assembly.

Constant displacement Higher efficiency, but harder to manufacture Close tolerance between scrolls Ugly to analyze see text for details

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Sliding Vane Compressors

Uses a slightly off-center rotor with sliding vanes to compress gas. Inlet gas flows into the vanes when they are fully extended and form the largest pocket. As the vanes turn toward the discharge port, the gases are compressed. As the volume decreases, the pressure increases until maximum compression is achieved. Then the gas is discharged out the compressor.

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Lobe Compressors

Characterized by 2 kidney-bean shaped impellers used to trap and transfer gases. The 2 impellers move in opposite directions on parallel mounted shafts as the lobes sweep across the suction port. Compressed gases are released into the discharge line. The lobes do not touch each other. A few thousands of an inch clearing exists between the casing and lobes. Designed to have constant volume discharge pressures and constant speed drivers. Lobe Compressors can be used as compressors or vacuum pumps.

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Liquid Ring Compressors

It has one moving transfer element and a casing that is filled with water or seal liquid. As the rotor turns, the fluid is centrifugally forced to the outer wall of the elliptical casing. An air pocket is formed in the center of the casing. As the liquid ring compressor rotates, a small % of the liquid escapes out the discharge port. Make up water or seal liquid is added to the compressor during operation. The liquid helps cool the compressed gases

Used to compress hazardous and toxic gases as well as hot gases.

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Reciprocating piston compressors

Low flow rates High compression ratios Most common type of compressors. Work by trapping and compressing specific volumes of gas between a piston and a cylinder wall. The back and forth motion incorporated by a reciprocating compressor pulls gas in on the suction (or intake) stroke and discharges it on the other. Spring-loaded suction and discharge valves open/close automatically as the piston moves up and down in the cylinder chamber.

What is Sequence of Events?

It is a step by step basic approach to allow a better understanding of how a reciprocating compressor cylinder works under ideal conditions.

HEAD END

CRANK END

CROSSHEAD

Typical double acting reciprocating Compressor cylinder schematic

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When compressing a gas its volume is reduced, along with an increase in pressure and temperature.

CYLINDER PRESSURE

PV Diagram
STROKE OR VOLUME

SUCTION DRUM

SUCTION VALVE DISCHARGE VALVE

DISCHARGE DRUM

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300 CYLINDER PRESSURE 100 STROKE OR VOLUME

300
CYLINDER PRESSURE

100 STROKE OR VOLUME

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Whats going on at the discharge valve?

IN THE CYLINDER 300 PSIG

DISCHARGE PRESSURE AT THE DRUM

Area

Springs

TO OPEN THE VALVE

IN THE CYLINDER 320 PSIG 300 PSIG

300 PSIG DISCHARGE PRESSURE AT THE DRUM

IN THE CYLINDER

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300 PSIG

300 PSIG DISCHARGE PRESSURE AT THE DRUM

300 CYLINDER PRESSURE

STROKE OR VOLUME

100

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ACTUAL STROKE PORTION OF STROKE DISCHARGE VALVE OPEN

300
AIR ( K = 1.4 ) HELIUM ( K = 1.6 )

NATURAL GAS ( K = 1.25 )

100

CLEARANCE VOLUME
300

CYLINDER PRESSURE
100

STROKE OR VOLUME

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300 CYLINDER PRESSURE

STROKE OR VOLUME

100

300 CYLINDER PRESSURE

STROKE OR VOLUME

100

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ACTUAL STROKE FIXED CLEARANCE
300 CYLINDER PRESSURE

EFFECTIVE STROKE

STROKE OR VOLUME

100

FIXED CLEARANCE

ACTUAL STROKE FIXED CLEARANCE

CYLINDER PRESSURE
300

EFFECTIVE STROKE

VALVE LOSS

100

EFFECTIVE STROKE ACTUAL STROKE

STROKE OR VOLUME

VOLUMETRIC EFFICIENCY =

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300
NATURAL GAS ( K = 1.25 )

AIR ( K = 1.4 ) HELIUM ( K = 1.6 )

100
EFFECTIVE STROKE EFFECTIVE STROKE EFFECTIVE STROKE

EFFECT OF CLEARANCE VARIATIONS

300 CYLINDER PRESSURE

STROKE OR VOLUME

100

FIXED CLEARANCE

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VOLUME REDUCTION
CYLINDER PRESSURE 300

STROKE OR VOLUME

100

CLEARANCE POCKET OPENED

ADDITIONAL INFO
Unloading also accomplished with suction valve

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Basic Parts Of Positive Displacement Reciprocating Compressors

Piston Connecting Rod Crankshaft Diver Piston Rings Suction Line Discharge Line Spring -Loaded Suction and Discharge Valves

Example:
The refrigerant vapor is compressed by a piston that is located inside a cylinder. The piston is connected to the crankshaft by a rod. As the crankshaft rotates, it causes the piston to travel back and forth inside the cylinder. Suction valve and the discharge valve, are used to trap the refrigerant vapor within the cylinder during this process.

