Compressors

Types, principles and applications

By:
Eng. Bassem Abdellatif Eleaba
Overview
Introduction
A gas compressor is a mechanical device that increases the pressure of a gas by
reducing its volume.

As gases are compressible, the compressor also reduces the volume of a gas.

In some cases, high pressure is needed in order to liquefy a gas. This is often
carried out to greatly decrease the volume of the gas to allow storage and
transportation of the liquids to anywhere in the world.

Compressors are similar to pumps:

• Both increase the pressure on a fluid.
• Both can transport the fluid through a pipe.
Types of Compressors
Difference between fan, blower and compressor

The pressure rise ΔP(psig) which is the main difference between fans,

compressors and blowers can be stated as follows:

Fans 2 psig

Blowers 2-10 psig

Compressors >10 psig

Overview
Types of Compressors

Video
Overview
Basic Theory of Compressing Air
The air we breathe has two major constituents. They are Nitrogen and
Oxygen. The approximate composition of atmospheric air has 78% nitrogen,
21% oxygen and 1% other gases by volume and 76% nitrogen, 23% oxygen and
1% other gases by weight.
Even though air is not a “perfect” gas, the presence of nitrogen and oxygen in
major proportion makes it obey very closely to a “perfect” or “ideal” gas. We
all know that an “Ideal” gas obeys some laws. They are
Boyle’s law (PV=C).
Charles’s law (V/T = C).
The above two laws can be combined to form a combination law which can be
represented as
PV/T = C.
Overview
Basic Theory of Compressing Air

Charles’s law Boyle’s law

V/T = C PV=C
Overview
Overview

Comparison of Head Capacity characterstic curves

for most common compressors
Overview

General performance curve for axial-flow, centrifugal, and positive

displacement compressors
 Part I
Rotodynamic
compressors
Centrifugal Compressors
 Centrifugal compressors

• Widespread use, many applications

• Gas is accelerated outwards by rotating impeller

• Can be built for operation as low as 5 psi, or operation as high as 8,000 psi

(35 kPa or 55,000 kPa)

• Sizes range from 300 hp to 50,000 hp

 Centrifugal compressors

Centrifugal & Centripetal Forces

Consider a ball attached to a bar

which is able to rotate on a shaft.

 Centrifugal compressors

Centrifugal & Centripetal Forces

The ball is applying a 'Centrifugal'

force and the string is applying a

'Centripetal' force - (pulling-in-

towards-the-centre) - that causes the

path of the ball to change or curve.

Should the string break, the ball will

fly off in a straight line.

 Centrifugal compressors

Centrifugal Compressor Principle

 Centrifugal compressors

Centrifugal Compressor Principle

THE COMPRESSING ACTION CONSISTS OF TAKING A QUANTITY OF AIR AND
FORCING IT INTO A SMALLER AND SMALLER SPACE

THIS SQUARE REPRESENTS A

QUANTITY OF AIR

THIS SQUARE REPRESENTS THE SAME QUANTITY OF AIR

BUT SQUEEZED INTO A SMALLER VOLUME

LET’S SEE HOW THIS IS DONE

COMPRESSOR OPERATION
 SQUEEZE

PUSH BACK

COMPRESSOR OPERATION
 SQUEEZE

PUSH BACK
 SQUEEZE

PUSH BACK

COMPRESSOR OPERATION
 SQUEEZE

PUSH BACK

COMPRESSOR OPERATION
BIG AT FRONT SMALL AT REAR

THIS IS WHY COMPRESSORS ARE SHAPED

THE WAY THEY ARE

COMPRESSOR OPERATION
FRONT REAR

COMPRESSORS HAVE A SERIES OF ‘STAGES’

EACH STAGE GIVES A SMALL PRESSURE RISE
OVER THE PREVIOUS STAGE

COMPRESSOR OPERATION
 FIRST
STAGE SECOND
THIRD
STAGE
STAGE FOURTH
STAGE FIFTH
STAGE
STATORS

STATORS
STATOR

STATOR
ROTOR

ROTOR

STATORS
STATOR

STATORS
ROTOR

STATOR
ROTOR

STATORS
ROTOR

STATOR
FRONT REAR
FRONT REAR

EACH STAGE CONSISTS OF A ‘ROTOR BLADE’ IN

FRONT OF A ‘STATOR VANE’

ROTOR BLADE ROTATE LIKE PROPELLOR BLADES

STATOR VANES ARE FIXED TO THE ENGINE CASING

COMPRESSOR OPERATION
FRONT REAR

COMPRESSOR ROTOR BLADES DO THE PUSHING

BACK

COMPRESSOR OPERATION
FRONT REAR

COMPRESSOR STATORS VANES DO THE SQUEEZING

I.E. COMPRESSING

COMPRESSOR OPERATION
WHENEVER AIR IS FORCED INTO A SMALLER SPACE TWO THINGS HAPPEN

FIRST:- THE PRESSURE OF THE TRAPPED AIR INCREASES

SECOND:- THE TEMPERATURE OF THE TRAPPED AIR ALSO INCREASES

YOU CAN PROVE THESE TWO EFFECTS WITH A BICYCLE PUMP!

