R O T A R Y C O M P R E S S O R S

CHAPTER

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ROTARY COMPRESSORS

Positive Displacement Rotary Air Compressors

Positive displacement rotary air compressors include sliding vane, dry screw, wet screw,
liquid ring, and impeller or lobe types. Dynamic compressors include centrifugal and
axial flow types that are similar to liquid pumps. Dynamic compressors use several stages
or steps, each consisting of an independent impeller, to achieve their operating
pressures. Each of these air compressors is discussed in more detail in the following
paragraphs.

Vane Compressors

The SLIDING VANE compressor shown in Fig. 3-1 is a rotary, positive displacement
compressor. This compressor is a compact unit that is less efficient than a piston
compressor but is more efficient than any other rotary compressor. Sliding vane
compressors closely resemble vane pumps, but are larger. The compressor consists of a
rotor with radial slots mounted off-center in a round casing. The rotor is equipped with
rectangular vanes placed in the slots. As the rotor turns, the negative pressure created by
the vanes causes air to be drawn through the inlet into the compressor. As the rotor
continues to turn, the vanes confine the air in a space that gets progressively smaller. As
the vanes approach the discharge portion of the casing, the air is compressed and then
discharged to the receiver through the discharge port.

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Fig. 3-1. A sliding vane compressor

SINGLE-STAGE vane compressors are capable of developing up to 50 psi discharge

pressure. Although this is suitable for some applications, it may be low for others. If
higher pressure is needed, a TWO-STAGE model is used. Two-stage compressors are
capable of pressures up to 1215 psi. They may have a common drive shaft and be
enclosed in a common housing, or they may be independent units positioned on either
side of a common drive motor. Many two-stage compressors are also furnished with an
intercooler (air or water) between stages.

Vane compressors are smaller in physical size than piston compressors having
comparable discharge pressure and flow capabilities. However, their operating efficiency
is also slightly lower. At 100 psi they deliver slightly less than 4 cfm per hp, compared to
approximately 5 cfm per hp for piston compressors. Their delivery in cfm per hp is
higher than that of dynamic compressors. Because most vane compressors operate at
motor speeds of 1,200 to 1,800 rpm, pressurized lubrication is required for the bearings
and other rotating parts.

Rotary Screw Compressors

The dry ROTARY SCREW positive displacement compressor shown in Fig. 3-2
combines the compactness of a rotary compressor with a more constant pressure than
can be obtained from a piston compressor. The design of rotary screw compressors is
quite different from other compressors. They are constructed with two rotors; one with

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a concave (female) profile and the other with a convex (mate) profile. The rotor may or
may not have the same number of lobes or blades, depending on the manufacturer. The
rotors are made of steel, aluminum alloys, or other high strength metals. The rotors
mesh with about 0.003 (three one thousandths of an inch) clearance between them. The
rotors are driven, and prevented from touching by a set of timing gears.

As the rotor revolves, a negative pressure area is created at the inlet allowing air to be
drawn into the casing. Air entering the inlet is then trapped between the rotors and the
casing. As the male and female rotors mesh, the air is carried along in a progressively
smaller space until it is discharged. Successive pockets of air are picked up, compressed,
and discharged in this manner. Each cavity completes its discharge as the following
cavity begins discharging. This provides a smooth, continuous, and shock free flow of
air.

Single-stage compressors are powered by motors as large as 75 hp, and produce

approximately 300 cfm at 50 psi. Two-stage compressors have smaller second-stage
screws fed by a direct flow passage from the first-stage discharge port. The second stage
may be driven directly from the drive source or from the first-stage blower. The pressure
range is about 150 psi for two-stage compressors and 250 psi for three-stage
compressors.

Usually there is no intercooler, but water or air-cooled intercoolers and screw

compressors are available for various dry-type models. Unlike piston or reciprocating
compressors, screw compressors operate at speeds between 3,000 and 12,000 rpm.
Because of the high speeds, they are kept running continuously. When the system has
reached its maximum pressure, the discharge line is unloaded by diverting compressed
air back to the atmosphere.

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Fig. 3-2. A dry rotary screw compressor.

Dry rotary screw compressors are generally used in pneumatic power systems where
comparatively large amounts of oil free air are needed. They can also supply large
quantities of air at 80 to 120 psi and use less floor space than a piston compressor. They
are more economical to install than a piston compressor, but have lower displacements
(3½ to 3¼) cfm per hp and higher operating costs. The close tolerances between the
rotors and the casing, and their wedge like action make them susceptible to dirt.
Therefore, they must be well protected by intake filters.

