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SUBMITTED BY: ASAD IMRAN REGISTRATION NUMBER: 2009-CHEM-63
COMPRESSORS: A compressor is a mechanical device, like pumps, used in various different applications. A machine that increases the pressure of a gas or vapor (typically air), or mixture of gases and vapors. The pressure of the fluid is increased by reducing the fluid specific volume during passage of the fluid through the compressor. When compared with centrifugal or axialflow fans on the basis of discharge pressure, compressors are generally classed as high-pressure and fans as low-pressure machines. Compressors are used to increase the pressure of a wide variety of gases and vapors for a multitude of purposes. A common application is the air compressor used to supply high-pressure air for conveying, paint spraying, tire inflating, cleaning, pneumatic tools, and rock drills. The refrigeration compressor is used to compress the gas formed in the evaporator. Other applications of compressors include chemical processing, gas transmission, gas turbines, and construction. Important Terminologies for Compressors: Capacity of a Compressor : The capacity of a compressor is the full rated volume of flow of gas compressed and delivered under conditions of total temperature, total pressure, and composition prevailing at the compressor inlet. It sometimes means actual flow rate, rather than rated volume of flow. This is also called free air delivery (FAD) i.e. air at atmospheric conditions at any specific location. This term does not mean air delivered under identical or standard conditions because the altitude, barometer, and temperature may vary at different localities and at different times. Due to ageing of the compressors and inherent inefficiencies in the internal components, the free air delivered may be less than the design value, despite good maintenance practices. Sometimes, other factors such as poor maintenance, fouled heat exchanger and effects of altitude also tend to reduce free air delivery. In order to meet the air demand, the inefficient compressor may have to run for more time, thus consuming more power than actually required. The power wastage depends on the percentage deviation of FAD capacity. For example, a worn out compressor valve can reduce the compressor capacity by as much as 20 percent. A periodic assessment of the FAD capacity of each compressor has to be carried out to check its actual capacity. If the deviations are more than 10 percent, corrective measures should be taken to rectify the same.
Where
P2 = Final pressure after filling (kg/cm2a) P1 = Initial pressure (kg/cm2a) after bleeding) P0 = Atmospheric pressure (kg/cm2a) V = Storage volume in m3 which includes receiver, after cooler and delivery piping T = Time take to build up pressure to P2 in minutes.
Compressor Efficiency :
For practical purposes, the most effective guide in comparing compressor efficiencies is the specific power consumption, i.e. kW/volume flow rate, for different compressors that would provide identical duty. There are several different measures of compressor efficiency that are commonly used including i. ii. iii. Isothermal Efficiency Volumetric Efficiency Adiabatic Efficiency Mechanical Efficiency
iv.
1) Isothermal efficiency:
2) Volumetric efficiency:
Where D = Cylinder bore, meter L = Cylinder stroke, meter S = Compressor speed rpm = 1 for single acting and 2 for double acting cylinders n = No. of cylinders
Where T = on-load time (minutes) t = off-load time (minutes) Well maintained system can reduce the leakage as less than 10% leakages of the total leakage.
SELECTION OF A COMPRESSOR: While selecting a compressor following factors are kept into mind Efficiency at full, partial and no load Noise level Size Oil carry-over Vibration Maintenance Capacity Pressure
Compressor displacement:
Compressor displacement is the volume displaced by the compressing element per unit of time and is usually expressed in cubic feet per minute (cfm). Where the fluid being compressed flows in series through more than one separate compressing element (as a cylinder), the displacement
PREPARED BY ASAD IMRAN REGISTRATION NUMBER: 2009-CHEM-63 5
Classification of compressors:
Types of Compressors:
There are two basic compressor types: positive-displacement and dynamic. POSITIVE DISPLACEMENT COMPRESSOR: In the positivedisplacement type, a given quantity of air or gas is trapped in a compression chamber and the volume it occupies is mechanically reduced, causing a corresponding rise in pressure prior to discharge. At constant speed, the air flow remains essentially constant with variations in discharge pressure. DYNAMIC COMPRESSORS: Dynamic compressors impart velocity energy to continuously flowing air or gas by means of impellers rotating at very high speeds. The velocity energy is changed into pressure energy both by the impellers and the discharge volutes or diffusers. In the centrifugal-type dynamic compressors, the shape of the impeller blades determines the relationship between air flow and the pressure (or head) generate TYPES OF POSITIVE DISPLACEMENT COMPRESSOR
1) Reciprocating Compressor:
A RECIPROCATING COMPRESSOR
These compressors have pistons, and move in cylinders. Types of reciprocating compressors are: Open Compressors: One extremity of the crankshaft is drawn out of the crankcase, due to which multiple drives can be used with the compressor. A mechanical seal is used to check external seepage of refrigerant and oil, and escape of air towards inside. These compressors are driven by electric motors or internal combustion engines. With belt drive, changes in speed are achieved by altering the dimensions of the pulleys, while with direct drive units the compressor is planned to operate at speed of motor. Hermetic Compressors: These compressors are serviceable hermetic, in which motor and compressor are enclosed in the same housing, while the welded hermetic type has the compressor and motor sealed in a welded steel shell.
