706 ________________________________________________________ Applied Thermodynamics

16
Reciprocating and Rotary
Compressor

16.1 INTRODUCTION
Compressors are work absorbing devices which are used for increasing pressure of fluid at the expense
of work done on fluid.
The compressors used for compressing air are called air compressors. Compressors are invariably
used for all applications requiring high pressure air. Some of popular applications of compressor are, for
driving pneumatic tools and air operated equipments, spray painting, compressed air engine, supercharging
in internal combustion engines, material handling (for transfer of material), surface cleaning, refrigeration
and air conditioning, chemical industry etc. Compressors are supplied with low pressure air (or any
fluid) at inlet which comes out as high pressure air (or any fluid) at outlet, Fig. 16.1. Work required for
increasing pressure of air is available from the prime mover driving the compressor. Generally, electric
motor, internal combustion engine or steam engine, turbine etc. are used as prime movers. Compressors
are similar to fans and blowers but differ in terms of pressure ratios. Fan is said to have pressure ratio
up to 1.1 and blowers have pressure ratio between 1.1 and 4 while compressors have pressure ratios
more than 4.

Fig. 16.1 Compressor

Compressors can be classified in the following different ways.
(a) Based on principle of operation: Based on the principle of operation compressors can be
classified as,
(i) Positive displacement compressors
(ii) Non-positive displacement compressors
In positive displacement compressors the compression is realized by displacement of solid boundary
and preventing fluid by solid boundary from flowing back in the direction of pressure gradient. Due to
solid wall displacement these are capable of providing quite large pressure ratios. Positive displacement
compressors can be further classified based on the type of mechanism used for compression. These
can be
Reciprocating and Rotary Compressor ______________________________________________ 707
(i) Reciprocating type positive displacement compressors
(ii) Rotary type positive displacement compressors
Reciprocating compressors generally, employ piston-cylinder arrangement where displacement
of piston in cylinder causes rise in pressure. Reciprocating compressors are capable of giving large
pressure ratios but the mass handling capacity is limited or small. Reciprocating compressors may also
be single acting compressor or double acting compressor. Single acting compressor has one delivery
stroke per revolution while in double acting there are two delivery strokes per revolution of crank shaft.
Rotary compressors employing positive displacement have a rotary part whose boundary causes posi-
tive displacement of fluid and thereby compression. Rotary compressors of this type are available in the
names as given below;
(i) Roots blower
(ii) Vaned type compressors
Rotary compressors of above type are capable of running at higher speed and can handle large
mass flow rate than reciprocating compressors of positive displacement type.
Non-positive displacement compressors, also called as steady flow compressors use dynamic
action of solid boundary for realizing pressure rise. Here fluid is not contained in definite volume and
subsequent volume reduction does not occur as in case of positive displacement compressors. Non-
positive displacement compressor may be of ‘axial flow type’ or ‘centrifugal type’ depending upon type
of flow in compressor.
(b) Based on number of stages: Compressors may also be classified on the basis of number
of stages. Generally, the number of stages depend upon the maximum delivery pressure.
Compressors can be single stage or multistage. Normally maximum compression ratio of 5
is realized in single stage compressors. For compression ratio more than 5 the multi-stage
compressors are used.
Typical values of maximum delivery pressures generally available from different types of com-
pressor are,
(i) Single stage compressor, for delivery pressure up to 5 bar
(ii) Two stage compressor, for delivery pressure between 5 and 35 bar
(iii) Three stage compressor, for delivery pressure between 35 and 85 bar
(iv) Four stage compressor, for delivery pressure more than 85 bar
(c) Based on capacity of compressors: Compressors can also be classified depending upon the
capacity of compressor or air delivered per unit time. Typical values of capacity for different
compressors are given as;
(i) Low capacity compressors, having air delivery capacity of 0.15 m3/s or less
(ii) Medium capacity compressors, having air delivery capacity between 0.15 and 5 m3/s.
(iii) High capacity compressors, having air delivery capacity more than 5 m3/s.
(d) Based on highest pressure developed: Depending upon the maximum pressure available from
compressor they can be classified as low pressure, medium pressure, high pressure and
super high pressure compressors. Typical values of maximum pressure developed for
different compressors are as under;
(i) Low pressure compressor, having maximum pressure up to 1 bar
(ii) Medium pressure compressor, having maximum pressure from 1 to 8 bar
(iii) High pressure compressor, having maximum pressure from 8 to 10 bar
(iv) Super high pressure compressor, having maximum pressure more than 10 bar.
708 ________________________________________________________ Applied Thermodynamics
16.2 RECIPROCATING COMPRESSORS
Reciprocating compressor has piston cylinder arrangement as shown in Fig. 16.2.

Fig. 16.2 Line diagram of reciprocating compressor

Reciprocating compressor has piston, cylinder, inlet valve, exit valve, connecting rod, crank,
piston pin, crank pin and crank shaft. Inlet valve and exit valves may be of spring loaded type which get
opened and closed due to pressure differential across them. Let us consider piston to be at top dead
centre (TDC) and move towards bottom dead centre (BDC). Due to this piston movement from TDC to
BDC suction pressure is created causing opening of inlet valve. With this opening of inlet valve and
suction pressure the atmospheric air enters the cylinder.
Air gets into cylinder during this stroke and is subsequently compressed in next stroke with both
inlet valve and exit valve closed. Both inlet valve and exit valves are of plate type and spring loaded so as
to operate automatically as and when sufficient pressure difference is available to cause deflection in
spring of valve plates to open them. After piston reaching BDC it reverses its motion and compresses the
air inducted in previous stroke. Compression is continued till the pressure of air inside becomes suffi-
cient to cause deflection in exit valve. At the moment when exit valve plate gets lifted the exhaust of
compressed air takes place. This piston again reaches TDC from where downward piston movement is
again accompanied by suction. This is how reciprocating compressor keeps on working as flow device.
In order to counter for the heating of piston-cylinder arrangement during compression the provision of
cooling the cylinder is there in the form of cooling jackets in the body. Reciprocating compressor
described above has suction, compression and discharge as three prominent processes getting com-
pleted in two strokes of piston or one revolution of crank shaft.
Reciprocating and Rotary Compressor ______________________________________________ 709
16.3 THERMODYNAMIC ANALYSIS
Compression of air in compressor may be carried out following number of thermodynamic processes
such as isothermal compression, polytropic compression or adiabatic compression. Figure 16.3 shows
the thermodynamic cycle involved in compression. Theoretical cycle is shown neglecting clearance
volume but in actual cycle clearance volume can not be negligible. Clearance volume is necessary
in order to prevent collision of piston with cylinder head, accommodating valve mechanism etc.
Compression process is shown by process 1–2, 1–2¢, 1–2² following adiabatic, polytropic and isothermal
processes.
On p-V diagram process 4–1 shows the suction process followed by compression during 1–2
and discharge through compressor is shown by process 2–3.
Air enters compressor at pressure p1 and is compressed up to p2. Compression work requirement
can be estimated from the area below the each compression process. Area on p–V diagram shows that
work requirement shall be minimum with isothermal process 1–2². Work requirement is maximum with
process 1–2 i.e. adiabatic process. As a designer one shall be interested in a compressor having minimum
compression work requirement. Therefore, ideally compression should occur isothermally for minimum
work input. In practice it is not possible to have isothermal compression because constancy of temperature