IN A JET ENGINE COMPRESSOR, IT IS A CONSTANT FLOW OF AIR

CONSTANTLY BEING COMPRESSED.

COMPRESSOR OPERATION
 Centrifugal compressors

Centrifugal Compressor Principle

They use the rotating action of an impeller wheel to exert centrifugal force on gas
inside a round chamber (volute).

Gas is sucked into the impeller wheel through a large circular intake and flows
between the impellers.

The impellers force the gas outward, exerting centrifugal force on it.

The gas is pressurized as it is forced

against the sides of the volute.

Centrifugal compressors are desirable for

their simple design and few moving parts.
 Centrifugal compressors

Centrifugal Compressor Parts

A centrifugal compressor is built up of two main parts :

•THE ROTOR (or rotating element)

•THE CASING (or housing or body)

Video
 Centrifugal compressors

Centrifugal Compressor ROTOR

The Rotor is made up of one or more impellers mounted onto a shaft.

A compressor having a single impeller is called a 'Single-stage' machine. This type is

generally used as a 'Blower' or 'Fan', due to the small increase in pressure of air or

gas across the single wheel

 Centrifugal compressors

Centrifugal Compressor ROTOR

 Centrifugal compressors

Centrifugal Compressor Impeller

These consist of wheel-shaped elements containing 'Vanes' at the centre of which is the

gas inlet called the 'EYE' of the impeller.

The impeller is mounted on the shaft which is connected to the driver.

The speed of rotation of the wheel imparts

kinetic energy to the gas in the form of velocity

which will be converted to pressure (potential)

energy.
 Centrifugal compressors

Centrifugal Compressor Impeller Types

OPEN – Built with the blades in a radial direction no enclosing covers on either the front
or backsides (normally found in superchargers).

SEMI-CLOSED – Built with the blades in a radial direction with an enclosing cover on the
backside which extends to the periphery of the blade (normally found in air
compressors).

CLOSED – Built with backward or forward leaning blades and has enclosing covers on
both the front and backside (normally found in multi-stage centrifugal compressors). R-
R uses closed impellers.
 Centrifugal compressors

Centrifugal Compressor ROTOR

•Through a multi-stage compressor, the pressure is built up from stage to stage and,

as it increases, the volume of the gas decreases.

•Because of the volume decrease after each stage, the wheels become progressively

narrower and, after the final stage the

gas is passed into the discharge line.

•Again, due to increased pressure and

decreased volume, the discharge line

has a smaller diameter than the suction line

 Centrifugal compressors

Centrifugal Compressor CASING

•The casing houses the rotor and other components.

There are two types of casing

1. Horizontal Split 2. Vertical Split

Cross section of Horizontal Split

Discharge volutes Impeller inlet

labyrinth seals
Impellers
Shaft and
Drive coupling labyrinth seal

Journal bearing

Casing Thrust bearing

(horizontally split
flange) Compressor
discharge nozzle

Compressor
Picture of Horizontal Split
Picture of Horizontal Split
 Cross section of Vertical Split Compresor

•It is also called as barrel type compressors.

•It is a mandatory design for high pressures or for compressing

gases rich in hydrogen.

•The cylindrical casing ensures good stress

distribution and extremely good gas tightness.

•Unlike casing the seal components

are horizontally split.

 Picture Of Barrel Type Compressor

•During assembly of the compressor they are mounted together with

the rotor and inserted axially in to the casing.
•Normally the end covers are retained by shear ring segments.
•This is for to avoid the casing damage in case of rotor shifting axially
or pressure build up inside
the compressor due to
variation in gas compositions.
 Centrifugal compressors

Centrifugal Compressor Casing Diaphragms

•These separate the stages (wheels) of the rotor.

•Between each stage and the shaft, the diaphragms are fitted with

labyrinth seals in order to minimize leakage between the stages.

• They also hold the 'DIFFUSERS'.

 Centrifugal compressors

Centrifugal Compressor Casing Diaphragms

•These separate the stages (wheels) of the rotor.

•Between each stage and the shaft, the diaphragms are fitted with

labyrinth seals in order to minimize leakage between the stages.

