Compressors , Fans &

Blowers

INTRODUCTION

The main use of the fans, compressors and

blowers is the transportation of gases
The main item of most processes is the
compressor selection
There are wide variety of compressors so
it is crucial to define the operating
conditions before selection

Major Factors During Selection

Head or Pressure Rise

Flow Rate
Temperature Limitations
Consumption of Power
Cost

The pressure rise which is the main difference

between fans, compressors and blowers can be
stated as follows:
P(psig)
Fans
Blowers
Compressors

2
2-10
>10

Compressors & Gas Compression

Categories and Types

Compression Process
Compressor Characteristics
Key Design Parameters
Calculation Methods
Specification Data Sheet
Selection Guidelines
Control Systems
Typical operating Problems

Compressor Application and

Classification

Compressors are used in a variety of applications

Example: In natural gas plants, compressors are

used to
establish feed gas process pressures. Compressors
also provide
clean, dry air for instruments and control devices
In a refinery or chemical plant, compressors are
used to
compress gases such as light hydrocarbons,
nitrogen,
hydrogen, carbon dioxide, and chlorine
These gases are sent to headers, from which they

Classification of Compressors
There are three basic designs for compressors :
i) Dynamic
ii) Positive displacement
iii) Thermal.
Dynamic compressors include centrifugal (radial
flow) and
axial (straight-line) flow compressors.
Dynamic compressors accelerate airflow by
drawing air in
axially and spinning it outward (centrifugal
compressors) or in
a straight line (axial flow compressors).

 Positive displacement compressors include rotary

and
reciprocating compressors.
Positive displacement compressors compress gas
into a smaller
volume and discharge it at higher pressures.
Thermal compressors use ejectors to direct highvelocity gas or
steam into the process stream, entraining the gas,
then
converting the velocity into pressure in a diffuser

Compressors Family Tree

Compressors & Gas Compression

Categories and Types

The principles of compression

are:

Gases and vapors are compressible.

Compression decreases volume.
Compression moves gas molecules close
together.
Compressed gases will resume their original
shape when released.
Compressed gases produce heat because of
molecular
friction.
The smaller the volume, the higher the
pressure.
Force area = Pressure.
Gas volume varies with temperature and
pressure.
Liquids and solids are not compressible

Dynamic Compressors
@ Centrifugal Compressor

Gas enters a centrifugal compressor at the

suction inlet and is accelerated radially by moving
impellers.
Centrifugal compressors have one moving
element, the drive shaft and impeller.
The impeller discharges into a circular, narrow
chamber called the diffuser
More sensitive to density and fluid
characteristics
Designed to operate at speeds in excess of
3000 rpm
Can be single stage or multistage
Single stage designed for high gas flow rates
and low discharge pressure
Multi stage designed for high gas flow rates
and high discharge pressure

The advantages of centrifugal compressors can be

classified as;

They are more efficient than reciprocating ones

They provide high flowrates
They are compact, less site area
They need lower maintainance requirements
They are tolerant to liquid carry

Centrifugal Compressor

Compressors & Gas Compression

Centrifugal Compressor

Single-stage Centrifugal Compressor

Multi-stage Centrifugal Compressor

Dynamic Compressors
@ Axial Flow Compressor

Normally used for jobs where highest flow and

pressure
required
Request twice as many stages as centrifugal
perform (8% to 10%)
Primary application of axial compressors
involves transfer of clean gas such as air
Internal component are sensitive to corrosion,
pitting and deposits
More lighter, more efficient and smaller than
centrifugal pumps
Main purpose is in gas turbine applications

The advantages of axial compressors

-

They have higher efficiency

They have higher capacity (flow rate)
They are in smaller size

The disadvantages of axial compressors

-

They limited operating range

They are more subjected to corrosion
They are subjected to deposits
They have higher capital costs
They have lower heads