Fig. 16.3 Compression cycle on p-V diagram

during compression can not be realized. Generally, compressors run at substantially high speed while
isothermal compression requires compressor to run at very slow speed so that heat evolved during
compression is dissipated out and temperature remains constant. Actually due to high speed running of
compressor the compression process may be assumed to be near adiabatic or polytropic process following
law of compression as pV n = C with value of ‘n’ varying between 1.25 and 1.35 for air. Compression
process following three processes is also shown on T-s diagram in Fig. 16.4. It is thus obvious that
actual compression process should be compared with isothermal compression process. A mathematical
parameter called isothermal efficiency is defined for quantifying the degree of deviation of actual
compression process from ideal compression process. Isothermal efficiency is defined by the ratio of
isothermal work and actual indicated work in reciprocating compressor.
710 ________________________________________________________ Applied Thermodynamics

Fig. 16.4 Compression process on T-s diagram

Isothermal work
Isothermal efficiency =
Actual indicated work
Practically, compression process is attempted to be closed to isothermal process by air/water
cooling, spraying cold water during compression process. In case of multi-stage compression process
the compression in different stages is accompanied by intercooling in between the stages.
Mathematically, for the compression work following polytropic process, pV n = C. Assuming
negligible clearance volume the cycle work done,
Wc = Area on p-V diagram
LM FG p V - p V IJ OP – p V
N H n -1 KQ
= p2 V2 + 2 2 1 1
1 1

=G
F n IJ [p V – p V ]
H n -1K 2 2 1 1

=G
F n IJ (p V ) LM p V - 1OP
H n -1K N pV Q
2 2
1 1
1 1

F n IJ (p V ) LMF p I - 1OP
( n - 1)

W =G
H n -1K MNH p K
n

PQ
2
c 1 1
1

F n IJ (mRT ) LMF p I - 1OP

W = GH
( n - 1)

n -1K MNH p K
n

PQ
2
c 1
1

W =G
F n IJ mR (T – T )
or, c H n -1K 2 1

In case of compressor having isothermal compression process, n = 1, i.e. p1V1 = p1V2

Wc, iso = p2V2 + p1V1 ln r – p1V1
Reciprocating and Rotary Compressor ______________________________________________ 711
V1
Wc, iso = p1V1 ln r, where r =
V2
In case of compressor having adiabatic compression process, n = g

FG g IJ mR (T
Wc, adiabatic =
H g -1K 2 – T1)

or,
Wc, adiabatic = mCp (T2 – T1)

Wc, adiabatic = m (h2 – h1)

p1V1 ln r

F n I a p V f LMF p I OP
Hence, isothermal efficiency, hiso = ( n - 1)

H n - 1 K MNH p K
n
-1
PQ
2
1 1
1

The isothermal efficiency of a compressor should be close to 100% which means that actual
compression should occur following a process close to isothermal process. For this the mechanism be
derived to maintain constant temperature during compression process. Different arrangements which
can be used are:
(i) Faster heat dissipation from inside of compressor to outside by use of fins over cylinder.
Fins facilitate quick heat transfer from air being compressed to atmosphere so that
temperature rise during compression can be minimized.
(ii) Water jacket may be provided around compressor cylinder so that heat can be picked by
cooling water circulating through water jacket. Cooling water circulation around compressor
regulates rise in temperature to great extent.
(iii) The water may also be injected at the end of compression process in order to cool the air
being compressed. This water injection near the end of compression process requires special
arrangement in compressor and also the air gets mixed with water and needs to be separated
out before being used. Water injection also contaminates the lubricant film on inner surface
of cylinder and may initiate corrosion etc. The water injection is not popularly used.
(iv) In case of multistage compression in different compressors operating serially, the air leaving
one compressor may be cooled up to ambient state or somewhat high temperature before
being injected into subsequent compressor. This cooling of fluid being compressed between
two consecutive compressors is called intercooling and is frequently used in case of
multistage compressors.
Considering clearance volume: With clearance volume the cycle is represented on Fig. 16.3 (b).
The work done for compression of air polytropically can be given by the area enclosed in cycle 1–2–3–
4. Clearance volume in compressors varies from 1.5% to 35% depending upon type of compressor.
Wc, with CV = Area1234

F n IJ (p V ) LMF p I O F n I LMF p I OP
( n - 1) ( n - 1)

=G - 1P – G
H n -1K MNH p K PQ H n - 1 JK (p V )
n

MNH p K
n

PQ
2
1 1 4 4
3
-1
1 4

Here p1 = p4, p2 = p3
712 ________________________________________________________ Applied Thermodynamics

F n IJ (p V ) LMF p I O F n I LF p I OP
( n - 1) ( n - 1)

=G - 1P – G J (p V )× M
H n -1K MNH p K PQ H n - 1 K MNH p K
n n
-1
PQ
2 2
Wc, with CV 1 1 1 4
1 1

F n IJ p × LMF p I O
( n - 1)

=G - 1P × (V – V )
H n - 1 K MNH p K
n

PQ
2
Wc, with CV 1 1 4
1

In the cylinder of reciprocating compressor (V1 – V4) shall be the actual volume of air delivered
per cycle. Vd = V1 – V4. This (V1 – V4) is actually the volume of air inhaled in the cycle and delivered
subsequently.

