Title,:- Air Compressors:
We all have seen a cylinder with motors and pipes used for filling the air to our bicycles or vehicle tyres. Those cylinders
with motors and pipes are air compressors. Thus, an air compressor is a mechanical device that increases the air pressure
above the atmospheric pressure by compressing it. This high-pressure air is stored in a cylinder attached to it.
Air compressors produce compressed air and they have many applications. The process is used in manufacturing oxygen
cylinders, spray cans, etc. Due to these wide applications, let us study the working of air compressors, various types,
their advantages, and disadvantages.
Let us also look at some of their applications. This topic can pose problems in the SSC JE or GATE ME exams if not learnt
well. So, let us start learning!
➢ What are Air Compressors?
Compression is a process of increasing the pressure of any state of matter. Air compression is the process of increasing the
air pressure above the atmospheric pressure. The value of atmospheric pressure is given as ' I atm' or '101,325 Pa (Pascals)'.
The mechanical device used to compress air is called an 'Air compressor'. Thus, the air compressor is a mechanical
pneumatic device powered by IC engines or electric motors to convert the of air to potgntial_gnugy.
The compressed air from the air compressors is usually stored in a high-pressure vessel. An example is shown in the images
below.
Fig I : Typical Air Compressor
Air compressors are usually run by steam engines, IC engines, or electric motors. There is an upper limit provided by
engineers to each type of compressor manufactured, crossing which it gets shut down. The pressurized compressed air in the
cylinders has kinetic energy when released and can be used in various applications, which are discussed below.
An air compressor cannot be considered a pump as the former works with only gas or air while the latter works with liquids
only. Let us now learn the basic principle behind the working of these mechanical devices.
➢ Working Principle of Air Compressors
Every air compressor follows obeys Boyle's Law which states, "The product of pressure and volume of the mass of a
confined gas is constant and proportional to the temperature."
Mathematically, PV T.
A general working principle of these compressors is listed below.
The compressor, usually a piston-cylinder arrangement or other types as discussed below, is a work-absorbing device.
The air from the atmosphere is sucked into the device.
The working element compresses the air to high pressure increasing its volume.
According to Boyle's Law, the temperature is also increased in this process.
Then, the compressed air from the compressor is delivered to the high-pressure vessel to store the potential energy in
the form of air.
This is represented mathematically and diagrammatically in the image below.
Here,
PI and P2 = Inlet and outlet pressure respectively,
VI and V2 = Inlet and outlet velocity respectively.
Let us study the types and then the working principle of each type in detail.
➢ Types of Air Compressors
The commonly known types of air compressors are given in the classification tree below.
• Positive Displacement Air Compressor
The compression here follows a process of trapping the air, and then compressing it. This reduces the volume while
increasing the pressure. The air above the condensing pressure after the rise in pressure level is expelled from the enclosed
chamber. A fresh supply of air is then drawn, and the cycle continues.
These type of compressors forces air into the chamber. The air is displaced continuously by a rotating mechanical
component. Air cavities are formed when the component moves from one place to another.
In this article, we shall discuss the two types based on the requirement ofAE/JE Mechanical examination: Reciprocating and
Rotary type air compressors.
• Reciprocating Compressors
The reciprocating type is a positive displacement air compressor that is similar to IC engines. The only difference is the
absence of combustion gases for the piston to work. These have a piston connected to the crankshaft reciprocating inside a
cylinder. The suction and delivery valves are at the top of the compressor cylinder.
There are three major types of reciprocating air compressors: Single acting, double acting, and diaphragm type.
• Single Acting Reciprocating Air Compressors
Let us refer to the image below as we learn more about the type. These are commonly known as single stage reciprocating
air compressors.
Fig 4: Single Stage Reciprocating Air Compressor Schematic
In this type, one end of the piston is used for suction and compression. The first stroke draws the air inside the compressor
chamber followed by the compression in the second stroke. The other end of the piston is free and is not open for work.
As seen from the image above, the induction (suction) valve intakes the air at atmospheric pressure. The work is done by
only one end of the piston, usually the upper part, in the compressor. Water jacket maintains the temperature well below
the operating temperature of the air, which may increase according to Boyle's law.
