S. N.

PATEL INSTITUTE OF TECHNOLOGY & RESARCH CENTET, UMRAKH

DEPARTMENT OF MECHANICAL ENGINEERING

Basic Mechanical Engineering

SUBJECT CODE: 3110006 | B.E.1ST YEAR

Air Compressor
Prepared By,
Prof. Mayank Parmar
Assistant Professor
Department of Mechanical Engineering,
S. N . Patel Institute of Technology and Research Centre,
Umrakh.
At & Po Baben, 394601.
 Introduction
Air compressor is mechanical device which takes atmospheric air at low
pressure and compress it to high pressure and deliver to storage tank with the help
of some suitable arrangement i.e. a reciprocating piston and cylinder arrangement or
a rotary arrangement.

Uses of Compressed
air
 Operating pneumatic drill, hammers for the formation of rivet heads.
For filling air in automobile tyres.
For spray painting.
Increasing inlet pressure of I.C. Engine.
To operate air motor in mines where fire risks are more.
 Pumping of water.
Gas turbine power plant.
 Conveying the materials like sand and concrete along a pipe line.
 For sand blasting.
Operating blast furnaces.
 Operating air brakes used in buses, trucks, trains etc.
 Classification of Compressors
1. According to method of compression
a. Reciprocating compressor
This type of compressor compresses air by reciprocating action of piston inside a
cylinder. It is suitable for producing high pressure.
b. Rotary Compressor
In a rotary compressor, air or gas is compressed due to the rotation of impeller or
blades inside a casing similar to a rotary pump.
c. Centrifugal compressor
A machine in which compression of air to desired pressure is carried out by a
rotating impeller as well as centrifugal action of air.

2. According to method delivery pressure

 Low pressure - up to 1.1 bar
 Medium pressure - 1.1. to 8 bar
 High pressure - 8 to 10 bar
 Very high pressure - above 10 bar
3. According to principle of operation
a. Positive Displacement
In this type, pressure of air is increased by reducing the volume of it. Here air is
compressed by positive displacement of air with piston or with rotating element.
These are capable with low volume flow rate.
Examples: Reciprocating compressor, Roots Blower etc.
b. Roto Dynamic or steady flow compressor
In this type, compression of air is carried out by a rotating element imparting
velocity to the flowing air and developed desired pressure. Here compression is
achieved by dynamic action of rotor.
Examples: Centrifugal, Axial flow, etc.

4. According to the number of stages

a. Single stage compressor - pressure up to 5 bar
b. Multistage compressor - pressure above 5 bar
5. According to the number of cylinder
a. Single cylinder
b. Multi cylinder
6. According to the pressure limit
a. Fans - pressure ratio 1 to 1.1
b. Blowers - pressure ratio 1.1 to 2.5
c. Compressor - pressure ratio above 2.5

7. According to fluid to be compressed

a) Air compressor
b) Gas compressor
c) Vapour compressor

8. According to volume of air delivered

a. Low capacity - volume flow rate up to 10 /min
b. Medium capacity - volume flow rate 10 /min to 300 /min
c. High capacity: Volume flow rate above 300 /min
 Reciprocating air compressor
It consists of the cylinder in which a piston reciprocates. The piston is driven by
crank through connecting rod. The crank is mounted in a crankcase. There are two
valves, i.e. intake valve and delivery valve. The valves are generally pressure
differential type. Thus they operate automatically by the difference of pressure across
the valve.

Fig.1 Suction stroke Fig.2 Delivery stroke

 Working of reciprocating air compressor
Suction Stroke
The piston moves down in the cylinder as show in fig.1, the pressure inside the
cylinder is lower than the outside of the compressor. Because of this pressure
difference the suction valve will be open or lift off its seat up to the stop is provided
to limit of the lift. The fresh air will be taken in the cylinder. The delivery valve will
remain closed during this stoke.

Delivery Stroke
During this stoke as shown in fig.2, the piston moves upward inside the cylinder
causes slight high pressure will closed the inlet valve. Since both inlet and delivery
valves are closed the pressure of air will rapidly rise. This pressure will lift the
delivery valve up to the stop or open delivery valve. Pressurized air is removed from
the delivery valve and stored in a receiver.
 Case-1 Operation of a compressor without Clearance
Process (4-1) : During suction process ,
air of volume V1 enters into the
compressor at pressure P1 and
Temperature T1
Process (1-2): During this the Constant
air is compressed from P1 to P2. Volume
decreases from V1 to V2 and temperature
raise from T1 to T2.
Process (1-2’): Isothermal compression
process
Process (1-2’’): Adiabatic compression
process
Point 4 : Suction Valve Open
Process (2-3): Delivery process : Point 1 : Suction Valve Closed
Compressed air of volume V2 and Point 2 : Delivery Valve Open
Pressure P2 temperature T2 is delivered Point 3: Delivery Valve Closed
from the compressor.
 Case-2 Operation of a compressor with Clearance
In actual compressor always there is clearance volume at the end of stroke. The
small clearance is required because of,
(1) Preventing striking of piston at cylinder head,
(2) Thermal expansion due to high temperature at the end of compression,
(3) Maintaining machine tolerance.

