1 Copy of Overview Compressors PDF

Compressors Overview
COMPRESSORS
OVERVIEW
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Compressors: Overview
Introduction
Compression Methods
I- Intermittent Mode Compressors
Reciprocating Compressors
Rotary Compressors
Helical-Lube Compressor
Straight-Lube Compressor
Sliding Vane Compressor
Liquid Piston Compressor
II- Continuous Compression Compressors
Ejectors
Dynamic Compressors
Centrifugal Compressors
Axial Compressors
Mixed Flow Compressors
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Classification of
Fans, Blowers and Compressors
The word Fan is ordinarily used to describe Machines with
Pressure Rises up to about 2 psig.
Between 2 psig and 10 psig. Pressure Rise,
The name applied to the Machine is Blower.
For Higher Discharge Pressures, term used is Compressor.
American Society of Mechanical Engineers (ASME)

uses the Specific Ratio, which is
Ratio of Discharge Pressure over Suction Pressure,
to define Fans, Blowers and Compressors
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Introduction
A Compressor is a Device used to
Increase the Pressure of a Compressible Fluid
The Inlet and Outlet Pressure are related corresponding
With The Type of Compressor and its Configuration
The Fluid is any Compressible Fluid, either Gas or Vapor,
and can have a Wide Molecular Weight Range.
Applications of compressed gas vary
from Consumer Products, such as The Home Refrigerator,
to Large Complex Petrochemical Plant Installations
Typical Applications: Air Separation, Vapor Extraction,
Refrigeration, Steam Recompression, Process and Plant Air
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Compression Methods
Compressors have Numerous Forms,
The Exact Configuration being based on the Application.
Compressors Divided into 2 Groups
based on Compression Mode.
There are 2 Basic Modes: Intermittent and Continuous.
The Intermittent Mode is Cyclic in Nature, in that
A Specific Quantity of Gas is ingested by Compressor,
Acted upon, and Discharged Before the Cycle is Repeated.
The Continuous Compression Mode is one in which
The Gas is moved into the Compressor, is
Acted upon, Moved through Compressor, and Discharged
without Interruption of the flow at any point in the process.
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Compressors using the intermittent Compression Mode are

Referred to as Positive Displacement Compressors,
of which there are 2 Distinct Types:
Reciprocating
and Rotary
Continuous-Mode Compressors are also characterized by
2 Fundamental Types:
Dynamic
and Ejector
Figure 1 Diagrams the relationship of compressors by Type.
Figure 2 shows the Application Range of each compressor
Figure 3 compares the Characteristic Curves of
The Dynamic Compressors, Axial and Centrifugal,
with A Positive Displacement machine.
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Figure 1 Chart of Compressor Types

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Fig. 2 Typical Application Ranges of Compressor Types.

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Figure 3 General Performance Curves for Axial Flow,

Centrifugal, and Positive Displacement Compressors.
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Intermittent Mode
Compressors
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The Reciprocating Compressor is the Best Known
and the Most widely used of All compressors.
The Displacing Action of the Piston together with
the Inlet Valve Causes Gas to enter the Cylinder
where it is in turn Compressed and Discharged.
Action of Discharge Valve Prevents Backflow of Gas into
Compressor from Discharge Line during Next intake Cycle
When Compression takes place on One Side
of Piston Only, The compressor is said to be Single-Acting.
The Compressor is Double-Acting
When compression takes place on Each Side of the Piston.
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Configurations consist of a Single Cylinder

or Multiple Cylinders on a Frame.
When a Single Cylinder is used or When Multiple Cylinders
on a common frame are connected in Parallel,
Arrangement is referred to as a Single-Stage Compressor.
When Multiple Cylinders connected in Series,
The Arrangement is referred to as a Multistage Compressor.
Figs. 4, 5, 6 are Reciprocating Compressor Arrangements.
The Reciprocating Compressor is
in the Lower Flow End of the Compressor Spectrum
It is particularly well suited for High-Pressure Service.
Above 1.5 to 1 Pressure Ratio, Reciprocating Compressor
is One of the Most Efficient of All the Compressors
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Fig. 4 Single-Stage, Double-Acting Reciprocating Compressor
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Double Acting Water-Cooled Air Compressor Package

