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1. INTRODUCTION ..................................................................................................... 1
7.
8.
9.
10.
CAPACITY AND
EFFICIENCY ................................................................................................ 18
11.
12.
ADVANTAGES ..................................................................................................................... 19
13.
APPLICATIONS.................................................................................................................... 20
14.
CONCLUSION ..................................................................................................................... 21
15.
REFERENCES....................................................................................................................... 22
1. INTRODUCTION
A new compressor technology introduced during the 2008
International Air-
Types of Compressors
The main types of gas compressors are illustrated and discussed
below:
Centrifugal compressors
Centrifugal compressors use a rotating disk or impeller in a shaped housing to
force thegas to the rim of the impeller, increasing the velocity of the gas. A diffuser
(divergent duct)section converts the velocity energy to pressure energy. They are
primarily used for continuous,stationary service in industries such as oil refineries,
chemical and petrochemical plants andnatural gas processing plants. Their
application can be from 100 hp (75 kW) to thousands ofhorsepower. With multiple
staging, they can achieve extremely high output pressures greaterthan 10,000 psi
(69 MPa).Many large snow-making operations (like ski resorts) use this type of
compressor. Theyare also used in internal combustion engines as superchargers
and turbochargers. Centrifugalcompressors are used in small gas turbine engines or
as the final compression stage of mediumsized gas turbines.
Axial-flow compressors
Axial-flow compressors are dynamic rotating compressors that use arrays of fan-
likeaero foil to progressively compress the working fluid. They are used where
there is arequirement for a high flows or a compact design
The arrays of aero foil are set in rows, usually as pairs: one rotating and one
stationary. Therotating
aero foil’s
, also known as blades or rotors decelerate and pressurize the fluid.The stationary
aero foil is, also known as a stators or vanes, turn and decelerate the
fluid;preparing and redirecting the flow for the rotor blades of the next stage. Axial
compressors arealmost always multi-staged, with the cross-sectional area of the gas
passage diminishing alongthe compressor to maintain an optimum axial Mach
number. Beyond about 5 stages or a 4:1design pressure ratio, variable geometry is
normally used to improve operation.Axial compressors can have high efficiencies;
around 90% polytrophic at their designconditions. However, they are relatively
expensive
rs
Rotary screw compressors use two meshed rotating positive-displacement
helicalscrews to force the gas into a smaller space. These are usually used for
continuous operation incommercial and industrial applications and may be either
stationary or portable. Theirapplication can be from 3 hp (2.24 kW) to over 500 hp
(375 kW) and from low pressure to veryhigh pressure (>1200 psi or 8.3 MPa).
They are commonly seen with roadside repair crewspowering air-tools. This type
is also used for many automobile engine superchargers because itis easily matched
to the induction capacity of a piston Engine
Rotary vane compressors
Rotary vane compressors consist of a rotor with a number of blades inserted in
radialslots in the rotor. The rotor is mounted offset in a larger housing which can
be circular or amore complex shape. As the rotor turns, blades slide in and out of
the slots keeping contactwith the outer wall of the housing.[1] Thus, a series of
decreasing volumes is created by therotating blades. Rotary Vane compressors are,
with piston compressors one of the oldest ofcompressor technologies.With suitable
port connections, the devices may be either a compressor or a vacuum pump.They
can be either stationary or portable, can be single or multi-staged, and can be
driven byelectric motors or internal combustion engines. Dry vane machines are
used at relatively lowpressures (e.g., 2 bars) for bulk material movement whilst oil-
injected machines have thenecessary volumetric efficiency to achieve pressures up
to about 13 bars in a single stage. Arotary vane compressor is well suited to
electric motor drive and is significantly quieter inoperation than the equivalent
piston compressor
, requiring a large number of components,tight tolerances and high quality
materials. Axial-flow compressors can be found in medium tolarge gas turbine
engines, in natural gas pumping stations, and within certain chemical plants.
Reciprocating compressors
Reciprocating compressors use pistons driven by a crankshaft. They can be
eitherstationary or portable, can be single or multi-staged, and can be driven by
electric motors orinternal combustion engines. Small reciprocating compressors
from 5 to 30 horsepower (hp)are commonly seen in automotive applications and
are typically for intermittent duty. Largerreciprocating compressors up to 1000 hp
are still commonly found in large industrialapplications, but their numbers are
declining as they are replaced by various other types ofcompressors. Discharge
pressures can range from low pressure to very high pressure (>5000 psior 35 MPa).