F n IJ p V
=G
LMF p I n-1
OP
H n -1K MNH p K
n

PQ
Wc, with CV 1 d
2
-1
1

If air is considered to behave as perfect gas then pressure, temperature, volume and mass can be
inter related using perfect gas equation. The mass at state 1 may be given as m1, mass at state 2 shall be
m1, but at state 3 after delivery mass reduces to m2 and at state 4 it shall be m2.
So, at state 1, p1V1 = m1RT1
at state 2, p2V2 = m1RT2
at state 3, p3V3 = m2RT3 or, p2V3 = m2RT3
at state 4, p4V4 = m2RT4, or p1V4 = m2RT4
Ideally there shall be no change in temperature during suction and delivery i.e., T4 = T1 and
T2 = T3. From earlier equation,

F n IJ p LF p I ( n - 1)
OP
= G –V) M
H n -1K MNH p K
n
-1
PQ
2
Wc, with CV 1 (V1 4
1

Temperature and pressure can be related as,

Fp I
( n - 1)
T2
HpK
n
2
=
1 T1

FG p IJ FpI
( n - 1) ( n - 1)
T T4
Hp K Hp K
n n
and 4
= 4 Þ 1
=
3 T3 2 T3
Substituting,
LM T - 1OP
FG n IJ (m RT
H n -1K NT Q
2
Wc, with CV = 1 1 – m2RT4)
1
Substituting for constancy of temperature during suction and delivery.
F n IJ (m RT – m RT ) LM T - T OP
= G
H n -1K N T Q
2 1
W c, with CV 1 1 2 1
1
or,

FG n IJ (m
Wc, with CV =
H n -1K 1 – m2) R(T2 – T1)
Reciprocating and Rotary Compressor ______________________________________________ 713
Thus, (m1 – m2) denotes the mass of air sucked or delivered. For unit mass of air delivered the
work done per kg of air can be given as,

FG n IJ R(T
Wc, with CV =
H n -1K 2 – T1), per kg of air

Thus from above expressions it is obvious that the clearance volume reduces the effective swept
volume i.e. the mass of air handled but the work done per kg of air delivered remains unaffected.
From the cycle work estimated as above the theoretical power required for running compressor
shall be as given ahead.
For single acting compressor running with N rpm, power input required, assuming clearance
volume.
LF n I R|F p I U|O( n - 1)

Power required = M p aV - V f S - 1V P ´ N
MNH n - 1 K |TH p K
n

|WPQ
2
1 1 4
1

LF n I R|F p I ( n - 1)
U|OP
for double acting compressor, power = M p aV - V f S V|P ´ 2N
MNH n - 1 K |TH p K
n
2
-1
WQ
1 1 4
1

Volumetric efficiency: Volumetric efficiency of compressor is the measure of the deviation from
volume handling capacity of compressor. Mathematically, the volumetric efficiency is given by the ratio
of actual volume of air sucked and swept volume of cylinder. Ideally the volume of air sucked should be
equal to the swept volume of cylinder, but it is not so in actual case. Practically the volumetric efficiency
lies between 60 and 90%.
Volumetric efficiency can be overall volumetric efficiency and absolute volumetric efficiency
as given below:
Volume of free air sucked into cylinder
Overall volumetric efficiency =
Swept volume of LP cylinder
or

(Volumetric efficiency
(Mass of air delivered per unit time )
referred to free air conditions) =
F Mass of air corresponding toswept I
GH volume of LP cylinder per unit time
for free air conditions
JK
Here free air condition refers to the standard conditions. Free air condition may be taken as 1 atm
or 1.01325 bar and 15°C or 288 K. Consideration for free air is necessary as otherwise the different
compressors can not be compared using volumetric efficiency because specific volume or density of air
varies with altitude. It may be seen that a compressor at datum level (sea level) shall deliver large mass
than the same compressor at high altitude.
This concept is used for giving the capacity of compressor in terms of ‘free air delivery’ (FAD).
“Free air delivery is the volume of air delivered being reduced to free air conditions.” In case of air the
free air delivery can be obtained using perfect gas equation as,
714 ________________________________________________________ Applied Thermodynamics
pa × Va a
p V - V4
= 1 1
f =
a
p2 V2 - V3 f
Ta T1 T2
where subscript a or pa, Va, Ta denote properties at free air conditions

or,
p1 × Ta × V1 - V4
Va = = FAD per cycle.
a f
pa × T1
This volume Va gives ‘free air delivered’ per cycle by the compressor.
Absolute volumetric efficiency can be defined, using NTP conditions in place of free air condi-
tions.
Volume of air sucked into cylinder at NTP
Absolute volumetric efficiency =
Swept volume of LP cylinder
( Mass of air delivered per unit time )
=
e
Massof air corresponding to swept volume
of LP cylinder per unit time estimated at NTP j
Thus, volumetric efficiency referred to free air conditions.
Volume of air sucked referred to freeair conditions ( FAD )
hvol. =
Swept volume
Va
=
aV - V f
p T aV - V f
1 3

p T aV - V f
1 a 1 4
=
a 1 1 3

F p T I × RS aV + V f - V UV .
hvol.
HpTK T V W
1 a s c 4
=
a 1 s

Here, Vs is swept volume, Vs = V1 – V3

and Vc is clearance volume, Vc = V 3
F p T I RS1 + FG V IJ - FG V IJ UV
hvol. =
H p T K T H V K H V KW
1 a c 4
a 1 s s
Here,
V4 V V
= 4 × c
Vs Vc Vs
V4 VcFG IJ
= ×
V3 Vs H K
Vc
Let the ratio of clearance volume to swept volume be given by C.i.e. = C.
Vs
FG p T IJ × RS1 + C - C × FG V IJ UV
HpTK T
hvol. =
H V KW
1 a 4

a 1 3

F p T IJ × RS1 + C - C × FG p IJ UV
=G
1/ n
hvol.
H p T K |T H p K |W
1 a 2
or,
a 1 1
Reciprocating and Rotary Compressor ______________________________________________ 715
Volumetric efficiency depends on ambient pressure and temperature, suction pressure and tem-
perature, ratio of clearance to swept volume, and pressure limits. Volumetric efficiency increases with
decrease in pressure ratio in compressor.

16.4 ACTUAL INDICATOR DIAGRAM

Theoretical indicator diagram of reciprocating compressor as shown in earlier discussion refers to the
ideal state of operation of compressor. The practical limitations, when considered in the indicator dia-
gram yield actual indicator diagram as shown in Fig. 16.5.