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Double Acting Reciprocating Compressor
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2-Stage Reciprocating Compressor

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Fig. 5 3-Stage Single-Acting Reciprocating Compressor

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Fig. 6 Typical Multi-Stage Crosshead Reciprocating Compressor

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Reciprocating Compressor Cylinder Configurations

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Diaphragm Compressor
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Rotary
Compressors
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Rotary Compressors
The Features these Compressors have in common are:
1. They impart Energy to the Gas being compressed
by way of an input shaft moving Rotating Elements.
2. They perform Compression in an Intermittent Mode.
3. They do not use Inlet and Discharge Valves.
The Helical and Spiral-Lobe Compressors are Similar
The Gas is Moved Axially along Rotor to the Discharge Port
where the Gas is discharged into the Discharge Nozzle.
The Volume of the Trapped Gas is Decreased as it Moves
Toward the Outlet, with the Relative Port Location
Controlling the Pressure Ratio.
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Fig. 7 shows an Exploded view of a Helical-Lobe Compressor.
The Spiral-Lobe Version is the More limited of the two
and is used Only in the Lower Pressure Applications.
Figure 7 Helical Lobe, or Screw, Rotary Compressor

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A Rotor Set for an Oil-Free Helical-Lobe Compressor

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The Helical-Lobe Compressor is divided into: A Dry

and A Flooded form.
The Dry Form uses Timing Gears.
The Flooded Form uses a Liquid Media
to keep the rotors from touching.
The Helical-Lobe Compressor is the Most Sophisticated
and Versatile of the Rotary Compressor Group
and operates at the Highest Rotor Tip Mach Number
of Any of the Compressors in the Rotary Family.
This compressor is usually referred to as the
"Screw Compressor" or the "SRM Compressor"
Applications of the Helical-Lobe compressor bridges the gap
between the Centrifugal and the Reciprocating Compressors.
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Helical Lobe Compressor

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The Straight-Lobe Compressor is Similar to

Helical-Lobe Machine, But is Much Less Sophisticated
It has 2 Untwisted or Straight Lobe Rotors
which Intermesh as they Rotate.
A 3-Lobe Version is Available.
All Versions of the Straight-Lobe Compressor
Use Timing Gears to phase the rotors
Gas is trapped in the open area of the lobes
as the lobe pair crosses the inlet port.
There is No Compression as Gas is moved
to the Discharge Port.
It is compressed by the Backflow from the Discharge Port.
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Straight Lobe Rotary Compressor

The Operating Cycle of the Straight-lobe
Rotary Compressor is shown in Fig. 8.
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Fig. 8 Operating Cycle of a Straight Lobe Rotary Compressor
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Spiraxial Compressor Helical Rotors

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The Sliding-Vane Compressor

uses a Single Rotating Element (see Fig. 9).
The Rotor is Mounted Eccentric to Center of the Cylinder
Portion of the Casing and is Slotted and Ftted with Vanes.
The Vanes are Free to move In and Out within the Slots
as the Rotor revolves.
Gas is trapped between a pair of vanes
as the Vanes cross the Inlet Port.
Gas is moved and compressed Circumferentially
as the Vane Pair moves toward the Discharge Port.
The Port Locations Control the Pressure Ratio.
(This compressor must have an external source of lubrication for the vanes.)
Sliding-Vane Compressor is widely used as Vacuum Pump.

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Figure 9 Rotary Slide Vane Air Compressor
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Sliding Vane Compressor

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The Liquid Piston Compressor or Liquid Ring Pump

uses a Single Rotor, Figure 10.
The Rotor consists of a set of Forward-Curved Vanes.
The Inner Area of the Rotor contains Sealed Openings
which in turn rotate about a Stationary Hollow inner Core.
The Inner Core contains the Inlet and Discharge Ports.
The rotor turns in an Eccentric Cylinder of either a Single
or Double-Lobe Design.
Liquid is carried at the tips of the Vanes and moves In and Out
as the rotor turns, forming a Liquid Piston.
The Port Openings are so located as to allow gas to enter
when the Liquid Piston is moving away from center.
Port is then Closed and compression takes place, with discharge
Port coming Open as the liquid piston approaches the innermost part.
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Liquid Piston Compressor

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Figure 10a Sectional of a Liquid Piston Compressor

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Figure 10b End view of a Liquid Piston Compressor.