The other side of the piston indirectly helps the stroke by aiding the opening and closing of the crankcase. The piston works
by the air pushing it down in one direction, and the spring action by the crankshaft brings the piston back to its normal
position. This increases the pressure above the atmospheric pressure of air.
This is supplied through the delivery valve. Thus, the work is done by only one piston in these types of air compressors for
the supply of compressed air.
Advantages of Single Acting Reciprocating Compressors:
o The compressor has a simple working
o It is Easier to repair
Disadvantages of Single Acting Reciprocating Compressors:
o The system should run at full potential even for a small amount of work output.
Application of Single Acting Reciprocating Compressors:
o Commonly used in woodworking, food production in the bakery, and metalwork.
o They are commonly known as gas air compressors.
• Double Acting Reciprocating Air Compressors
A schematic diagram of a typical double acting reciprocating air compressor is shown below. These are usually categorized
under multi-stage reciprocating air compressors, but let us restrict the study to double acting/stage compressors concerned
with the AE/JE mechanical engineering exams.
To receiver
or next stage
Double-acting
compressor or stage
Fig 5: Double Acting Reciprocating Air Compressor Schematic
This is a well-known type of positive displacement compressor. Here, unlike single acting, both sides of the piston are used
to intake and compress the air. The piston moves downward and draws the air. It then moves upward by compressing the air
and pushing it towards the delivery (exhaust) valve.
Here, both sides of the piston are used in the compressor chamber for the total work of air compression. The volume of the air
is reduced by the end of the process. Water jackets are provided to maintain the temperature of the air while the compressor is
working.
The operation of the induction and delivery valve depends on the piston movement of the air compressor.
Advantages of Double Acting Reciprocating Compressors:
o Greater control over the compression process
o Only the first stage could be used to produce energy
Disadvantages of Double Acting Reciprocating Compressors:
o Higher capital investment
o Complicated repair process
Applications of Double Acting Reciprocating Compressors:
o It is well-known to be used in various airforce applications in the military
• Diaphragm Reciprocating Air Compressors
The diaphragm type of air compressor is a classic of the positive displacement category. It has piston rings and a seal with
backup as shown in the image below. In this type, a moving membrane Gust like a human diaphragm) is driven by the rod
and crankshaft to intake the air.
Fig 6: Diaphragm Type Reciprocating Air Compressors Schematic
The membrane and the plate are in contact with the air, unlike the other types where the piston is in contact. Usually, the
diaphragm or the membrane is manufactured to withstand the stress of the compressing action.
As these are commonly used with toxic gases as operating gases, the diaphragm should be non-reactive. The oil space is
used to maintain the system temperature while the perforated plates let the oil lubricate the piston-cylinder arrangement.
This concludes the discussion on the reciprocating type.
Advantages of Diaphragm Reciprocating Compressors:
No air leakage and contamination during the process
Low vibration
Disadvantages of Double Acting Reciprocating Compressors:
Requires a large area to install.
Applications of Double Acting Reciprocating Compressors:
Widely used for compressing toxic gases and rare gases such as hydrogen, nitrogen, etc.
• Rotary Air Compressors
Unlike other types of compressors that use piston-cylinder movement, Rotary air compressors use the action of gears to
compress air. These compressors involve the rotating element developing a liquid seal. This creates a suction at the inlet.
The air is displaced positively by the mechanical component in this type of compressor. There are three major types of this
compressor: Lobe type or Roots Blower, Screw type, and Vane type.
• Lobe Type or Roots Blower Rotary Air Compressors
A typical roots blower with two lobes is shown in the image below.
7:
Roots Blower Rotary Air compressor
There are two rotors in the compressor, and generally one of them is connected to the external drive that drives the other
rotor. The shape, technically known as the lobe, of these rotors, follows a cycloid or involute profile.
The mating between these two imparts accurate sealing to the delivery side. Low-pressure air is compressed by the action
converting it to high-pressure air by the end of the process.
Advantages of Double Acting Reciprocating Compressors:
o Simple in design compared with other rotary air compressors.
o Efficiency in operating at lower rpm.
Disadvantages of Double Acting Reciprocating Compressors:
o Extremely susceptible to the wear of internal components
Applications of Double Acting Reciprocating Compressors:
o They are commonly used in the pulp and paper industry.
o It is also used in pharmaceutical industries.