Fig. 16.5 Actual indicator diagram

Actual p-V diagram varies from theoretical p-V diagram due to following: Compressor has
mechanical types of valves so the instantaneous opening and closing of valves can never be achieved.
Also during suction and discharge there occurs throttling due to reduction in area of flow across inlet
and exit valve. 123 4 shows theoretical indicator diagram and actual indicator diagram is shown by
12¢34¢ on p-V diagram. Compression process 1–2 ends at state 2. At state 2 exit valve should open
instantaneously which does not occur and also due to restricted opening there shall be throttling causing
drop in pressure. Due to time lag in opening of exit valve compression process is continued up to 2¢.
Thus, additional work is done during delivery from compressor as shown by hatched area 2 2¢3.
After delivery stroke the inlet valve should theoretically open at 4 but does not open at this point
instead is opened fully at 4¢. Shift from state 4 to 4¢ is there due to inertia in opening of valve throttling,
gradual opening, and friction losses etc. Thus it is seen that during suction there occurs intake depres-
sion as shown in actual indicator diagram. Work required as shown in actual indicator diagram is
more than theoretical diagram. In order to have compressor close to ideal compressor with minimum
losses it shall be desired to have actual indicator diagram close to theoretical diagram, which requires
less inertia and efficient operation of valves. Friction losses in pipings and across valves should be
minimized.
716 ________________________________________________________ Applied Thermodynamics
16.5 MULTISTAGE COMPRESSION
Multistage compression refers to the compression process completed in more than one stage i.e. a part
of compression occurs in one cylinder and subsequently compressed air is sent to subsequent cylinders
for further compression. In case it is desired to increase the compression ratio of compressor then
multi-stage compression becomes inevitable. If we look at the expression for volumetric efficiency then
it shows that the volumetric efficiency decreases with increase in pressure ratio. This aspect can also be
explained using p-V representation shown in Fig. 16.6.

Fig. 16.6 Multistage compression

Figure 16.6 a, shows that by increasing pressure ratio i.e. increasing delivery pressure the volume
of air being sucked goes on reducing as evident from cycles 1234 and 12¢ 3¢4¢. Let us increase pressure
from p2 to p2¢ and this shall cause the suction process to get modified from 4–1 to 4¢–1. Thus volume
FG p IJ to FG p ¢ IJ ,
HpK Hp K
2 2
sucked reduces from (V1 – V4) to (V1 – V4¢) with increased pressure ratio from
1 1
thereby reducing the free air delivery while swept volume remains same.
Therefore, the volumetric efficiency reduces with increasing pressure ratio in compressor with
single stage compression. Also for getting the same amount of free air delivery the size of cylinder is to
be increased with increasing pressure ratio. The increase in pressure ratio also requires sturdy structure
from mechanical strength point of view for withstanding large pressure difference.
The solution to number of difficulties discussed above lies in using the multistage compression
where compression occurs in parts in different cylinders one after the other. Figure 16.6 b, shows the
multistage compression occurring in two stages. Here first stage of compression occurs in cycle 12671
and after first stage compression partly compressed air enters second stage of compression and occurs
in cycle 2345. In case of multistage compression the compression in first stage occurs at low temperature
and subsequent compression in following stages occurs at higher temperature. The compression work
requirement depends largely upon the average temperature during compression. Higher average tem-
perature during compression has larger work requirement compared to low temperature so it is always
desired to keep the low average temperature during compression.
Apart from the cooling during compression the temperature of air at inlet to compressor can be
reduced so as to reduce compression work. In multistage compression the partly compressed air leav-
ing first stage is cooled up to ambient air temperature in intercooler and then sent to subsequent cylinder
(stage) for compression. Thus, intercoolers when put between the stages reduce the compression work
and compression is called intercooled compression. Intercooling is called perfect when temperature at
Reciprocating and Rotary Compressor ______________________________________________ 717
inlet to subsequent stages of compression is reduced to ambient temperature. Figure 16.6 c, shows
multistage (two stage) intercooled compression. Intercooling between two stages causes temperature
drop from 2 to 2¢ i.e. discharge from first stage (at 2) is cooled up to the ambient temperature state (at
2¢) which lies on isothermal compression process 1–2¢–3². In the absence of intercooling the discharge
from first stage shall enter at 2. Final discharge from second stage occurs at 3¢ in case of intercooled
compression compared to discharge at 3 in case of non-intercooled compression. Thus, intercooling
offers reduced work requirement by the amount shown by area 22¢3¢ 3 on p-V diagram. If the inter-
cooling is not perfect then the inlet state to second/subsequent stage shall not lie on the isothermal
compression process line and this state shall lie between actual discharge state from first stage and
isothermal compression line.

Fig. 16.7 Schematic for two-stage compression (Multistage compressor)

Figure 16.7 shows the schematic of multi stage compressor (double stage) with intercooler
between stages. T–s representation is shown in Fig. 16.8. The total work requirement for running this
shall be algebraic summation of work required for low pressure (LP) and high pressure (HP) stages.
The size of HP cylinder is smaller than LP cylinder as HP cylinder handles high pressure air having
smaller specific volume.

Fig. 16.8 T-s representation of multistage compression

Mathematical analysis of multistage compressor is done with following assumptions:
(i) Compression in all the stages is done following same index of compression and there is no
pressure drop in suction and delivery pressures in each stage. Suction and delivery pressure
remains constant in the stages.
718 ________________________________________________________ Applied Thermodynamics
(ii) There is perfect intercooling between compression stages.
(iii) Mass handled in different stages is same i.e. mass of air in LP and HP stages are same.
(iv) Air behaves as perfect gas during compression.
From combined p-V diagram the compressor work requirement can be given as,

FG n IJ p V R|F p I
( n - 1)
U|
Work requirement in LP cylinder, WLP =
H n -1K S|H p 2
K
n
-1 V|
T W
1 1
1

F n IJ p V R|F p I
( n - 1)
U|
= G S|H p - 1V
H n -1K K
n
2¢

|W
Work requirement in HP cylinder, WHP
T
2 2
2

For perfect intercooling, p1V1 = p2V2¢ and

F n IJ p V R|F p I ( n - 1)
U|
=G S|H p K V|
H n -1K
n
2¢
WHP -1
T W
2 2¢
2

Therefore, total work requirement, Wc = WLP + WHP, for perfect intercooling

F n IJ LM p V R|SFG p IJ U| R|F p I U|OP

n -1 n -1

W =G - 1V + p V SG
H n - 1 K MN |TH p K |TH p JK V|P
n n
2¢
2
-1
c 1 1
1 |W 2 2¢
2
WQ
F n IJ LM p V R|SFG p IJ U| R|F p I U|O
n -1 n -1

=G - 1V + p V SG - 1VP
H n - 1 K MN |TH p K |W |TH p JK |WPQ
n n
2 2¢
1 1 1 1
1 2

F n IJ p V LMFG p IJ F p IJ - 2OP
n-1 n -1

W =G +G
H n - 1 K MNH p K
n n

Hp K PQ
2 2¢
c 1 1
1 2

Power required can be given in HP as below, considering speed to be N rpm.