Axial Flow Compressor

Compressors & Gas Compression

Axial Compressor

Combined Axial and Radial

Compressor Applications

They have flow rates ranging from 50,000 to 690,000m3/hr

They have pressure ratio ranging from 5.8 to 12.5

POSITIVE DISPLACEMENT COMPRESSORS

Positive Displacement Compressors

Reciprocating Compressors

Rotary Compressors

RECIPROCATING COMPRESSORS

They are the oldest type of compressors

They have higher maintainance costs and lower capacity
than dynamic compressors
They are widely used in industry
They have cylinders which are equipped with suction
and delivery valves
Compression cycle is composed of 3 cycles which are
intake, compression and discharge

They intake gas by the help of cylinders

The pistons motion is reversed and the gas which
taken in is compressed
The gas is expelled during the delivery stroke

In multistage reciprocating compressors;

The gas is compressed to an intermediate pressure

The other cylinders raise the pressure to the end
pressure
There also exist intercoolers

Positive Displacement Compressors

@ Reciprocating piston Compressor

Work by tapping and compressing specific

amount of gas
between a piston and cylinder
wall
The back and forth motion incorporated by a
reciprocating compressor pull gas on the suction
and discharge on the other
Spring loaded suction and discharge valves
work automatically as piston moves up and
down
Have a flexible pressure range and overall
capacity, low power cost high efficiency rating

Reciprocating Piston Compressor

ROTARY COMPRESSORS

The two rotating components confine a volume

of gas
The volume of the pocket decreases in rotation
so pressure increases

The rotary compressors have high range of

capacity and compression ratio
The rotary compressors are classified as; Lobed,
Helical Screw, Sliding Vane

Positive Displacement Compressors

@ Rotary Compressor (Sliding Vane)

Use off center rotor with sliding vane to

compress gases
body (cast iron or steel), rotor and shaft ( high
strength alloy steel), sliding vanes (asbestosphenolic resin, metal)
Does not use suction or discharge valve
because it is

 Positive Displacement
Compressors
@ Rotary Compressor
(Lobe)
Characterized by the two
kidney bean shape
impellers
Used to trap and transfer
gases
Two impellers move on
opposite direction during
operation
Designed to have
constant volume discharge
pressure and constant
speed drives

Positive Displacement Compressors

@ Rotary Compressor (Liquid Ring)

Unusual compressor design (combines centrifugal
action, with positive displacement and rotary action)
May be found in the following application :
Hazardous gases
Toxic gases
Hot gases and vapor

Screw Compressor

HELICAL SCREW COMPRESSORS

There are mainly two screws which are called

male and female
The gas is compressed between the lobes of the
screw and move along the axis to an outlet port

These units can be; oil flooded and dry

The contamination of oil is prevented by
dry compressors
Oil flooded units are used in refrigeration
systems and plant air service

FANS & BLOWERS

Blower and Fans

Simple devices typically classified as compressors
two basic design (axial flow and centrifugal flow)
mostly are single stage devices.
- centrifugal blower (low pressure air systems,
refrigeration unit or laboratory hoods)
- fan (direct airflow into or out of ind.
equipment such as cooling tower, boilers or HVAC
system)
centrifugal fan to move gases over a wide range
of conditions

FANS

They are the air displacement systems

moving air continuously to moderate
pressures
Due to little change in pressure of air in
fans, air is considered to be
incompressible
They can have pressure rise up to 2 psig.

The characteristics of fans can be

classified as;

The volumetric flowrate of the gas displaced by

the fan is directly proportional with the fan speed
The static pressure varies with the square of the
fan speed
The power consumed varies with the cube of the
fan speed

FANS

Axial

Tube

Centrifugal

Vane

Radial Forward Backward Air Foil

Blade Curved Curved

AXIAL FANS
Gas moves parallel to the axis of rotation

There are two types of axial fans;

Tube axial fans
Vane axial fans

Tube axial fans are used for wide range of

volumes at medium pressure

In vane axial fans there is air guide vane on the

discharge side and the air flow pattern is a straight
line hence improvement in efficiency and
reducement in turbulance is observed

CENTRIFUGAL FANS

Gas stream moves

perpendicular to the axis of
rotation
They are classified as; radial
blade, forward curved,
backward curved and air foil

wheel

RADIAL BLADE
CENTRIFUGAL FANS

They are used for pneumatic

transportation and exhausting process
gas in high resistance systems
With relatively low capacity, they can
achive high static pressure
They can develop high pressures with
high speeds
Blades clean themselves
They are not used for ventilating
purposes