In certain applications, such as air compression, multi-stage double-
actingcompressors aresaid to be the most efficient compressors available, and are
typically larger,noisier, and more costly than comparable rotary units
Scroll compressors
A scroll compressor, also known as scroll pump and scroll vacuum
pump, uses two interleavedspiral-like vanes to pump or compress fluids
such as liquids and gases. The vane geometry maybe involutes,
Archimedean spiral, or hybrid curves. They operate more smoothly,
quietly, andreliably than other types of compressors in the lower volume
range.Often, one of the scrolls is fixed, while the other orbits
eccentrically without rotating, therebytrapping and pumping or
compressing pockets of fluid or gas between the scrolls.
Diaphragm compressors
A diaphragm compressor (also known as a membrane compressor) is a
variant of theconventional reciprocating compressor. The compression
of gas occurs by the movement of aflexible membrane, instead of an
intake element. The back and forth movement of themembrane is driven
by a rod and a crankshaft mechanism. Only the membrane and
thecompressor box come in touch with the gas being
compressed.Diaphragm compressors are used for hydrogen and
compressed natural gas (CNG) aswell as in a number of other
applications.
normallyavailable .
4. FRICTIONLESS COMPRESSOR TECHNOLOGY
Frictionless Compressor Technology is one of the fast growing
Technology in themechanical engineering field. In the case of
Traditional centrifugal compressors, we use rollerbearings &
hydrodynamic bearings, both of them consume power & require oil &
lubricationsystem. This can be overcome by introduction of the new
compressor technology which iscalled as
FRICTIONLESS COMPRESSOR TECHNOLOGY
. The frictionless compressor technology isthe compressor with which
the application of the magnetic bearings & permanent
magnetsynchronous motor. In the frictionless compressor instead of the
roller bearings &hydrodynamic bearings, magnetic bearings will be use.
Magnetic bearings consume less power& there is no need for the oil and
lubrication systems. Permanent magnet brushlesssynchronous motor has
the permanent magnet instead of the copper windings. Thiscompressor
has the high efficiency, reliability, less maintenance cost & the staff.
With help ofthe digital control system, controlling & monitoring of the
work is very easy. The frictionlesscompressor technology makes new
revolutions in the field of air conditioning, refrigeration etc..
They Are Different because
1.
Magnetic bearings.2.
Oil-free design.3.
VFD control.4.
Power Management.4.
6.
THE BEARINGS
Traditional centrifugal compressors use roller bearings and
hydrodynamic bearings,both of which consume power and require
oil and a lubrication system. Recently, ceramic rollerbearings, which
avoid issues related to oil and reduce power consumption, were
introduced tothe HVAC industry. The lubrication of these bearings is
provided by the refrigerant
itself.
Magnetic-bearing technology is significantly different. A digitally
controlled magnetic-bearing system, consisting of both permanent
magnets and electromagnets, replaces
conventional lubricated bearings. The frictionless compressor shaft is the
compressor’s only
moving component. It rotates on a levitated magnetic cushion. Magnetic
bearings
—
two radialand one axial
—
hold the shaft in position
When the magnetic bearings are energized, the motor and impellers,
which are keyeddirectly to the magnetic shaft, levitate. Permanent-
magnetic bearings do the primary work,while digitally controlled
electromagnets provide the fine positioning. Four positioning signalsper
bearing hold the levitated assembly to a tolerance of 0.00002 in. As the
levitated assemblymoves from the center point, the electroma
gnets’ intensity is adjusted to correct the position.
These adjustments occur 6 million times a minute. The software has
been designed toautomatically compensate for any out-of-balance
condition in the levitated assembly
7.
OIL-FREE DESIGN
Oil management, particularly as it pertains to the lubrication of
compressor bearings, is acritical issue in refrigeration system design. But
with magnetic bearings, this issue is avoided.Only a very small amount
of oil is required to lubricate other system components, such as sealsand
valves; often, however, experience shows that even this small amount of
oil is not needed.Avoiding oil-management systems means avoiding the
capital cost of oil pumps, sumps,heaters, coolers, and oil separators, as
well as the labor and time required to perform oilrelated services.
Reports indicate that for many installations, compressor-maintenance
costshave been cut by more than 50 percent..Magnetic bearings
eliminate the need for these systems and oil management in general.In
fact, the only required regular maintenance of the compressor is the
quarterly tightening ofthe terminal screws, the annual blowing off of
dust and cleaning of the boards, and thechanging of the capacitors every
five years. Complete service agreements and extendedmaintenance
contracts can be provided by the manufacturer