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Reciprocating Compressor Intake stroke The piston travels away from the discharge valve and creates a vacuum effect Reduction in the pressure within the cylinder to below suction pressure forces the suction valve to open and the refrigerant vapor is drawn into the cylinder.

Reciprocating Compressor Compression stroke & discharge The piston reverses its direction and travels toward the discharge valve, compressing the refrigerant vapor The suction valve is then closed, trapping the refrigerant vapor inside the cylinder. As the piston continues to travel toward the discharge valve, the refrigerant vapor is compressed. The discharge valve is forced open and the compressed refrigerant vapor leaves the cylinder.

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Reciprocating Piston Piston assembly with valves to control flow Can either be single stage or multi-stage

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Shown only one cylinder

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Multistage Compressors

Discharge from Stage 1 is suction for Stage 2

Utilizes piston / cylinder Usually two stages with an intercooler (MAE302)

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Uses oil to seal piston and for some cooling

Reciprocating Compressor Advantages/Disadvantages Advantages: Good for small application Uses no / little power when unloaded Cheap and simple to operate Operates over a wide range of pressures

Disadvantages Noisy Maintenance can be an issue Not good for larger applications Oil-free air units are expensive

Non-Positive Displacement

Centrifugal compressor Radial flow Axial Compressor Axial Flow

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Centrifugal compressors
High flow rates Low compression ratios Several centrifugal stages may be used to obtain higher compression ratios

Centrifugal compressors accelerate the velocity of the gases (increases kinetic energy) which is then converted into pressure as the gas flow leaves the volute and enters the discharge pipe. Usually operate at speeds > 3,000 rpm. Deliver much higher flow rates than positive displacement compressors

2 Types of Centrifugal Compressors

Single- Stage : Compress the gas once Use for high gas flow rates, low discharge pressures

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Multi- Stage : Take the discharge of one stage and pass it to the suction of another stage Use for high gas flow rates, high discharge pressures

Basic Components
Impellers, Vanes, Volutes, Suction Eyes, Discharge lines, Diffuser Plates, Seals, Shaft, Casing Suction Vane Tips = Part of the impeller vane that comes into contact with gas first. Discharge Vane Tips = Part of the impeller vane that comes into contact with gas last

Radial Flow (Centrifugal) Compressor

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Centrifugal Compressor
Fluid flow is perpendicular to the axis of rotation Used in first jet turbine engines

Centrifugal Compressor: Axial Design

Composed of a rotor that has rows of fanlike blades. In industry, axial compressors are used allot high flows and pressures are needed. Gas flow is moves along the shaft. Rotating blades attached to a shaft push gases over stationary blades called stators. Stator blades are attached to the casing.

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As the gas velocity is increased by the rotating blades, the stator blades slow it down. As the gas slows, kinetic energy is converted into pressure. Gas velocity increases as it moves from stage to stage until it reaches the discharge. Multi-Stage axial compressors can generate very high flow rates and discharge pressures. Axial compressors are usually limited to 16 stages (due to temperature/material limitations) Pound for pound, axial compressors are lighter, more efficient, and smaller than centrifugal compressors

Axial Compressors
Fluid flow is parallel to axis of rotation Used in modern aircraftHave several stages to increase compression pressure ratio. Used in modern gas turbine engines

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Compression
Radial/centrifugal flow Adv: simple design, good for low compression ratios (5:1) Disadv: Difficult to stage, less efficient

Axial flow Good for high compression ratios (20:1) Most commonly

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Centrifugal Compressor Advantages / Disadvantages

Advantages Can be staged for high pressure applications Typically used for loads greater than 200 hp Can be 1,500 hp or larger Low maintenance Part load performance is adequate (close off inlet)

Disadvantages Intercooling must be provided for higher pressures Not as efficient as screws Disadvantages Intercooling must be provided for higher pressures Not as efficient as screws

Two-Stage Single-Shaft Centrifugal Compressor Advanced Design

LPC Design

Impeller

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HPC Design

Impeller LPC and HPC Subassembly

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Compressors Application

Compressors Application

Typical Compressor System

Safety valves and pressure relief valves used to remove excess pressure that could damage equipment and people. Silencers are mounted on the inlet and outlet of a compressor to reduce the noise. Compressors are very noisy. Exxon had one for a refinery light ends stream nicknamed Old Snort by the technicians.