FORWARD CURVED
CENTRIFUGAL FANS

They discharge higher

volume of air at slower fan
speeds

They operate with a moderate

amount of noise

They require little space

They are used for clean gases

BACKWARD CURVED
CENTRIFUGAL FANS

They develop much of their

energy directly as pressure

They develop less velocity

heads by operating at
medium speeds

Small variations in system

volume result in small
variations in air pressure

AIR FOIL CENTRIFUGAL FANS

They are backward

curved centrifugal fans
with an air foil cross
section

They can operate more

silently since air forms no
turbulance while flowing
through the wheels

BLOWERS

Blowers are used for supplying low

pressure air up to between 2-10
psig.
They consist of two parallel shaft
rotors
They may have 2 4 lobes
The rotating shaft in the constitution
of the blower traps some gas
The compression of the gas in the
blower is negligible

Blowers

They are used for;

-

Pneumatic transportation of particulate material

Water and waste treatment

Providing moderate vacuum

Compressors & Gas Compression

Ranges of Application

Compressors & Gas Compression

Compression Process

Gas compression is a thermodynamic process where change

takes place in the physical state of the gas

Compression adds energy to the gas resulting in pressurevolume changes defined by ideal gas laws

Compression take place under conditions defined:

Adiabatic: no heat added or removed from systems
Isothermal: constant temperature in system
Polytropic: heat added or removed from system

Compression of real gases in actual compressors deviate

from conformance with ideality, usually significantly,
affecting compressor design.

Compressors & Gas Compression

Compressor Characteristics

Capacity/Head
Performance
Terminology

Compressors & Gas Compression

Reciprocating Compressor

Performance Diagram
Terminology

Piston Displacement
Clearance Volume
Volumetric Efficiency
Pressure Ratio
Rod Loading

Compressors & Gas Compression

Reciprocating Compressor

Compressors & Gas Compression

Reciprocating Compressor

Compressors & Gas Compression

Centrifugal Compressor

Performance Curves
Terminology

Operating Point
Surge Point
Stonewall
Stability
Turndown

Compressors & Gas Compression

Centrifugal Compressor

Compressors & Gas Compression

Centrifugal Compressor

Compressors & Gas Compression

Centrifugal Compressor Performance

Compressors & Gas Compression

Centrifugal Compressor
Key Design Parameters

Capacity
Gas Properties
Pressure Head
Power
Efficiency
Multi-Stages

Compressors & Gas Compression

Centrifugal Compressor
Key Design Parameters

Capacity
Flow Rates

Normal
Maximum
Minimum

Design Capacity

Compressors & Gas Compression

Centrifugal Compressor
Key Design Parameters

Gas Properties

Composition
Contaminants
Molecular Weight MW
Specific Heat Ratio Cp/Cv
Compressibility

Compressors & Gas Compression

Centrifugal Compressor

10C
38C
66C
93C
121C

Compressors & Gas Compression

Centrifugal Compressor

Compressors & Gas Compression

Centrifugal Compressor

Compressors & Gas Compression

Centrifugal Compressor

100F = 560R: 560/549 = 1.02

100F = 311K, 549R = 305K: 311/305 = 1.02

PV = ZmRT/MW
P=100psia = 6.89 bar a
T=100F = 37.8C = 310.9K
= m/V = P(MW)/(ZRT)
= 6.89E5x34.27/(0.946x8314x310.9)
= 9.7kg/m3
= 0.61lb/ft3

Compressors & Gas Compression

Centrifugal Compressor

0.077

1.02
0.973

Compressors & Gas Compression

Centrifugal Compressor

0.88

Compressors & Gas Compression

Centrifugal Compressor
Key Design Parameters

Head
Available vs. Required Head
Available Head is Compressor Related
H(Available) = CV2/g
C = Pressure Coefficient (0.55)