Wc ´ N
Power = , HP
75 ´ 60
If we look at compressor work then it shows that with the initial and final pressures p1 and p2¢
remaining same the intermediate pressure p2 may have value floating between p1 and p2¢ and change the
work requirement Wc. Thus, the compressor work can be optimized with respect to intermediate pres-
sure p2. Mathematically, it can be differentiated with respect to p2.
LMF n I R|F p I n -1
F p IJ U|OP n -1

MNGH n - 1 JK p V S|TGH p JK +G V|P

d Wc d n n

Hp K
2¢
= 2
-2
WQ
1 1
d p2 d p2 1 2

F n IJ p V × d R|SFG p IJ F p IJ - 2 U|V
n -1 n-1

=G +G
d Wc
H n - 1 K d p |TH p K
n n

Hp K
2 2¢
d p2
1 1
2 1 2 |W
Reciprocating and Rotary Compressor ______________________________________________ 719

FG n IJ p V RSF n - 1 I × p -F
UV
H n IK × p
1- n -1 n -1 1 - 2n
n -1
H n - 1 K TH n K
d Wc n
× p2 n n
p2 n
W
= 1 1 1 2¢
d p2

d Wc
Equating, = 0 yields.
d p2
1- n -1 n -1 1 - 2n
p1 n × p2 n = p2 ¢ n × p2 n
- 2 + 2n n -1 n -1
or p2 n = p2 ¢ n × p1 n
FH IK
fFH IK
n -1
or
2
p2 n a
= p1 × p2 ¢
n -1
n or, p22 = p1 × p2¢, p2 = p1 × p2 ¢

p2 p p2 FG p IJ 1/ 2

HpK
2¢
or = 2 ¢ or =
p1 p2 p1 1

Pressure ratio in Ist stage = Pressure ratio in IInd stage

Thus, it is established that the compressor work requirement shall be minimum when the pressure
ratio in each stage is equal.
In case of multiple stages, say i number of stages, for the delivery and suction pressures of pi +1
and p1 the optimum stage pressure ratio shall be,

FG p IJ 1/ i

H p K
i +1
Optimum stage pressure ratio = for pressures at stages being p1, p2, p3, p4, p5, ¼,
1
pi – 1, pi, pi + 1
Minimum work required in two stage compressor can be given by

F n IJ p V LF p I n-1
OP
= G × 2 MG
H n -1K MNH p JK
n
-1
PQ
2
Wc, min 1 1
1

For i number of stages, minimum work,

 n −1 n −1 n −1 n −1

FG n IJ p V 
 2 p
 p 
 n  p  n 
+  +  + +
3 p 4
 n
…
 pi + 1  n
 − i

Wc, min =
H n -1K 1 1
 1  p2   p3   pi 


F n IJ p V LMFG p IJ OP
n -1

= i ×G
H n - 1 K MNH p K
n
-1
PQ
2
Wc, min 1 1
1

or,

F n IJ p V LMF p I n -1
OP
= i×G
MNGH p JK
n ×i

H n -1K PQ
i +1
Wc, min 1 1 -1
i

It also shows that for optimum pressure ratio the work required in different stages remains same
for the assumptions made for present analysis. Due to pressure ratio being equal in all stages the
temperature ratios and maximum temperature in each stage remains same for perfect intercooling.
720 ________________________________________________________ Applied Thermodynamics
Cylinder dimensions: In case of multistage compressor the dimension of cylinders can be esti-
mated basing upon the fact that the mass flow rate of air across the stages remains same. For perfect
intercooling the temperature of air at suction of each stage shall be same.
If the actual volume sucked during suction stroke is V1, V2, V3 ¼, for different stages then by
perfect gas law, p1V1 = RT1, p2V2 = RT2, p3V3 = RT3
For perfect intercooling (T1 = T2 = T3 = ¼) so
p1V1 = RT1, p2V2 = RT1, p3V3 = RT1,
or p1V1 = p2V2 = p3V3 = ¼

If the volumetric efficiency of respective stages in h V1 , h V2 , h V3 , ¼

V1
Then theoretical volume of cylinder 1, V1, th = ; V1 = h V1 ×V1, th
h V1

V2
cylinder 2, V2, th = ; V2 = hV2 × V2, th
h V2
V3
cylinder 3, V3, th= ; V3 = hV3 × V3, th
h V3

Substituting,
p1×hV1×V1, th = p2×hV2×V2, th = p3×hV3×V3, th = ¼
Theoretical volumes of cylinder can be given using geometrical dimensions of cylinder as diam-
eters D1, D2, D3, ¼ and stroke lengths L1, L2, L3, ¼.
p
or V1, th = D 2×L
4 1 1
p 2
V2, th = D ×L
4 2 2
p
V3, th = D 2×L
4 3 3
or,
p p p
p1×hVi× D 2 L = p2×hV2× D22 L2 = p3×hV3× D32×L3 = ¼
4 1 1 4 4
p1 hV1×D1 L1 = p2×hV2×D2 ×L2 = p3×hV3×D3 ×L3 = ¼
2 2 2

If the volumetric efficiency is same for all cylinders, i.e. hV1 = hV2 = hV3 = ¼ and stroke for all
cylinder is same i.e. L1 = L2 = L3 = ¼
Then, D12 p1 = D22 p2 = D32 p3 = ¼
These generic relations may be used for getting the ratio of diameters of cylinders of multistage
compression.
Energy balance: Energy balance may be applied on the different components constituting
multistage compression.
Reciprocating and Rotary Compressor ______________________________________________ 721
For LP stage the steady flow energy equation can be written as below:
m×h1 + WLP = mh2 + QLP
QLP = WLP – m (h2 – h1)
QLP = WLP – mCp (T2 – T1)