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Demister removes moisture (liquid) from the gas stream. The liquid falls to the bottom of the demister and is removed. The clean gases goes out the top of the demister. Dryer sometimes used on the compressor discharge line to remove any liquids (moisture). Silica gel and molecular sieves (3A mole sieve) often used Check valve line up on the compressor and associated equipment. Check compressor oil levels and bearing cooling water systems. Be sure all the compressor controls are set correctly. Turn on the compressor. Monitor equipment and process until conditions steady out

Location and Types of Compressors

Compressor Station

Compressor Station Compressor Station

Production

Processing

Transmission & Storage

Distribution

32,000 Compressors

5,000 Compressors 8,500 Compressors

0 Compressors

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Booster Station

Gathering Centre

LPG/Refinery

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Oil-free refrigerant compressor technology

Turbocor oil-free compressor reducing costs to 50% This revolutionary compressor technology provides efficiencies up to 30% better than any other compressor in its size range in addition to being extraordinarily quiet and virtually vibration free

2003 AHR Expo Innovation Awards

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Oil-free refrigerant compressor technology

Oil-free compressor with VFD and magnetic bearings Based on test results, 30-40% energy savings over reciprocating air-cooled compressor technologies are realistic.

Beam Type

Coaxial and Non-Coaxial Flanges One to Three Impellers High Pressure Ratio Axial Thrust Balance Sizes 300 to 1000

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Overhung Type

Axial Inlet Single Impeller High Volumes, Low Pressure Ratio Hydrostatic Lift Size 800 to 1000

Assembly

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Hydrogen Compressor

Hydro-Pac Hydrogen Compressor Model C12-40-7000LX 12,000 psi (80MPa), 40 hp (30 KW)

High Pressure Hydrogen Compressors

Since the 1980s, Hydro-Pac has manufactured compressors for high-pressure hydrogen applications. We have developed the techniques to safely and reliably compress this difficult gas. Our initial experience was the design and manufacture of ultra high-pressure hydrogen compressors for pressures of 30,000 psi to 120,000 psi (200 to 825 MPa). The recent interest in hydrogen gas as an energy source has prompted us to expand our product offerings for this important application. In addition to the ultra-high pressure machines, we

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manufacture units for pressures of 1,000 psi to 15,000 psi (7 to 100 MPa) and flow rates of 1 scfm to 350 scfm (3 to 1200 kg/day). Today, our hydrogen compressors are in use at fixed and mobile fueling stations, industrial sites, research and development facilities, and backup power systems.

Hydro-Pac hydrogen compressors feature:

Oil-free nonlubricated gas pistons and cylinders protect against oil contamination of the process gas. Full stroke length distance pieces isolate the hydraulic drive from the gas cylinders. This prevents contamination of the gas by the hydraulic drive oil. Hydro-Pac gas compressors work over a wide range of inlet pressures. In many cases inlet pressure regulators are not required. Intensifiers are ideally suited for high-pressures due to the simple geometry, slow operating speeds and in-line loads. Long slow stroke and small dead volume in the compressor cylinders result in a high volumetric efficiency. Water-cooled gas cylinders lower operating temperatures, which increases packing life. Hydraulically driven intensifiers allow control of both discharge pressure and gas flow rate by controlling the hydraulic drive. This may be important when matching the flow rate of the compressor to that of a reformer or electrolyzer. Straightforward arrangement and patented free piston design of Hydro-Pac compressors simplifies maintenance. Gas pressure assists in the compression stroke improving the overall efficiency of the machine

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Compressor Control System

Compressor Control Equipment

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Compressor Test Cell

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Example(Air Conditioners)

Compressor
Working fluid enters compressor as low pressure gas near room temperature Compressor does work on fluid: Pushes gas so gas temperature rises (first law and ideal gas law) Ordered energy becomes disordered

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Fluid leaves compressor as hot, high pressure gas.

Summary: Air conditioner

Evaporator: located in room air transfers heat from room air to fluid Condenser: located in outside air transfers heat from fluid to outside air Compressor: located in outside air does work on fluid and creates entropy A heat pump does work to transfer heat from cold to hot

Reference
The Process Technology Handbook, by Charles E. Thomas, UHAI Publishing, Berne, NY, 1997. Many compressors available ASHRAE Handbook is good source of more detailed information

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Objestives(MCQs)
1. When the gas enters the diffuser, the impeller (is/is not) acting directly on the gas. Ans: is not 2. When the gas is at tips of impeller blades, it is at (maximum/minimum) velocity. Ans: Maximum 3. Axial motion is (circular/straight line) motion. Ans: Straight line 4. An axial compressor has (stator/rotor/or both types) of blades. Ans: Both types 5. For large capacities and high heads (an axial/a centrifugal) compressor is used. Ans: A Centrifugal