Required head is System-Related

Z 1545 .T1 P2

H(Required)
( MW )( M ) P1

K 1

M is Compressio n Path Parameter

K Specific Heat Ratio C P / CV
Eh is Hydraulic Efficiency

Eh

Compressors & Gas Compression

Centrifugal Compressor

Horsepower Calculation
For centrifugal compressors the following
method is normally used:
First, the required head is calculated.
Either the polytropic or adiabatic efficiency
is used with the companion head.
H poly
H AD

( N 1) / N

P2
ZRT1

1
( N 1) /( N ) P1

( K 1) / K

ZRT1
P2

1
( K 1) / K P1

Compressors & Gas Compression

Centrifugal Compressor

Horsepower Calculation
H poly

ZRT1

( N 1) /( N )

H AD

ZRT1

( K 1) / K

P2

P
1

P
2
P1

( N 1) / N

( K 1) / K

Where:
Z
=
Average compressibility factor: using 1 will yield
conservative results
R
= 1544/(mol weight)
T1
= Suction Temperature, R
P1, P2
= Suction, discharge pressures, psia
K
= Adiabatic exponent, (N-1)/N = (K-1)/(KEp)
Ep
= Polytropic Efficiency
EA
= Adiabatic Efficiency

Compressors & Gas Compression

Centrifugal Compressor

Horsepower Calculation
The polytropic and adiabatic efficiencies are related as follows:
P ( K 1) / K P ( K 1) / K

2
2

1
1
P
P

E A 1 ( N 1) / N 1 ( K 1) / KE

P2

1 2
1
P1
P1

From Polytropic Head:

From Adiabatic Head:

HP = WHpoly/(Ep 33000)

HP = WHAD/(EA 33000)

BHP = HP/Em
Where:
HP = Gas Horse Power
BHP = Brake Horsepower
W = Flow, Lb/min

Compressors & Gas Compression

Efficiency

Hydraulic Efficiency
Adiabatic
Polytropic
Volumetric Efficiency
Reciprocating
Mechanical Efficiency
Drivers

Compressors & Gas Compression

Centrifugal Compressor
Approximate polytropic efficiencies for centrifugal and axial compressors

Compressors & Gas Compression

Temperature Rise
Temperature ratio across a compression stage is:
T2/T1 = (P2/P1)(K-1)/K

Adiabatic

T2/T1 = (P2/P1)(N-1)/N

Polytropic

Where:
K = Adiabatic exponent, Cp/Cv
N= Polytropic exponent, (N-1)/N = (K-1)/KEp
P1, P2 = Suction, discharge pressures, psia
T1, T2 = Suction, discharge temperatures, R
Ep = Polytropic efficiency, fraction

Compressors & Gas Compression

Temperature Rise
The usual centrifugal compressor is uncooled internally and
follows a polytropic path.
Temperature must often be limited to:
Protect against polymerization as in olefin or butadiene
plants
At T > 230-260C, the approximate mechanical limit,
problems of sealing and casing growth start to occur.
High temperature requires a special and more costly machine.
Most multistage applications are designed to stay below 250300C

Compressors & Gas Compression

Temperature Rise
Intercooling can be used to hold desired temperatures for high
overall compression ratio applications.
This can be done between stages in a single compressor frame or
between series frames.
Sometimes economics rather than a temperature limit dictate
intercooling.
Sometimes for high compression ratios, the job cannot be done
in one frame. Usually a frame will not contain more than 8 stages
(wheels). For many applications the compression ratio across a
frame is about 2.5 4.0
The maximum head that one stage can handle depends on gas
properties and inlet temperature. Usually this is about 2000 to
3400m for a single stage.

Compressors & Gas Compression

Surge Controls
A centrifugal compressor surges at certain conditions of low
flow.
Surge control help the machine to avoid surge by increasing flow.
For an air compressor, a simple spill to atmosphere is
sufficient.
For a hydrocarbon compressor, recirculation from discharge
to suction is used.