The WET rotary screw compressor is similar in design and construction to the dry
rotary screw compressor. However, as shown in Fig. 3-3, the wet type does not use
timing gears. One lobe powers the other. To prevent wear, and also reduce the air
temperature, oil is sprayed into the inlet chamber and is carried along by the air. The oil
remains as a liquid as it passes through the compressor, and is separated in the receiver
or by an oil separator.

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Fig. 3-3. A wet rotary screw compressor

Both wet and dry rotary screw compressors are driven at high speeds. Where electric
motors or other lower speed drives are used, a speed increaser is used to bring the
compressor up to an efficient operating range.

The LIQUID RING compressor shown in Fig. 3-4 is a different type of rotary
compressor. Although it appears similar to a vane compressor, it is quite different. The
main components include a casing, an off center drive shaft, a rotor with fixed blades,
and a liquid (usually water). During operation the liquid is carried around the inside of
the casing by the rotor blades. As the rotor turns, the liquid (reacting to centrifugal
force) follows the contours of the casing. Because the rotor and casing are not centered,
the liquid forms a flexible interior compression chamber. As the rotor blades pass the
inlet port, air is drawn into the compressor by the increasing size of the fluid-formed
chamber. The chamber size begins to decrease near the compressor outlet, and the air is

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discharged where the chamber is smallest.

Fig. 3-4. A liquid ring compressor

Liquid ring compressors have capacities of up to 5,000 cfm at 75 psi in single-stage

models. The same models can produce up to 10,000 cfm, but at lower pressure ranges
(about 15 psi). Higher pressures, above 75 psi, can also be obtained, but at a reduction in
capacity. Because they deliver oil free and dust free air, these compressors have been
found to be very efficient for instrument and control air. The cooling effect of the liquid
on the air being compressed contributes to their efficiency. Any contaminated air
entering the fluid chamber deposits the contaminants on the surface of the liquid. The
liquid remains sealed in the compressor, but can be drained and flushed as required.

Liquid ring compressors are usually directly connected to an electric motor having
normal motor speeds of either 1,750 or 3,500 rpm. If a different compressor speed is
required, it can be obtained through the use of V-belts or speed reducers. Although
these compressors are compact in size, they are not as efficient as other types. Their
capacity rating is approximately 2 cfm per hp at 75 psi.

Low-Pressure High-Volume Compressors

The IMPELLER compressor shown in Fig. 3-5 is a low-pressure compressor. These

compressors are often referred to as BLOWERS because they are designed for high
volume rather than pressure. The units are made up of a housing and two interlocking,
timed, gear driven impellers. The impellers may have two, three, or four lobes. The lobes
can be straight, or have a slight twist or helix configuration. The twist smoothes out the

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pressure pulsations at this discharge point. The timing gears prevent the lobes from ever
coming in contact.

Fig. 3-5. One type of impeller compressor.

Their operation can be compared to that of a gear pump. As the impellers rotate, they
create a negative pressure at the intake, which draws air into the housing. As they
revolve, the impellers carry the air along between the lobe and housing, toward the
discharge port. As the lobes mesh, the air is squeezed out the discharge port. The
impellers are machined to very close tolerances, and have only 0.003" to 0.006" clearance
between them. To be efficient, they must be operated at the recommended rpm.

These compressors handle relatively large amounts of air at pressures up to 10 psi. If

higher pressures are required, a second stage can be added to increase the discharge
pressure to 30 psi. Because of their low-pressure output, they are not often used in
pneumatic power systems. They are used to provide process or instrument air whenever

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larger quantities at lower pressures are required. The impellers require no lubrication
because they do not touch each other. In addition, the air temperature does not increase
much and the unit therefore requires little or no cooling.

Diaphragm Compressors

DIAPHRAGM compressors are used for many different light duty applications, and are
classed as positive displacement compressors. The diaphragm of the compressor, like
the one shown in Fig. 3-6, is usually connected to an eccentric drive by a piston and
connecting rod arrangement.

Fig. 3-6. A diaphragm compressor.

The diaphragm is made of a flexible reinforced rubber type material that is oil and
moisture resistant. The drive eccentric is fitted with a prelubricated sealed-for-life
bearing. As the piston or diaphragm plate travels downward, the diaphragm flexes
inward, drawing air into the pumping chamber. When the diaphragm plate reverses its
stroke, the diaphragm flexes outward, forcing air through the discharge valve. These
compressors are not as efficient as other types, but they do furnish small quantities (1 to
3 cfm) of air at 30 to 40 psi.