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The Capacity Range is Relatively Large, 2 to 16,000 cfm.

Like the Siding-Vane, the Liquid Piston Compressor is
Widely used in Vacuum Service.
The Compressor is also used in Pressure Service, 5 to 80 psi
with an Occasional Application up to 100 psi.
Because of the Liquid Piston, the Compressor can
Ingest Liquid in the Suction Gas Without Damage.
This Feature helps offset a somewhat Poor Efficiency.
The Compressor is used in Multiple Units
to form a Multistage Arrangement.
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Continuous
Compression
Compressors
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Ejectors
Continuous Compression Compressors are of 2 Types:
Ejector and Dynamic
Ejector can be identified as having No Moving Parts, Fig. 11).
Figure 11 Cross section of an Ejector.

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The Ejector is Not as Efficient as Mechanical Compressors.

Simplicity and Lack of Wearing Parts Contribute to the unit's
Inherent Reliability and Low Maintenance Expense
Ejector is Operated Directly by Motive Gas or Vapor.
Air and Steam are the two Most Common Motive Gases.
The Ejector uses a Nozzle to Accelerate the Motive Gas
In Suction Chamber, also referred to as the Mixing Chamber,
The Suction Gas is Entrained by the Motive Fluid.
The Mixture Moves into a Diffuser where High Velocity Gas is
Gradually Decelerated and Increased in Pressure.
The Ejector is Widely Used as a Vacuum Pump.
Ejectors are used both as Subsonic and Supersonic devices.
Ejector is immune to Liquid Carryover in the Suction Gas.
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Ejector
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Ejector
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Dynamic
Compressors
Centrifugal Compressor
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Dynamic Compressors
In Dynamic Compressors Energy is transferred
from a Moving set of Blades to the Gas.
Energy Forms are Velocity & Pressure in Rotating Element
Pressure Conversion taking place in Stationary Elements.
The Density and Molecular Weight have an influence on
The Amount of Pressure the Compressor can Generate.
The Dynamic Compressors are Subdivided into:
Radial, Axial, and Mixed flow.
The Radial Flow, or Centrifugal, Compressor is
A Widely used Compressor and is Second Only to
Reciprocating Compressor in Usage in Process Industries
A Multistage Centrifugal Compressor is seen in Fig. 12.
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The Compressor uses an Impeller consisting of:

Radial or Backward-leaning Blades
and a Front and Rear Shroud.
The Front Shroud is Optionally Rotating or Stationary
depending on the specific design.
As the Impeller Rotates Gas is moved between
the Rotating Blades from the area near the Shaft and
Radially Outward to Discharge into a Stationary Diffuser.
Energy is transferred to the Gas
while it is traveling through the Impeller.
Part of the Energy converts to Pressure along Blade Path
while the balance remains as Velocity at the Impeller Tip
where it is slowed in the Diffuser and converted to Pressure.
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Pressure Conversion taking place in the Impeller is

a function of the Backward leaning of the Blades.
More Radial Blade the Less Pressure Conversion in impeller
and the More conversion taking place in the Diffuser.
Centrifugal compressors are built in a Multistage where
multiple impellers are installed in one frame & operate in series
In Single-Wheel Configuration, Pressures Vary Considerably.
In Higher-Head Models Pressure Ratios of 3 are available.