The clearance volume is denoted by

Vc or V3.The residual compressed air
at a pressure P2 = P3 is filled in
clearance volume at the end of
upward stroke of piston.
So during the suction stroke this
residual compressed air expands and
denoted by the curve (3-4) on p-V
diagram This expansion will reduce
pressure from P2 = P3 to intake
pressure P4 = P1.
 Multistage Reciprocating Compressors
In a single stage compressor, if the pressure ratio is increased, the volumetric
efficiency decreases. When the pressure ratio is increase maximum, the volumetric
efficiency becomes zero, thus multistage compression is needed.
Problems with single stage compression are
The higher the delivery pressure, the higher will be delivery temperature. This
increase in temperature causes increase in specific volume and energy loss. So
compressor has to handle more volume of air at higher temperature.
The increase in temperature of air causes reduction in density of air, hence the
mass flow through compressor decreases.
The operation at high pressure and temperature will need heavy working parts.
In low pressure (L.P.) cylinder, air is compressed adiabatically from point 1 to 2.
This compressed air is passed through intercooler-l where it is cooled from 2 to 2’.
The air coming from intercooler-l is then admitted into the intermediate pressure
(I.P.) cylinder where it is compressed adiabatically from 2' to 3.
 The compressed air from I.P. cylinder is cooled from 3 to 3' in the intercooler-2.
Finally air enters into high pressure (H.P.) cylinder for getting higher pressure.
Advantages:
Without inter-cooling, the curve of compression will follow the path (1- 4”),
hence the saving in work input due to inter-cooling.
Volumetric efficiency is increased due to the smaller pressure range, as the effect
of expansion of air in the clearance volume is less.
Less shaft power is required for a given pressure ratio due to the saving in work
input.
Due to smaller working temperature, better lubricating effect is provided.
There is less leakage problems due to less pressure difference for each stage.
 Rotary air compressor
In rotary air compressor, the air is entrapped between two sets of engaging surface
and the pressure of air is increased by squeezing action or back flow of the air.

Types of Rotary air compressor

1. Rotodynamic Compressor
a) Centrifugal compressor or Radial Flow Compressor
b) Axial flow compressor
2. Positive Displacement Compressor
a) Roots blower
b) Vane compressor
Centrifugal Compressor or Radial Flow Compressor
A centrifugal compressor is used to supply large quantities of air at low pressures.

It consists of an impeller I. It carries a disc D. On this disc D, a large number of

radial vanes or blades B are mounted. The impeller is mounted on the compressor
shaft S. This shaft is usually rotates at high speed (20.000 to 30,000 RPM).

C is a volute casing, it is known as

diffuser.

The impeller is surrounded by means

of the casing. It surrounds the impeller
in such a way that it forms the
diverging passages for the air.

 Air coming out of the diffuser is

collected in the casing of the
compressor. It is then taken out from
the O.
Working
Air at low velocity and atmospheric pressure enters the compressor through eye
E. It flows radially outward through the impeller blades.

This air is subjected to a centrifugal force while passing through the impeller.
The pressure and velocity increases in the impeller.

The high-velocity air passes through the convergent passages formed by diffuser
blades. The velocity is reduced. This decrease in velocity (K.E) of the air increases
its pressure.

 It is found that, nearly half the pressure of the air is developed in the impeller and
the remaining half in the diffuser.

For single stage reciprocating compressor, The pressure ratios of 4 to 6 are

common. For higher pressure ratios, multi-stage compressors are used
Axial Flow Compressor
 Roots Blowers ( Twin Lobe)
The two lobe type roots blower is shown in figure. For higher pressure ratios, three
and four lobes versions are used.
One of the rotor is connected to the drive. The second rotor is gear driven from the
first. Thus both the rotors, rotate in phase. In order to seal delivery side from the inlet
side, the profile of the lobs is of cycloid or involutes. This sealing continues until
delivery commences.
 Vane compressor
It consists of a rotor mounted eccentrically in the body. This rotor is supported by
ball and roller bearings in the end cover of the body. The rotor is slotted to take the
blades. These blades are made from non-metallic material usually fiber.
The casing of the compressor is circular in which the drum rotates during rotation.
The vanes remain in contact with the cylinder. The slots in which the blades are fixed
are cut radially into the rotor. The blades or vanes can slide in and out due to the
centrifugal forces setup by the rotary motion of the rotor.
 Difference between Reciprocating Compressor and
Rotodynamic Compressor
Characteristics Reciprocating Compressor Rotodynamic Compressor

Delivery
Suitable for low discharge and Suitable for high discharge and
pressure versus
high pressure applications. low pressure applications.
discharge

Air discharge Not continuous Continuous

Speed Low speed High speed up to 30,000 RPM

Size Larger than rotary compressor Smaller

Volumetric Less than 100% due to Nearly 100% due to no

efficiency clearance volume clearance volume

Maintenance More Less

Maintenance and running cost Maintenance and running cost

Running Cost
is more is low
 Assignment

(1) What is compressor? Explain the use of the compressed air. (GTU:M17,
D14, D13, M12, M18, J15, D14, J13, J11)
(2) Explain Classification of compressor.( GTU: J16, J15, M12, D10)
(3) Explain working of the Single stage reciprocating compressor and derive
equation of work done in signal stage compressor without clearance.(GTU:
M18, J13, J13)
(4) Explain multistage reciprocating compressor. (GTU: J19, D15)
(5) Explain Root blower .( GTU: J19)
(6) Explain difference between Reciprocating compressor and Rotodyanamic
compressor.( GTU: J19)