• Screw Type Rotary Air Compressors
The screw type rotary air compressor uses a rotary type positive displacement mechanism. The explanation is understood
with the reference to the image below.
Fig 8: Screw Type Rotary Air Compressor
The compressor comprises closely meshing rotors of spiral shape to compress the air. In practical scenarios, while
running the system dry, a pair of timing gears are used to ensure precise alignment. This also ensures resistance to rapid
wear.
The lubricating oil forms a connection in the space between the rotors in an oil-flooded rotary screw air compressor. This
oil acts as a transfer medium of mechanical energy between the rotors to aid in the rotation of one powered by the other.
Advantages of Double Acting Reciprocating Compressors:
o Less noisy while under operation
o Outlet air temperature would be comparatively low
Disadvantages of Double Acting Reciprocating Compressors:
o This compressor has to be used frequently to avoid rust
o Needs excessive maintenance
Applications of Double Acting Reciprocating Compressors:
o Small air compressors or mini air compressors of this type are used as mobile units to fill the air.
o They are also used in the food packaging industry.
• Vane Type Rotary Air Compressors
The vane type compressor consists of a set of vanes mounted on a rotor as shown in the image below.
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Casing
Inlet Outlet
Rotor Vanes
Fig 9: Vane Type Rotary Air Compressors
The vanes on the rotor inside the chamber are of variable length. They are in contact with the walls of the casing as the
rotor rotates. The air from the inlet is drawn and compressed with this action.
This completes our discussion on the first category of air compressors. Let us move ahead with the next major category.
Advantages of Double Acting Reciprocating Compressors:
l) Easy to maintain
2) Simple design
Disadvantage of
Double Acting
reciprocate
compressor:
o Lubricant may contaminate the air
Applications of Double Acting Reciprocating Compressors:
o Used in the agricultural industry to supply compressed air to operate farm equipment.
• Dynamic Displacement
A steadily flowing air is impacted by kinetic energy by the mechanical elements in a compressor of this type, which
increases the pressure of the flowing air. There are two types: Centrifugal and Axial Compressors.
• Centrifugal Air Compressors
The rotational energy is imparted to the air by centrifugal air compressors in the possess of compression.
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Exitof
Compressed air
Casin
Air
intake
Impeller
Valute casing Impeller
Fig 10: Centrifugal Compressor
The rotational energy by the vanes is converted into a centrifugal force that pushes the air towards the discharge side. The
airflow is normal to the axis of the rotating shaft in this type. The vanes are of two types: Diffuser and Impeller.
Impeller vanes are curved which aids the flow of air. Diffuser vanes are fixed and are used to aid in the conversion of
the of air coming from impeller vanes to pressure energy. The components in figure 10 are
the main components of a centrifugal air compressor.
Centrifugal compressors are sometimes referred to as rotary compressors due to their construction.
Advantages of Double Acting Reciprocating Compressors:
l) Reliable and less expensive
2) Ability to handle high-pressure operations.
Disadvantages of Double Acting Reciprocating Compressors:
l) Less flexible and stable at higher compressions
2) Generates more vibrations.
Applications of Double Acting Reciprocating Compressors:
Mainly used by gas turbines and refrigeration compressors
• Axial Air Compressors
The axial air compressor, a widely known dynamic compressor, is a mechanical device employed to increase the pressure
of the air continuously in the system. In comparison with the centrifugal compressor, the axial compressors are small in
size and lightweight.
Let us have an idea of these types of compressors using the image below.
Fixed blades
Casing
Compressed
air
Rotating
blades
Axial Flow Compressor
The compressor has a drum on which the rotating blades are mounted. The fixed blades are to direct the flow and achieve
high speeds. The air radially enters the impeller and is discharged axially from the compressor.
In this system, the air is allowed to pass through in a parallel direction due to the rotating blades. When the axial flow
compressors are combined with gas turbines, they can generate electricity.
Advantages of Double Acting Reciprocating Compressors:
o Higher flow rate and greater pressure ratio
o Higher thrust and fuel efficiency
Disadvantages of Double Acting Reciprocating Compressors:
o Bulky construction
o High starting power
Applications of Double Acting Reciprocating Compressors:
o These compressors are used in the construction of jet engines, high-speed ship engines, and small-scale power
station
➢ Refreence
1. Google
2. Per book
