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AIR COMPRESSORS
4.1. INTRODUCTION
An air compressor is a machine to compress the air to raise its pressure. The air
compressor sucks air from the atmosphere, compresses it and then deliver the same under
a high pressure to a storage vessel; it may be conveyed by the pipe line to the place where
the supply of air compressed air is required. Since the compression of air requires some
work to be done on it, therefore the compressor must be driven by some prime mover.
The compressed air is used for many purposes such as for operating pneumatic
drills, riveters, road drills, paint spraying, in starting and supercharging of internal
combustion engines, in gas turbine plants, Jet engines and air motors, etc. It is also
utilized in the operation of lifts, rams, pumps and variety of devices. In industry,
compressed air is used for producing blast of air in blast furnaces and Bessemer
converters.
P
3 2
P2
Pvn = C
4
P1 1
V2 V1 V
1
= ( PV 1 1 ) 1 +
2 2 − PV
n − 1
n −1 + 1
= ( PV 1 1)
2 2 − PV
n − 1
n PV
= 1 1
PV 2 2
− 1
n −1 PV
1 1
n mRT2
Work Done / Cycle = 1 1
PV − 1
n −1 mRT1
n −1
n
P2 n
Work Done / Cycle = 1 1
PV
− 1 ----------------------- (1)
n −1
1
P
n −1
mRT1 − 1
n P2
n
=
n −1 P1
n −1
RT1 − 1
n P2 n
Work Done / kg of air = ----------------------- (2)
n −1 P1
P
3 2
5
6 1
4 Va
VC VS
4 – 1 Suction
1 – 2 Polytropic Compression
2 – 3 Delivery
3 – 4 Polytropic Expansion of Clearance Volume
1 a
P1
2
Work done / cycle = PV ----------------- (3)
n −1
Where Va = (V1 − V4 ) = Free air delivered
n −1
ma RT1 − 1
n P 2
n
Work done / cycle =
n −1 P1
n −1
RT1 − 1
n P2 n
Work done / kg of air = ------------------- (4)
n −1 P1
Equation (4) is same as Equation (2), (i.e) the clearance will not affect the work of compression
per kg of air.
Vc
Clearance = K = Χ100
Vs
P
3 2
5
6 1
4 Va
VC VS
It is the ratio of the actual volume of free air delivered to the displacement
volume.
Va
(i.e) ηvol =
Vs
=
V1 − V4 (V + V ) − V4
= s c
Vs Vs
V − (V4 − Vc )
= s
Vs
V − V
= 1− 4 c
Vs
V4
Vc − 1
Vc
= 1−
Vs
1
V4 P
V 3 − 1 n
Vc − 1 c P4
V3
= 1− = 1−
Vs Vs
1
V4 P4 n
3 3 = PV
PV n
4 4
n
=
V3 P3
1
V 2 n − 1
P
c P1
ηvol = 1 − ∴ P3 = P2 ; P4 = P1
Vs
1
Vc P2 n
= 1− − 1
Vs P1
1
= 1 − K − 1
P n
ηvol 2
P1
Vc
Where K = = Clearance Ratio
Vs
4.6. ISOTHERMAL EFFICIENCY: PV = C
P 2’
3 2
P2
PVn =C
PV =C
P1 4 1
’
V2 V1 V
n −1 P1
P
log e 2
η Iso = P1
n −1
n P2 n
− 1
n − 1 P1
Following are the main advantages of multistage compression over single stage
compression:
(i) The work done per Kg of air is reduced in Multistage compression with
intercooling as compared to single stage compression for the same
delivery
pressure.
(ii) It improves the volumetric efficiency for the given pressure ratio.
(iii) The size of the cylinders may be adjusted to suit the volume and pressure
of
the air.
(iv) It reduces the leakage loss considerably.
(v) It gives more uniform torque, and hence a smaller size flywheel is
required.
(vi) It provides effective lubrication because of lower temperature range.
(vii) It reduces the cost of compressor.
1
= 1 − K − 1
P n
ηVol 2
P1
P
For fixed clearance and η the ηVol decreases with increase in 2 (i.e) Pressure Ratio.
P1
ie
V
ηVol = a
Vs
P
ie 2 increases ηVol decrease.