• They also hold the 'DIFFUSERS'.

 Centrifugal compressors

Centrifugal Compressor Labyrinth Seal

•A labyrinth seal is a type of mechanical seal that provides a

tortuous path to help prevent leakage

Centrifugal Compressor Surging
 Surge Description

• 'Surging' is defined as 'A momentary back-flow' through the

compressor from the discharge to the suction.
• This can occur when the mass flow of gas to the compressor falls
below a critical level with a high pressure difference across the
machine.
• When there is not enough gas to replace that being pushed forward,
discharge gas will flow backwards through the compressor towards
the suction side.
• The gas flowing backward provides more volume to the suction side
and the compressor picks up and begins to push gas forward again.
• This surge cycle will continue until some change is made in the
process or compressor conditions.
 Surge Description

• Flow reverses in 20 to 50 milliseconds

• Surge cycles at a rate of 0.3 s to 3 s per cycle
• Compressor vibrates
• Temperature rises
• “Whooshing” noise
• Trips may occur
• Conventional instruments and human operators may fail
to recognize surge
Developing the compressor curve
Rc
Process limit
Adding control
margins
Maximum speed
Surge limit

Power limit

Stonewall or
choke limit

Stable zone
of operation
Actual available Minimum speed
operating zone

Qs, vol
 Some surge consequences

• Unstable flow and pressure

• Damage in sequence with increasing severity to seals,

bearings, impellers, shaft

• Increased seal clearances and leakage

• Lower energy efficiency

• Reduced compressor life

 Key Issues on
Turbomachinery Controls
• Often compressors used in process applications are critical and non
spared machines

• Because these machines can be large as 50,000 HP , profit

maximization requires maximum energy saving and efficient operation

• The economic consequences of non-availability of turbomachinery is

large

• Poor control is a major risk to the safe and reliable operation of

turbomachinery

• Poor control can lead to false limitations on production

 Major Process Parameters
during Surge
FLOW
• Rapid flow oscillations
• Reversal flow leads to reversal
thrust
• Potential damage
1 2 3
TIME (sec.)
PRESSURE
• Rapid pressure oscillations with
process instability

1 2 3
TIME (sec.)
TEMPERATURE • Rising temperatures inside
compressor which can be
seen at the Discgarge

1 2 3
TIME (sec.)

Operators may fail to recognize surge

Antisurge Control . . .
 Antisurge Control . . .
•'Anti-surge' system and control valve which, externally, recycles
discharge gas back to the suction side in order to maintain a 'Minimum
Flow Rate' to the machine.

•Because compression causes temperature increase, this recycle gas

is normally taken from the discharge side, downstream of the after-
cooler, in order to prevent greater and greater temperature increase at
the discharge side.

•This surge cycle will continue until some change is made in the
process or compressor conditions.
Antisurge Control . . .
Axial compressors
 Axial compressors

Axial compressors

• Gas flows in direction of rotating shaft

• Can be built for lower pressures only 10 to 100 psi (0.7 to 6.8 Bar)
• High flow rate
• Efficient
• Not as common as centrifugals
Stator Blades
Rotor Blades Shaft

Casing

Rotor
Blades
Stator
Blades

Casing
 Compressor Design and Operation

• Pressure is created
when high-speed air
is slowed by the
fixed stator blades
 Axial compressors

Cross section of axial compressor

Guide-vane
actuator linkage Labyrinth seals
Compressor rotor

Rotor blades

Adjustable guide vanes

Compressor Compressor
inlet nozzle Thrust bearing outlet nozzle
 Picture of axial compressor

Video
Compressor system classifications
Single-Case, Two-Section, Six-Stage
Single-Section, Three-Stage

Two-Case, Two-Section, Six-Stage

Parallel Network

Series Network
 Part II
Positive Displacement
Compressors
Positive Displacement Compressors
• They are divided into two types:
I. Reciprocating Compressors
II. Rotary Compressors
Reciprocating (Piston)
Compressors
Reciprocating Compressors

•Reciprocating compressors are used mainly when high-pressure

head is required at a low flow.

•They are divided into two types according to arrangement

I. Single-acting Compressors
II. Double-acting Compressors
 Single-acting
Compressors

Compress air during one

direction of piston travel
 Double-acting
Compressors

Have two compression

chambers, allowing
compression on both
extension and
retraction of the piston

Video
 Reciprocating Compressors

Major Components
 Reciprocating Compressors

Major Components

THE CYLINDER

•This is a metal tube-shaped casing (or body).

•It is generally fitted with a metal lining called a 'Cylinder Liner'.

•The liner is replaceable when it becomes worn and inefficient.