Fig. 16.9
For intercooling (Fig. 16.10) between LP and HP stage steady flow energy equation shall be;
mh2 = mh2 ¢ + QInt
or,
QInt = m (h2 – h2¢)
QInt = mCp (T2 – T2¢)

Fig. 16.10
For HP stage (Fig. 16.11) the steady flow energy equation yields.
mh2¢ + WHP = mh3¢ + QHP
QHP = WHP + m (h2¢ – h3¢)
QHP = WHP + mCp (T2¢ – T3¢) = WHP – mCp (T3¢ – T2¢)

Fig. 16.11
In case of perfect intercooling and optimum pressure ratio, T2¢ = T1 and T2 = T3¢
Hence for these conditions,
QLP = WLP – mCp (T2 – T1)
722 ________________________________________________________ Applied Thermodynamics
QInt = mCp (T2 – T1)
QHP = WHP – mCp (T2 – T1)
Total heat rejected during compression shall be the sum of heat rejected during compression and
heat extracted in intercooler for perfect intercooling.
F g - n I ´ Work
Heat rejected during compression for polytropic process =
H g -1 K
16.6 CONTROL OF RECIPROCATING COMPRESSORS
Output from the compressors can be controlled by different measures which regulate the compressor
output. In practical applications the compressors are fitted with air receiver to store the high pressure air
and supply as and when required. Therefore, the compressors are run only for the duration required to
maintain the limiting pressure inside receiver. When the pressure inside receiver starts dropping down
then the compressor again starts supplying compressed air till the level is restored. Different ways for
this control are based on throttle, clearance, blow off control and speed control.
(i) Throttle control has the regulation of opening/closing of inlet valve so that the quantity of
air entering can be varied. With partial opening of inlet valve throttling occurs at valve and
quantity of air entering is reduced while the pressure ratio gets increased.
(ii) Clearance control is the arrangement in which the clearance volume is increased when
pressure ratio exceeds the limit. For this cylinder has clearance openings which are closed
by spring loaded valves. Whenever pressure exceeds, then the clearance openings get opened
and the increased clearance volume reduces maximum pressure.
(iii) Blow-off control has spring loaded safety valve or by pass valve for blowing out excess air
in receiver. After release of excess air automatically the valve gets closed on its own.
(iv) Speed of compressor can also be controlled by regulating the prime mover, thereby
regulating compressor output. Thus, compressor is run on variable speed for its’ control.

16.7 RECIPROCATING AIR MOTOR

Air motors are actually prime movers run using the compressed air. It is used extensively in the applica-
tions where electric motor/IC engine/Gas turbine etc. can not be used due to fire hazard, specially in
coal/oil mining applications. Apart from use of air motors in coal/oil mines these are also used
for running pneumatic tools in workshops and manufacturing/assembly lines. Air motors have a recip-
rocating piston-cylinder arrangement where compressed air is admitted in cylinder with inlet valve open
for limited period in suction stroke and this causes piston movement to yield shaft work. Thus air
motors are reverse of air compressors. Schematic for air motor and p–V diagram for cycle used is
shown in Fig. 16.12.
Compressed air enters the cylinder up to state 1 and expands up to state 2. Expansion process is
generally polytropic and yields expansion work. Expansion is terminated even before the atmospheric
pressure is reached because in later part of expansion the positive work is less than negative work. The
exhaust valve opens causing drop in pressure from 2 to 3. Exhaust pressure is slightly more or nearly
equal to atmospheric pressure. The exhaust of air occurs at constant pressure up to state 4 where the
closing of exhaust valve occurs. The inlet valve is opened at state 5 causing sudden rise in pressure upto
state 6 after which piston displacement begins and is continued with compressed air inlet up to state 1
after which expansion occurs with inlet valve closed. Here point of cut-off is at state 1 which can be
Reciprocating and Rotary Compressor ______________________________________________ 723
suitably varied depending upon output required from air motor. Here, total work available is the result of
non-expansive work during 6–1 and expansion work during 1–2.
Work available from air motor can be quantified by the area enclosed on p-V diagram.
FG p V - p V IJ – (V FG p V - p V IJ
H n -1 K H n -1 K
1 1 2 2 5 5 4 4
Wmotor = p1 (V1 – V6) + 3 – V4) p3 –

Fig. 16.12 Reciprocating air motor

Air motor suffers from the drawback that in case of expansion the air temperature may even go
below the dew point temperature and moisture may condense or even get frozen also inside the cylinder.
This phenomenon may be prevented by increasing the temperature of air entering cylinder so that
temperature after expansion does not go near the dew point temperature. Some times air is heated before
being supplied to air motors in order to avoid condensation.

16.8 ROTARY COMPRESSORS

Rotary compressors are those compressors in which rotating action is used for compression of fluid.
Rotary air compressors have capability of running at high speeds up to 40,000 rpm and can be directly
coupled to any prime mover such as electric motor, turbine etc. due to compact design, no balancing
problem and less no. of sliding parts. Comparative study of rotary compressor with reciprocating
compressor shows that rotary compressors can be used for delivering large quantity of air but the
maximum pressure at delivery is less compared to reciprocating compressors. Generally, rotary com-
pressors can yield delivery pressure up to 10 bar and free air delivery of 3000 m3/min. Rotary compres-
sors are less bulky, and offer uniform discharge compared to reciprocating compressor even in the
absence of big size receiver. Lubrication requirement and wear and tear is less due to rotary motion of
parts in rotary compressors compared to reciprocating compressors.
Rotary compressors may work on the principle of positive displacement and dynamic action
both. Rotary compressors having positive displacement may be of following types:
(i) Roots blower
(ii) Screw type or Helical type compressor
(iii) Vane type compressor
724 ________________________________________________________ Applied Thermodynamics
Rotary compressors employing dynamic action may be of centrifugal type or axial type depending
upon the direction of flow. These centrifugal type or axial compressors may also be termed as non-
positive displacement type steady flow compressors.
(i) Roots blower: Roots blower is a positive displacement type rotary compressor. It has two
rotors having two or three lobes having epicycloid and hypocycloid or involute profiles such that they
remain in proper contact. Figure 16.13 shows two lobe rotors in a roots blower. To prevent wear and
tear two rotors have clearance in between. Out of two rotors one is driven by prime mover while other
one is driven by first rotor. When two rotors rotate then their typical geometry divides the region inside
casing into two regions i.e. high pressure region and low pressure region. Although there occurs slight
leakage across the mating parts which can only be minimised not eliminated completely.