P1
This means thatVa decreases withincreas in pressure ratio
Consider a two stage air compressor with different ‘n’ and imperfect inter cooling.
n1 −1
n2 −1
n1
− 1
P n1 n P n2
WD/Kg = −1 +
n1 − 1 1 P1 n2 − 1 3 P2
2 2 3
RT RT
P3 and P1 are fixed. Hence P2 should be determined for maximum work requirement.
dw
The Condition for maximum work is =0
dP2
4
P3
2
P2
3
P1 1
n1 −1
n2 −1
d n1 P n1
n P n2
i.e. RT1 − 1 +
2 2
RT3 3
−1 = 0 -------------- (1)
P n −1 P
dP2 n1 − 1 1 2 2
n1 − 1 n2 − 1
Let =x =y
n1 n2
d 1 P x 1 P y
RT1 − 1 + RT3 − 1 = 0
2 3
1 2
dP2 x P y P
1 P2 1 P y
x
d
T1 − 1 + T3 − 1 = 0
3
1 2
dP2 x P y P
1 xP2 x −1 1 − y −1
T1 x
+ T3 P3 y (− y ) P2( ) = 0
x P1 y
P2 x −1 P3 y
T1 x − T3 ( y +1) = 0
P1 P2
P2 x −1 P3 y
T1 = T
P2 ( )
3 y +1
P1 x
T3 y y
P2 x −1 P2( y +1) = P3 P1
T1
T3 x y
P2( x + y ) = P1 P3
T1
1
T x+ y
∴ P2 = 3 ( P1 x P3 y ) x + y
1
------
T1
(2)
n1 = n2; x=y
1
T 2x
(2) ⇒∴ P2 = 3 ( P1 x P3 x ) 2 x
1
T1
1
T 2x 1
P2 = 3 ( PP
1 3 ) 2
T1
1
If T3 = T1; (Perfect Inter cooling) P2 = ( PP
1 3) =
2 P1 P3 ---------------- (3)
This is the condition for minimum work required to run the compressor.
P2 2 = P1 P3
P2 P3
(i.e.) = = C (Pressure Ratio is constant)
P1 P2
P2 P3 P4 P P
If there are N stages, = = = ........ N = N +1 = C --------------- (4)
P1 P2 P3 PN −1 PN
From (4) We get PN +1 = PN C
1
PN +1 P N
i.e. = CN ∴ C = N +1
P1 P1
1
P2 PN +1 N
= --------------------- (5)
P1 P1
4.8.1. Minimum Work Required with Perfect Inter Cooling and Same Index of
Compression:
n1 −1
n2 −1
n1
− 1
P n1 n P n2
WD/Kg = −1 +
n − 1 1 P n − 1 3 P
2 2 3
RT RT
1 2
1 2
n −1
n −1
n P n
n P n
RT1 − 1 + RT1 − 1
2 2
=
n − 1 1
P n − 1 1
P
P2 P3
Qn1 = n2 and T3 = T1 ; =
P1 P2
n −1
WD = 2 n RT P2 − 1
n
1
--------------- (6)
kg n −1
1
P
n −1
n P n
There are n stages, minimum WD =N RT1 − 1
2
--------------- (7)
kg n − 1 1
P
1
P P N
But we know that 2 = N +1 from (5)
P1 P1
n −1
n
N +1
− 1
P Nn
∴(7) ⇒ WD = N RT1 P1
-------------- (8)
kg n −1
Pm LAN
I .P. =
60
Where, Pm = Mean Effective Pressure in N/m2
L = Stroke in m
π D2
A = Area of the piston in m2
4
N = speed in rpm
P LAN
For double acting I .P. = 2 m
60
n −1
− 1
n P n
WD =
cycle n − 1 1 a P
2
PV
1
n −1
n P2 n
Pm × Vs = PV 1 a − 1
n −1
1
P
n −1
n Va P2 n
Pm = P1 − 1
n − 1 Vs P1
n −1
P2 n
P1ηvol − 1
n
Pm =
n −1 P1
a
Pm = × S
l
Where, a = area of the indicator diagram
l = length of the indicator diagram
S = Spring constant
Indicated power can also be calculated using the relation
n −1
n P2 n RPM
I .P = 1 a
PV − 1
n −1
1
P 60
For multi stage compression with N stages
n −1
− 1
n P Nn
RPM
I .P = N 1 a
PV N +1
n −1 P1 60
4.10. MECHANICAL EFFICIENCY:
I .P I .P
ηM = =
B.P ShaftWork
T2
TW2 T3
TW1
T3
T2
Tw1
Tw2
T2 − T3
ε=
T2 − T1
Following are the main points of comparison of reciprocating and rotary air compressor:
2. The maximum free air discharge is about The maximum free air discharge is
300 m3/min. as high as 3000 m3/min.
3. They are suitable for low discharge of air at They are suitable for large
very high pressure . discharge of air at low pressure .
Though there are many types of rotary air compressors, yet the following are
important types:
The first two compressors are popularly known as Positive displacement compressor,
whereas the last two as Non- Positive displacement compressor.
Following are the main points of comparison of the centrifugal and axial flow air compressors:
2. It has low manufacturing and running It has high manufacturing and running
cost. cost.
3.
It requires low starting torque. It requires high starting torque.
4.
It is not suitable for multi- staging It is suitable for multi- staging
5.
It requires large frontal area for a given It requires less frontal area for a given
rate of flow. rate of flow. It makes the compressor
suitable for air crafts.