•The cylinder is also fitted with suction and discharge ports which

contain special spring loaded valves to allow liquid to flow in one

direction only - similar to check valves.

 Reciprocating Compressors

Major Components

THE PISTON
•It consists of a metal drive rod connected to the piston head which is

located inside the cylinder.

•The piston head is fitted with piston rings to give a seal against the cylinder

lining and minimise internal leakage.

•The other end of the drive rod extends to the outside of the cylinder and is

connected to the driver.

 Reciprocating Compressors

Major Components

THE PISTON
•In a single acting compressor, the backward stroke of the piston causes a

suction which pulls in gas through the inlet valve. (The same suction action

keeps the discharge valve closed).

• On the forward stroke, the positive pressure generated by the piston, closes

the inlet valve and opens the discharge valve.

• MUST NEVER be operated against a closed discharge system valve

because the action is positive displacement

 Reciprocating Compressors

Major Components
The Crosshead
It is a mechanism used which the connecting rod and piston rod are connected

in large reciprocating compressors to eliminate sideways pressure on the

piston, provides a straight-line motion for the piston rod and permits simple

packing to be used.
 Reciprocating Compressors

Major Components
Valves for reciprocating compressors
It is a feature of a reciprocating compressor, which is unique to it, is the
provision of check valves in the cylinder head for inlet and outlet ports.

Video
 Reciprocating Compressors

Major Components
Valves for reciprocating compressors

Poppet Valve Plate Valve

 Diaphragm
Compressors
 Diaphragm Compressors

Compressor Design and Operation

• It belongs to the family of displacement compressors.

• An elastic diaphragm causes the compression.

• It mainly used in vaccum applications.

Video
 Diaphragm Compressors

Compressor Design and Operation

• Instead of a piston moving linear between two end positions, the

diaphragm is moved in non-linear vibrations.
Sliding-Vane
Compressors
 Sliding-Vane Compressors

Design and Operation

• It is one of the rotary displacement compressors.

• They use a slotted rotor containing movable vanes to compress air

– Rotor is placed off center in a circular compression chamber,

allowing the chamber volume to change during rotation

– These volume changes allow the intake,

compression, and discharge of air during

compressor rotation
 Sliding-Vane Compressors

Design and Operation

• Centrifugal force keeps the vanes in contact with the
walls

Video
 Screw
Compressors
 Screw Compressors

Design and Operation

• Rotary screw compressors use intermeshing, helical screws to
form chambers that move air from the atmosphere into the
system on a continuous basis

• This produces a nonpulsating flow of air at the desired

pressure level

Video
 Screw Compressors

Design and Operation

• Rotary screw compressors have become popular for larger
industrial installations

– Lower initial cost

– Lower maintenance cost

– Adaptable to sophisticated electronic control systems

 Screw Compressors

Screw Compressor Types

• There are 2 types of screw compressors:
I. Oil-free type.
II. Oil-supply type.

• The rotor shape is the same, but at the position where they
mesh, the oil-free type rotates without contact, and the oil-
supply type rotates with contact.
 Screw Compressors

Screw Compressor Types

Oil-free type
• One feature of the oil-free screw compressor is that it generates
clean compressed air that does not contain oil.

• This type is widely used in industries such as food processing,

pharmaceuticals, chemicals, etc., where oil cannot be mixed in
with the air, and as an air source for instrumentation in general
industries.

• Also, in the oil-free screw compressor, the rotors rotate without

contact, so they have excellent durability with long intervals
between maintenance timing, and do not require much labor.
 Screw Compressors

Screw Compressor Types

Oil-supply type
• It also called oil-flodded screw
compresssor type.

• This oil serves a number of purposes:

I. it seals the clearance gaps between

the screws and the casing;

II. it lubricates the drive between the

male and female screws;

III. and it cools by extraction of the

heat of compression.
 Screw Compressors

Screw Compressor Types

Oil-supply type

Oil is removed by a separator to

provide near-oilless compressed
air for the pneumatic system

Oil system for

an oil-flooded
screw compressor
 Screw Compressors

Design and Operation

• The total leakage flow path is larger than in a corresponding
reciprocating compressor.

• In addition to the clearance between the rotors themselves and

between the rotors and the casing, there is also the "blow
hole", which is the triangular hole formed at the intersection of
the two rotors and the casing cusp
 Screw Compressors

Design and Operation

• Rotary screw compressors have become popular for larger
industrial installations

– Lower initial cost

– Lower maintenance cost

– Adaptable to sophisticated electronic control systems

Lobe (Roots)
Compressors
Design and Operation
• Impellers from a lobe-type compressor

Video
 Lobe Compressors

Design and Operation

• It consist of two impellers with two or three lobes that operate in an

elongated chamber in the compressor body

– Spinning impellers trap air in chambers that form between the lobes

– As the impellers turn, this trapped air is swept from the inlet port to

the outlet port to increase system pressure

 Lobe Compressors

Design and Operation

Features:
• Lobe-type compressors are often called Root blowers
• They are typically used in applications requiring air pressure of only 10 to
20 psi

 No wear on the rotary piston, and therefore no lubrication is required.