Centrifugal has the ability to Admit or Extract Flow to or from
the main flow stream, referred to as Sidestreams.
Centrifugals are in service as a Booster
or Multiple Compressors Operating in Series.
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Figure 12 High-Pressure Barrel Type Multi-Stage

Centrifugal Compressor
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Axial
Compressor
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Axial Compressor, Figure 13

Axial Compressors are Large-Volume Compressors.
They are characterized by the Axial Direction of the Flow
Energy from the Rotor is transferred to the Gas by Blading.
The Rotor consists of Multiple Rows of Unshrouded Blades.
Before and After Each Rotor Row is a Stationary (Stator) Row.
A Pair of Rotating and Stationary Blades Rows define a Stage.
When the Energy Transfer arranged to provide
50% of the Pressure Rise in the Rotating Row
and the Other 50% in the Stationary Row.
This Design is referred to as 50% Reaction.
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Figure 13 Axial Flow Compressor

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Axial Compressors are Smaller and are More Efficient

than Centrifugal Compressors
when a comparison is made at an equivalent flow rating.
The Exacting Blade Design, renders this an Expensive
piece of equipment when compared to Centrifugals.
But it is generally justified with an overall evaluation
which includes the Energy Cost
The Axial compressor, is manufactured as a Multistage
because of a Low Pressure Rise/stage,.
Axial Compressors are Integral Part of Large Gas Turbines.
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Mixed-Flow
Compressor
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Mixed-Flow Compressor
The Mixed-Flow Compressor is a Uncommon Form,
and is mentioned here in the interest of Completeness.
The Mixed-Flow Compressor very much resemble
the Radial-Flow Compressor
A Bladed Impeller is used, but the flow path has
both Radial and Axial components (see Figure 14).
Because the Stage Spacing is wide the compressor is used
as a Single-Stage Machine.
The Compressor Size is Flexible and Covers
the Centrifugal Compressor Higher Flow Rates Range.
The Head/Stage is Lower than available in the Centrifugal.
Mixed-Flow Compressor application is in pipeline booster
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Fig.14 Comparison of Radial and Mixed Flow

Compressor Impellers
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Compressor
System
From Compressor to End User
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Compressor System
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Compressors Overview

For Higher Discharge Pressures, term used is Compressor.

American Society of Mechanical Engineers (ASME)

Compressors using the intermittent Compression Mode are

Figure 1 Chart of Compressor Types

Fig. 2 Typical Application Ranges of Compressor Types.

Figure 3 General Performance Curves for Axial Flow,

Configurations consist of a Single Cylinder

Fig. 4 Single-Stage, Double-Acting Reciprocating Compressor

Double Acting Water-Cooled Air Compressor Package

Double Acting Reciprocating Compressor

2-Stage Reciprocating Compressor

Fig. 5 3-Stage Single-Acting Reciprocating Compressor

Fig. 6 Typical Multi-Stage Crosshead Reciprocating Compressor

Reciprocating Compressor Cylinder Configurations

Figure 7 Helical Lobe, or Screw, Rotary Compressor

A Rotor Set for an Oil-Free Helical-Lobe Compressor

The Helical-Lobe Compressor is divided into: A Dry

Helical Lobe Compressor

The Straight-Lobe Compressor is Similar to

Straight Lobe Rotary Compressor

Fig. 8 Operating Cycle of a Straight Lobe Rotary Compressor

Spiraxial Compressor Helical Rotors

The Sliding-Vane Compressor

Sliding-Vane Compressor is widely used as Vacuum Pump.

Figure 9 Rotary Slide Vane Air Compressor

Sliding Vane Compressor

The Liquid Piston Compressor or Liquid Ring Pump

Liquid Piston Compressor

Figure 10a Sectional of a Liquid Piston Compressor

Figure 10b End view of a Liquid Piston Compressor.

The Capacity Range is Relatively Large, 2 to 16,000 cfm.

Figure 11 Cross section of an Ejector.

The Ejector is Not as Efficient as Mechanical Compressors.

The Compressor uses an Impeller consisting of:

Pressure Conversion taking place in the Impeller is

In Higher-Head Models Pressure Ratios of 3 are available.

Figure 12 High-Pressure Barrel Type Multi-Stage

Axial Compressor, Figure 13

Figure 13 Axial Flow Compressor

Axial Compressors are Smaller and are More Efficient

Fig.14 Comparison of Radial and Mixed Flow

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