Compressors & Gas Compression

Surge Controls
There are many types of surge controls.
Avoid the low-budget systems with a narrow effective range,
especially for large compressors.
Good systems include the flow/P type.
The correct flow to use is the compressor suction. However, a
flow element in the suction can rob excessive horsepower.
Therefore, sometimes the discharge flow is measured and the
suction flow calculated within the controller by using pressure
measurements. The compressor intake nozzle is also sometimes
calibrated and used as a flow element.

Compressors & Gas Compression

Compressor Calculation Method

Define gas properties: MW, Cp/Cv, Z 1

Define inlet conditions: Temp & Press.
Calculate gas flow rate: Normal and Design 1
Establish total discharge pressure.
Calculate compression ratio and number of stages
Define selection & polytropic efficiency
1. At inlet conditions

Compressors & Gas Compression

Compressor Calculation Method

contd

Calculate heat capacity factor M

Calculate required polytropic head
Calculate hydraulic gas horsepower
Calculate discharge temperature
Calculate total brake horsepower
Estimate inter-stage cooling requirement

Compressors & Gas Compression

Compressor Calculation Example 1:
Calculate compressor required to handle a process gas at the
following operating conditions: Inlet press and temp at 20 psia
and 40F. Discharge pressure of 100 psia. Gas rate 2378
lb.mol/hr of the following composition and calculated
properties:

Ethane

Mol% Mol/h Mol.

Wt
2
48
30.1

Cp

Tc

Pc

0.60

11.96

0.24

550

11

708

14

15.70 666

633

617

587

23

551

17

Propane 95

2259

44.1

41.9

16.55

Butane

71

58.1

1.74

22.50 0.68

Total

100

2378

44.24

16.62

766

667

618

Compressors & Gas Compression

Compressor Calculation Example 1:

contd

Calculation:
Inlet flow:
Weight flow = 2378 x 44.24/60 = 1753 lb/min
Pr = 20/618 = 0.0324, Tr = (40+460)/667 = 0.75
Compressibility factor Z = 0.97 (from generalized Z chart)
Density = (MW x P1)/(10.73 x T1 x Z)
= (44.24 x 20)/(10.73 x (40 + 460) x 0.97)
= 0.17 lb/cu.ft
Inlet volume = 1753/0.17 = 10 310 cu.ft/min

Compressors & Gas Compression

Compressor Calculation Example 1:

contd

Calculation:
Heat Capacity Factor
k = Cp/Cv = Cp/(Cp 1.99) = 16.62/(16.62 1.99) = 1.137
M = (k-1)/(kEp)
Assume Ep = 77%:
M = (1.137 1)/(1.137 x 0.77) = 0.156

Compressors & Gas Compression

Compressor Calculation Example 1:

contd

Calculation:
Polytropic Head, Hp

H poly

ZRT1 P2

M P1

= 0.97 x (1545/44.24) x (40 + 460)/0.156 x [(100/20)0.156 -1]

= 30 988 ft

Compressors & Gas Compression

Compressor Calculation Example 1:

contd

Calculation:
Discharge Temperature, T2
T2 = T1(P2/P1)M
= 500(5)0.156
= 643R
= 183F
Gas Horsepower (GHP) & Brake Horespower (BHP)
GHP = W . Hpoly/(33000Ep)
= 1753 x 30988/(33000 x 0.77)
= 2140
BHP = 2140/0.98 = 2180 (Assume Mechanical Eff. = 98%)

Compressors & Gas Compression

Example

Calculate the Brake Horsepower for the following Compressor:

Compressors & Gas Compression

Example

Calculate the Brake Horsepower for the following Compressor:

Calculate Gas Mixture Properties

Composition:

Composition
Hydrogen
Nitrogen
Total Gas Mix

H2 = 65.6/(65.6+21.4) = 75.4 vol%

N2 = 100 75.4 = 24.6 vol%
Mole%
75.4
24.6
100.0

Mole Wt
2
28

MW
1.51
6.89
8.40

mass%
18.0
82

Use Z = 1 for conservative results

Cp
14.3
1.04
11.04

MW
2.57
0.85
3.42

Compressors & Gas Compression

Example

Calculate the Brake Horsepower for Compressor: Contd

Lets look at the first stage:

First calculate Polytropic Head:
H poly

ZRT1

( N 1) /( N )