Fig. 16.13 Roots blower

Figure 16.13 b shows the general arrangement in roots blower. It has inlet at section 1–1 and exit
at 2–2. Air at atmospheric pressure enters the casing and is trapped between rotor A and the casing.
When the rotor rotate then air trapped in volume space V is displaced towards high pressure region due
to rotation of rotor. Exit end is connected to receiver in which air is gradually transferred and the
pressure inside receiver increases due to cumulative effect of air being transferred from atmospheric
pressure region to receiver region. In one revolution this positive displacement of air trapped between
rotor and casing from inlet end to receiver end shall occur four times in case of two lobe rotor as
shown. While in case of three lobes rotor this transfer shall occur six times. Every time when V volume
of air is displaced without being compressed to the receiver side high pressure region, then the high
pressure air rushes back from receiver and mixes irreversibly with this air until the pressure gets
equalized. Thus, gradually air pressure builds up and say this pressure becomes p2. For inlet air pressure
being p1, the work done per cycle,
Reciprocating and Rotary Compressor ______________________________________________ 725
W = (p2 – p1) ´ V
In one revolution the total work required shall depend on number of lobes in rotor and in case of
two lobes rotor,
Wrevolution = (p2 – p1) ´ (4 V)
Let volume thus compressed in one revolution, be Vc = 4V
FG p - 1IJ V
Hp K
2
Wrevolution = (p2 – p1)×Vc = p1 c
1

The efficiency of compression can be defined by taking the ratio of work required in compressing
the air isentropically and actual work done. This efficiency is also called roots efficiency.
Work required in reversible adiabatic (isentropic ) compression
Roots efficiency =
Actual work required in compression
For compressing volume Vc from pressure p1 to p2 the work required in reversible adiabatic
(isentropic) compression shall be;

F g Ip R|F p I U| g -1

V S - 1V
g

H g - 1K |TH p K
2

|W
Wisen = 1 c
1

F g I p V R|SF p I - 1U|V
g -1
g
H g - 1 K |TH p K
1 c
2

|W
1
hroots =
W a= W f
F g I p V R|SF p I - 1U|V
actual revolution
g -1
g

H g - 1 K T|H p K
2

W|
1 c
1
hroots =
F - 1I V
p
Hp K
2
p
1 c
1

p2
Let pressure ratio be given by, r =
p1
so,
R|r - 1U|
g -1

g I |T
S g
V|
F W
hroots =
H g - 1 K {r - 1}
The expression for roots blower efficiency shows that the efficiency depends upon pressure
ratio and the increase in pressure ratio yields decrease in roots efficiency. At low pressure ratios the
roots efficiency is quite high. Reduced efficiency with high pressure ratios is attributed to the mecha-
nism involved in pressure rise. With high pressure ratio there occurs the reversal of flow during positive
displacement of air from casing to receiver. This reversal causes the loss of energy thereby lowering
efficiency due to increased actual work requirement.
726 ________________________________________________________ Applied Thermodynamics
Roots blower are available in the capacity ranging from 0.15 m3/min to 1500 m3/min and the
pressure ratios are of the order of 1 to 3.5. These are generally used for scavenging, supercharging of
IC engines etc. Generally the roots efficiency is around 50–60% but high efficiency values up to 80%
can also be achieved with low pressure ratios.
(ii) Screw type or Helical type compressor: Screw type compressor is very much similar to
roots blower.

Fig. 16.14 Line sketch of screw compressor

These may have two spiral lobed rotors, out of which one may be called male rotor having
3–4 lobes and other female rotor having 4–6 lobes which intermesh with small clearance. Meshing is
such that lobes jutting out of male rotor get placed in matching hollow portion in female rotors. Initially,
before this intermeshing the hollows remain filled with gaseous fluid at inlet port. As rotation begins the
surface in contact move parallel to the axis of rotors toward the outlet end gradually compressing the
fluid till the trapped volume reaches up to outlet port for getting discharged out at designed pressure.
Since the number of lobes are different so the rotors operate at different speed.
The material of casing may be cast iron or cast steel while rotors may be of steel and generally
internally cooled by circulation of lubrication oil. Surface of lobes are smooth and the shaft is sealed by
carbon rings at oil pressure. Two rotors are brought into synchronization by the screw gears. Thrust
upon rotors is taken care of by oil lubricated thrust bearings.
These compressors are capable of handling gas flows ranging from 200 to 20000 m3/h under
discharge pressures of 3 bar gauge in single stage and up to 13 bar gauge in two stages. Even with
increase in number of stages pressures up to 100 bar absolute have been obtained with stage pressure
ratio of 2.
Reciprocating and Rotary Compressor ______________________________________________ 727
Mechanical efficiency of these compressors is quite high and their isothermal efficiencies are
even more than vane blowers and may be compared with centrifugal and axial compressors. But these
are very noisy, sensitive to dust and fragile due to small clearances.
(iii) Vane type compressor: Schematic of vane type compressor is shown in Fig. 16.15. It has
cylindrical casing having an eccentrically mounted rotor inside it. The rotor has number of slots in it
with rectangular vanes of spring loaded type mounted in slots. These vanes are generally non metallic
and made of fibre or carbon composites or any other wear resistant material. These vanes remain in
continuous contact with casing such that leakage across the vane-casing interface is minimum or
absent. It has one end as inlet end and other as the delivery end connected to receiver. Upon rotation the
eccentric rotor has the vanes having differential projection out of rotor depending upon their position.
Air is trapped between each set of two consecutive blades in front of inlet passage and is positively
displaced to the delivery end after compressing the volume V1 initially to V2, V3 and V4. When com-
pressed volume comes in front of delivery passage and further rotation results in the situation when
partly compressed air is forced to enter the receiver as their is no other way out. This cumulative
transfer of partly compressed air in receiver causes irreversible compression resulting in gradual pres-
sure rise. The p-V representation shown in Fig. 16.15 (b) indicates that the total pressure rise is due to
the combined effect of reversible pressure rise inside casing and irreversible pressure rise inside re-
ceiver. Generally, the contribution of reversible pressure rise and irreversible pressure rise is in propor-
tion of 50 : 50.