Dynamic Compressors

Dynamic compressors are designed to deliver large amounts of air (as high as 100,000

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cfm) at pressures up to 125 psi. They are used primarily to provide process air, but may
also be used for ventilation. Their minimum capacities of about 3,000 cfm make them
too large for most pneumatic power systems. At the same time, smaller units deliver air
at pressures (25 to 30 psi) too low for compressed air systems. These low-pressure types
are usually classified as blowers, rather than compressors. Dynamic compressors are
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compact and powerful than the blowers or fans used in heating or ventilating
installations, but are less efficient and more noisy. The two main types of dynamic
compressors are CENTRIFUGAL and AXIAL FLOW.

Centrifugal Compressors

One type of centrifugal compressor is shown in Fig. 3-7. This is a THREE-STAGE

com-pressor, and is typical of many multistage compressors currently being
manufactured. The compressor consists of three individual compressing impellers (of
different sizes) mounted on a speed increaser. The speed increaser is mounted on a
bedplate that also supports the power source. The power source can be an electric
motor, internal combustion engine, or a steam or gas turbine. Most centrifugal
compressors are equipped with intercoolers; and aftercoolers to prevent the air
temperature from increasing excessively. Typical of all centrifugal compressors, the
impellers must rotate at high speeds to be efficient.

When the unit is running, air enters through a large inlet passage on the bottom of the
left end, just before the first stage. The rotating first-stage impeller reduces the pressure
allowing air to enter the inlet or "eye" of the first stage. The speed of the impeller
imparts a high velocity to the air as it moves to the outer portion of the impeller
housing. The air then enters a diffuser that converts part of the velocity (kinetic energy)
into pressure (potential energy). The air then moves into the inlet opening of the next
stage, where the same process takes place. The air pressure is increased approximately
the same amount at each stage. For example, if a three-stage unit compresses the air to
about 6 psi per stage, the discharge pressure is approximately 18 psi.

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Fig. 3-7. A centrifugal compressor.

Larger and more powerful compressors capable of delivering 150,000 cfm at a discharge
pressure of above 150 psi are also available. These compressors are free from oil
contamination, and use only a small amount of floor area for the cfm delivered. Two
disadvantages of centrifugal compressors are that they require more horsepower per cfm
than other compressors, and that they operate at very high speeds (from 3,000 to 12,000
rpm). However, they can deliver a wide range of airflow at an almost constant discharge
pressure.

Single-stage and multistage centrifugal compressors are shown in Fig. 3-8. The
construction of these compressors is quite different from the ones previously discussed.
They resemble centrifugal pumps in construction. Using intercoolers between the
various stages of multistage compressors improves the compressor efficiency by
reducing the power needed to compress the air. Depending on the application, the
impellers have different shapes and are classed as having radial or mixed flow. Many of
the mixed-flow and single stage compressors are used as pressure boosters or blowers.

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Fig. 3-8. Single-stage and multistage centrifugal compressors.

Control of centrifugal compressor output varies, but it can be grouped into four major
methods: Speed variation, suction throttling, discharge throttling, and recirculation. The
most efficient method of the four is speed variation. However, many compressors lose
efficiency when the speed is reduced too far below normal operating speeds.

Suction throttling is preferred to discharge throttling, but either of these is more efficient
than recirculation. Suction throttling is accomplished by using a butterfly valve or
variable inlet vanes. A throttling valve is used for discharge throttling. A combination of
suction/discharge throttling is used on some compressors. Discharged air can be
recirculated to the suction inlet, but this method is usually inefficient.

Axial-Flow Compressors

The multistage AXIAL-FLOW compressor shown in Fig. 3-9 is another type of

centrifugal compressor. It is capable of delivering a relatively constant airflow at lower
pressures (approximately 50 psi). Axial-flow compressors have several rows of blades
mounted on a rotor. The blades speed up the air passing through them much like a fan
does.

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Fig. 3-9. A multistage axial flow compressor.

Rows of stationary diffuser blades are mounted between the rotating blades. The
stationary blades convert and increase some of the axial speed of the air at about 3 psi of
pressure per stage. The more stages, the higher the discharge pressure. Because of their
large-cfm, low-pressure delivery, most axial-flow compressors are limited to process air
applications.

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