P2

P
1

( N 1) / N

T2/T1

= (P2/P1)(N-1)/N

ln(T2/T1)

= (N-1)/N ln(P2/P1)

(N-1)/N

= ln(T2/T1)/ln(P2/P1)

T1 = 22C = 295K
T2 = 99C = 372K
P1 = 2418 kPag = 2518 kPa a
P2 = 4300 kPag = 4400 kPa a

= ln(372/295)/ln(4400/2518)
= 0.416
Hpoly

= 1 x (8.314/8.4) x 295 x ((4400/2518)0.416 -1)

0.416
= 183.4 kJ/kg

Compressors & Gas Compression

Example

Calculate the Brake Horsepower for Compressor: Contd

First stage:
Cp/Cv

= Cp/(Cp-R)
= 3.42/(3.42-8.314/8.4)
= 1.4

(N-1)/N

= (K-1)/(KEp)

Ep

= (1.4 -1)/(1.4 x 0.416)

= 0.69

W = (107 000/22.414) x 8.4 = 40100kg/h = 11.14 kg/s

Compressors & Gas Compression

Example

Calculate the Brake Horsepower for Compressor: Contd

First stage:
Gas Horsepower

= W . Hpoly/Ep
= (11.14 x 183.4)/0.69
= 2960 kJ/s
= 3.0 MW

Similar for stage 2, 3 and Recycle:

GHP(stage 2) = 2.9MW
GHP(stage 3) = 3.3 MW
GHP(recycle stage) = 1.0 MW
Total GHP = 3.0 + 2.9 + 3.3 + 1.0 = 10.2 MW
A good assumption for Mechanical Efficiency = 95%
BHP = 10.2/0.95 = 10.6 MW

Compressors & Gas Compression

Compressors & Gas Compression

Supporting Equipment in a Compressor System

Supporting Equipment in a Compressor System

Intercooler and after cooler heat exchanger

- compression of gases create heat in compressor
- control high temperature
- intercooler lower the temperature as gas is discharge
out of first stage of compressor
- as the gas is compressed (create more heat),
discharge
into after cooler before go to receiver
Safety valve
- used to relieve excess pressure that could damage
operating
equipment
- sized to handle specific flow rates

Supporting Equipment in a Compressor System

(cont.)

Silencers
- most compressor exceed OSHA standards noise pollution
- muffle some of the damaging noise produced by compressor
- should be mounted on the inlet and outlet of a compressor
Demister
- designed to remove liquid droplets from gas
- function as a cyclone
- heavier component fall to the bottom of the demister and
removed
- clean gas escapes out the discharge line on the top of the
demister
Dryer
- for dry air service, discharge of a compressor is run through
a dryer
- filled with moisture adsorbing chemicals called desiccant dryer
(alumina, mol sieves and silica gel)
- operation uses parallel or series dryer

Compressor system

Start up and shutdown a dynamic

compressor

Start up and shutdown a positive displacement compressor

Troubleshooting a centrifugal compressor

Troubleshooting a reciprocating compressor

Compressor Symbols

CONCLUSIONS

The fans have wide range of flowrate

The material selection is important during
manufacturing fans
The blowers have low power and pressure
applications
The blower is less efficient method of
compression

CONCLUSIONS

The centrifugals are tolerant to liquid carry

The liquid with the gas can cause erosion and
severe damage in centrifugals
In axial equipment, high compression efficiency
is observed
The axial equipment is applied for high flow
andlow discharge pressures

CONCLUSIONS

The reciprocating systems are applicable for low flow rate

of high pressure ratio
The oil contamination is important in reciprocating systems
The reciprocating systems have higher maintainance cost
The reciprocating systems are not suited to dirty gasses
The process gases that are taken in should be clean and dry
in axial equipments
The reciprocating systems are not tolerate liquid droplets in
the suction flow

CONCLUSIONS

The screw compressor have higher initial cost

than reciprocating compressors for the same duty
The sliding vane compressors have low pressure
applications
The sliding vane compressors operate at low
speeds
The noise level of the sliding vane compressors
is low