2) Rotary: Compressors of the rotary type are generally low capacity equipment, used normally in home refrigerators and freezers, and not used for air conditioning. These compressors can consist of one vane, which is placed in the body, and sealed against the rotor, or multivane rotary, with vanes located in the rotor.
A ROTARY COMPRESSOR
1) Centrifugal Compressors These compressors revolve at excessive speed, and refrigerant is compressed by the application of centrifugal force. These compressors are normally used with refrigerants possessing higher specific volumes, which need lower compression ratios. Multi-stage units can be used to attain greater discharge pressures, and the number of stages is determined by the discharge temperature of the gas as it exits from the rotor. These compressors are utilized for water chilling in air conditioning and for low temperature freezing purposes.
PREPARED BY ASAD IMRAN REGISTRATION NUMBER: 2009-CHEM-63 8
A CENTRIFUGAL COMPRESSOR
Its impeller accelerates the flow by flinging it outward. This also increases the pressure. The pressure is increased further, and the flow is slowed, when the flow meets the diffusers that ring the impeller. Centrifugal compressors use the rotating action of an impeller wheel to exert centrifugal force on refrigerant inside a round chamber (volute). Refrigerant is sucked into the impeller wheel through a large circular intake and flows between the impellers. The impellers force the refrigerant outward, exerting centrifugal force on the refrigerant. The refrigerant is pressurized as it is forced against the sides of the volute. Centrifugal compressors are well suited to compressing large volumes of refrigerant to relatively low pressures. The compressive force generated by an impeller wheel is small, so chillers that use centrifugal compressors usually employ more than one impeller wheel, arranged in series. Centrifugal compressors are desirable for their simple design and few moving parts. Centrifugal compressors running by taking in out air near their hub and rotating it by means of an impeller . The impeller , which is usually an aluminum alloy , guides the air toward the outer
PREPARED BY ASAD IMRAN REGISTRATION NUMBER: 2009-CHEM-63 9
2) AXIAL COMPRESSOR:
Axial compressors use a series of fan-like rotating rotor blades to progressively compress the gasflow. Stationary stator vanes, located downstream of each rotor, redirect the flow onto the next set of rotor blades. The area of the gas passage diminishes through the compressor to maintain a roughly constant axial Mach number. Axialflow compressors are normally used in high flow applications, such as medium to large gas turbine engines. They are almost always multi-staged. Beyond about 4:1 design pressure ratio, variable geometry is often used to improve operation.
PREPARED BY ASAD IMRAN REGISTRATION NUMBER: 2009-CHEM-63 10
AN AXIAL COMPRESSOR
The air in an axial compressor flows in an axial direction through a series of rotating rotor blades and stationary stator vanes. The flow path of an axial compressor decreases in cross-section area in the direction of flow , lowering the volume of the air as compression advances from stage to stage of compressor blades.
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>3) Diagonal or mixed-flow compressors A mixed flow compressor combines the axial and radial components to produce a diagonal flow unit. The exit mean radius is greater than at the inlet, but the flow tends to exit in an axial rather than radial direction. This eliminates the need for a relatively large diameter exit diffuser associated with centrifugal compressors, The impeller can be machined from solid using NC machines, in much the same way as that of a centrifugal compressor
Diagonal or mixed-flow compressors are similar to centrifugal compressors, but have a radial and axial velocity component at the exit from the rotor. The diffuser is often used to turn diagonal flow to the axial direction. The diagonal compressor has a lower diameter diffuser than the equivalent centrifugal compressor.
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Main Applications: Standard Centrifugal Compressors General Engg & other industries such as Glass, Automobiles, Electronics, Synthetic Fibers, Textiles, plant & instrument air Compressors for steel plants, refinery, power plants etc. Normally with flow rates starting higher then 2000 m3/hr till 15000 m3/hr as single or multiple units
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http://www.fscc-online.com/%22Passing%20Gas%22-article/passing_gas.html http://en.wikipedia.org/wiki/Axial_compressor
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