 Air contains no oil.

 Sensitive to dust and sand.

 Liquid Ring
Compressors
 Liquid-Ring Compressors

Design and Operation

•It is a rotating positive displacement pump.

•They are typically used as a vacuum pump but can also be used as a gas
compressor.

•The liquid generally used is water.

Video
 Liquid-Ring Compressors

Design and Operation

•It`s function is similar to a rotary vane pump the difference being that the
vanes are an integral part of the rotor and churn a rotating ring of liquid to
form the compression chamber seal.

•They are an inherently low friction design, with the rotor being the only
moving part.

•Sliding friction is limited to the shaft seals.

• Liquid ring pumps are typically powered by

•an induction motor.
 Liquid-Ring Compressors

Design and Operation

Video
 Scroll
Compressors
 Liquid-Ring Compressors

Design and Operation

• It is used in air conditioning equipment, as an automobile supercharger (where it

is known as a scroll-type supercharger) and as a vacuum pump.

•It is also called spiral compressor, scroll pump and scroll vacuum pump.

• is a device for compressing air or refrigerant.

Video
 Liquid-Ring Compressors

Design and Operation

If its operating in reverse is known as a scroll expander,

and can be used to generate mechanical work from the
expansion of a fluid, compressed air or gas.

Many residential central heat pump and air conditioning

systems and a few automotive air conditioning systems
employ a scroll compressor instead of the more traditional
rotary, reciprocating, and wobble-plate compressors.
 Compressor Design and Operation

• Compressor staging involves connecting a number of basic

compressor units in series to raise air pressure in small

increments

• This method permits easier control of air temperature, which

results in more-efficient compressor package operation

 Compressor Design and Operation

• Inline, staged, reciprocating compressor

Capacity Control
 Compressor Capacity Control

• Compressor-capacity control refers to the system that

matches the compressed-air output to the system-air
demand.

• The better the air output of the compressor matches system

consumption, the more cost effective the operation of the
system.
 Compressor Capacity Control

• Compressor capacity control systems include:

– Bypass Control
– Start-stop Control
– Inlet Valve Unloading Control
– Speed Variation Control
– Inlet Size Variation Control
 Compressor Capacity Control

• Bypass control uses a relief-type valve to exhaust

excess air.

• Air is continuously delivered to the system at the

compressor’s maximum flow rate.

• This type of control is not considered desirable as it

is inefficient.
Compressor Capacity Control

• Start-stop capacity control is commonly used

with small, electric motor-driven compressor
packages that operate pneumatic systems
consuming air on an intermittent basis.
Compressor Capacity Control
• Start-stop control uses a
pressure-sensitive switch
to start and stop the
compressor to maintain a
preselected pressure
range

Permission granted to reproduce for

© Goodheart-Willcox Co., Inc. 106
educational use only.
 Compressor-Capacity Control
• Start-stop control: compressor start

Permission granted to reproduce for

© Goodheart-Willcox Co., Inc. 107
educational use only.
 Compressor Capacity Control
• Start-stop control: compressor stop

Permission granted to reproduce for

© Goodheart-Willcox Co., Inc. 108
educational use only.
 Compressor Capacity Control

• Inlet valve unloading controls compressor output by

holding the inlet valve open whenever maximum
system pressure is achieved
– Allows the prime mover to operate continuously
– Can be used in systems having internal
combustion engines or electric motors as the
prime mover
Permission granted to reproduce for
© Goodheart-Willcox Co., Inc. 109
educational use only.
Compressor Capacity Control
• Varying compressor speed can control compressor
capacity

– Can be used with reciprocating and rotary

compressor designs

– Primarily used on large, industrial installations

– Sensors monitor pressure and send a signal to

control compressor speed
Permission granted to reproduce for
© Goodheart-Willcox Co., Inc. 110
educational use only.
 Compressor Capacity Control

• Varying the size of the compressor inlet can control

compressor capacity
– Compressor operates at a constant speed
– The volume of air that can enter the compressor is
restricted
– Output varies with the size of the inlet
– Primarily used on dynamic compressors

Permission granted to reproduce for

© Goodheart-Willcox Co., Inc. 111
educational use only.
Thank You