AIR COMPRESSO RS

Reciprocating air compressor compressors efficiencies and types mean effective construction pressure. work of compression without clearance effect of clearance Multistage optimum intermediate pressure for perfect intercooling

Reciprocating air compressors

Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or portable, can be single or multi-staged and can be driven by electric motors or internal combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are commonly seen in automotive applications and are typically for intermittent duty. Larger reciprocating compressors well over 1,000 hp (750 kW) are commonly found in large industrial and petroleum applications. Discharge pressures can range from low pressure to very high pressure (>18000 psi or 180 MPa).

Types Reciprocating air compressors

 In certain applications, such as air compression, multi-stage double-acting compressors are said to be the most efficient compressors available, and are typically larger, and more costly than comparable rotary units. Another type of reciprocating compressor is the swash plate compressor, which uses pistons which are moved by a swash plate mounted on a shaft - see Axial Piston Pump . Household, home workshop, and smaller job site compressors are typically reciprocating compressors 1 hp or less with an attached receiver tank.

Reciprocating air compressors are positive displacement compressors. This means they are taking in successive volumes of air which is confined within a closed space and elevating this air to a higher pressure. The reciprocating air compressor accomplishes this by using a piston within a cylinder as the compressing and displacing element. The reciprocating air compressor is considered single acting when the compressing is accomplished using only one side of the piston. A compressor using both sides of the piston is considered double acting. The reciprocating air compressor uses a number of automatic spring loaded valves in each cylinder that open only when the proper differential pressure exists across the valve. Inlet valves open when the pressure in the cylinder is slightly below the intake pressure. Discharge valves open when the pressure in the cylinder is slightly above the discharge pressure. A compressor is considered to be single stage when the entire compression is accomplished with a single cylinder or a group of cylinders in parallel. Many applications involve conditions beyond the practical capability of a single compression stage. Too great a compression ration (absolute discharge pressure/absolute intake pressure) may cause excessive discharge temperature or other design problems. For practical purposes most plant air reciprocating air compressors over 100 horsepower are built as multi-stage units in which two or more steps of compression are grouped in series. The air is normally cooled between the stages to reduce the temperature and volume entering the following stage. Reciprocating air compressors are available either as air-cooled or water-cooled in lubricated and non-lubricated configurations, may be packaged, and provide a wide range of pressure and capacity selections.

2.1.1 Reciprocating compressor In industry, reciprocating compressors are the most widely used type for both air and refrigerant compression (see Figure 5). They work on the principles of a bicycle pump and are characterized by a flow output that remains nearly constant over a range of discharge pressures. Also, the compressor capacity is directly proportional to the speed. The output, however, is a pulsating one. Electrical Energy Equipment: Compressors and Compressed Air Systems Energy Efficiency Guide for Industry in Asia www.energyefficiencyasia.org UNEP 5 Reciprocating compressors are available in many configurations, the four most widely used are horizontal, vertical, horizontal balance-opposed and tandem. Vertical type reciprocating compressors are used in the capacity range of 50 150 cfm. Horizontal balance opposed compressors are used in the capacity range of 200 5000 cfm in multi-stage design and up to 10,000 cfm in single stage designs (National Productivity Council, 1993). The reciprocating air compressor is considered single acting when the compressing is accomplished using only one side of the piston. A compressor using both sides of the piston is considered double acting. A compressor is considered to be single stage when the entire compression is accomplished with a single cylinder or a group of cylinders in parallel. Many applications involve conditions beyond the practical capability of a single compression stage. Too great a compression ratio (absolute discharge pressure/absolute intake pressure) may cause excessive discharge temperature or other design problems. Two stage machines are used for high pressures and are characterized by lower discharge temperature (140 to 160oC) compared Figure 5. A cross-sectional view of a reciprocating compressor (King, Julie) Figure 6. View of a multistage compressor (King, Julie) Electrical Energy Equipment: Compressors and Compressed Air Systems Energy Efficiency Guide for Industry in Asia www.energyefficiencyasia.org UNEP 6 to single-stage machines (205 to 240oC). For practical purposes most plant air reciprocating air compressors over 100 horsepower are built as multi-stage units in which two or more steps of compression are grouped in series. The air is normally cooled between the stages to reduce the temperature and volume entering the following stage. (National Productivity Council, 1993). Reciprocating air compressors are available either as air-cooled or water-cooled in lubricated and non- lubricated configurations, may be packaged, and provide a wide range of pressure and capacity selections.

An explanation of a few basic thermodynamic principles is necessary to understand the science of reciprocating compressors. Compression occurs within the cylinder as a four-part cycle that occurs with each advance and retreat of the piston (two strokes per cycle). The four parts of the cycle are compression, discharge, expansion and intake. They are shown graphically with pressure vs. volume plotted in what is known as a P-V diagram (Figure 3). Figure 3. Intake At the conclusion of a prior cycle, the piston is fully retreated within the cylinder at V1, the volume of which is filled with process gas at suction conditions (pressure, P1 and temperature, T1), and the suction and discharge valves are all closed. This is represented by point 1 (zero) in the P-V diagram. As the piston advances, the volume within the cylinder is reduced. This causes the pressure and temperature of the gas to rise until the pressure within the cylinder reaches the pressure of the discharge header. At this time, the discharge valves begin to open, noted on the diagram by point 2. With the discharge valves opening, pressure remains fixed at P2 for the remainder of the advancing stroke as volume continues to decrease for the discharge portion of the cycle. The piston comes to a momentary stop at V2 before reversing direction. Note that some minimal volume remains, known as the clearance volume. It is the space remaining within the cylinder when the piston is at the most advanced position in its travel. Some minimum clearance volume is necessary to prevent piston/head contact, and the manipulation of this volume is a major compressor performance parameter. The cycle is now at point 3. Expansion occurs next as the small volume of gas in the clearance pocket is expanded to slightly below suction pressure, facilitated by the closing of the discharge valves and the retreat of the piston. This is point 4. When P1 is reached, the intake valves open allowing fresh charge to enter the cylinder for the intake and last stage of the cycle. Once again, pressure is held constant as the volume is changed. This marks the return to point 1. Comprehending this cycle is key to diagnosing compressor problems, and to understanding compressor efficiency, power requirements, valve operation, etc. This knowledge can be gained by trending process information and monitoring the effect these items have on the cycle.