Fig. 16.15 Vane type compressor

Vane compressors are available for capacity up to 150 m3/min and pressure ratios up to 8 and
efficiency up to 75%. For higher pressure ratios the efficiency of vane compressors is more than that of
roots blower but the vane compressors have maximum speed up to 2500 rpm as compared to 7500 rpm
in case of roots blower. Vane compressors have large power requirement as compared to roots blower
728 ________________________________________________________ Applied Thermodynamics
due to large number of vanes on rotor. However, with small number of vanes the power required by
vaned compressor may be comparable to roots blower. Vane compressors require large maintenance
due to wear of vanes and other moving parts.
Work required per revolution for vane compressor with n number of vanes shall be partly in
reversible and partly in irreversible process.
Let the inlet air be at pressure p1 and volume trapped is V1. This volume is partly compressed
up to volume V4 and pressure rises from to p1 to p2, p3 and p4. Thus, the irreversible compression
occurs for volume V4 and pressure rising from p4 to pf.

F g I ×p V R|SF p I U|
g -1

Total work required, W = n

H g - 1 K |TH p K
4 g
V|
- 1 + n (pf – p4) × V4
W
1 1
1

16.9 CENTRIFUGAL COMPRESSORS

Centrifugal compressor is a radial flow machine compressing the fluid due to the dynamic action of
impeller. Centrifugal compressors have impeller mounted on driving shaft, diffuser and volute casing as
shown in Fig. 16.16. Centrifugal compressors have air inlet at the centre of impeller. The portion of
impeller in front of inlet passage is called impeller eye.

Fig. 16.16 Centrifugal compressor

Impeller is a type of disc having radial blades mounted upon it. Compressor casing has a diffuser
ring surrounding impeller and the air enters the impeller eye and leaves from impeller tip to enter diffuser
ring. Volute casing surrounds the diffuser ring. Volute casing has cross section area increasing gradually
up to the exit of compressor. These impellers of centrifugal compressors may also be of double sided
type such that air can enter from two sides (both) of impeller. Thus double sided impeller shall have
double impeller eye compared to single impeller eye as shown in Fig. 16.17.
Reciprocating and Rotary Compressor ______________________________________________ 729

Fig. 16.17 Single sided impeller and double sided impeller

Air enters the impeller eye axially and flows radially outwards after having entered compressor.
Radial flow of air inside compressor is due to impeller (blades) rotating about its axis. These impeller
blades impart momentum to the air entering, thereby rising its pressure and temperature. Subsequently
the high pressure fluid leaving impeller enters the diffuser ring where the velocity of air is lowered with
further increase in pressure of air. Thus in diffuser ring the kinetic energy of air is transformed into
pressure head. High pressure air leaving diffuser is carried by volute casing to the exit of compressor.
Due to increased cross section area of volute casing some velocity is further reduced causing rise in its
pressure, although this is very small. Total pressure rise in compressor may be due to ‘impeller action’
and ‘diffuser action’ both. Generally, about half of total pressure rise is available in impeller and remain-
ing half in diffuser. Pressure and velocity variation in centrifugal compressor is shown in Fig. 16.18.

Fig. 16.18 Pressure and velocity variation in compressors

Centrifugal compressors are used in aircrafts, blowers, superchargers, etc. where large quantity
of air is to be supplied at smaller pressure ratios. Generally, pressure ratio up to 4 is achieved in single
730 ________________________________________________________ Applied Thermodynamics
stage centrifugal compressors while in multistage compressors the pressure ratio up to 12 can be
achieved. These compressors run at speed of 20,000–30,000 rpm.
Thermodynamic analysis: In case of centrifugal compressors the fluid is being compressed
following reversible adiabatic process ideally. In actual case the frictionless adiabatic compression is not
possible due the frictional losses between fluid and casing. Irreversibilities also creep into compression
process due to the entry and exit losses such as throttling, shock at inlet and exit and eddy formation etc.
Therefore, the actual compression occurs following polytropic compression process. Figure 16.19
shows the T–s representation for ideal and actual compression process.

Fig. 16.19 T-s representation for compression in centrifugal compressor

Compression process may also be of cooled type and this cooling during compression modifies
the process to 1–2². Actual compression process may have the index of compression value (generally,
n = 1.5 to 1.7) more than that of adiabatic process (for air, g = 1.4). But the cooling reduces the index
value even less than the adiabatic index.
In centrifugal compressor the fluid moves with significant velocity during compression i.e. it has
considerable kinetic energy which can not be neglected. For correct thermodynamic analysis the kinetic
energy of fluid should be considered. The stagnation properties are evolved for considering the effect of
fluid velocity. These considerations are not required in analysis of reciprocating compressors because
the velocities are quite small and so negligible. Stagnation property refers to thermodynamic property of
fluid upon being decelerated to zero velocity isentropically as described in earlier chapter of gas power
cycles.
Velocity diagram for centrifugal compressor: Figure 16.20 shows the velocity diagram for impeller
blade of centrifugal compressor. Air enters the blade at 1 and leaves at 2. The air velocity at inlet and exit
corresponding to the blade angles are shown on velocity diagrams for axial entry i.e. a1 = 90°.
Tangential force acting on blade can be estimated by change in whirl velocity value;
= m (Cw2 – Cw1); for axial entry Cw1 = 0
FT = m Cw2. This tangential force shall be responsible for rotation of shaft. The work done on
impeller can be estimated using tangential force and distance travelled along the direction of force. This
work is also called Euler’s work.
W = m×Cw2 ´ U2
Reciprocating and Rotary Compressor ______________________________________________ 731

Fig. 16.20 Velocity diagrams for centrifugal compressor

For radial blades on impeller the whirl velocity Cw2 shall coincide with U2 i.e. velocity diagram at
exit of impeller blade;

and, W = mU22
This work required can also be estimated in terms of thermodynamic properties. By steady flow
energy equation between sections 1 and 2 for no heat interaction in case of adiabatic compression
process for no change in potential energy.
C12 C2
h1 + + W = h2 + 2
2 2
FG IJ – m FG h + C IJ
C22 2

H
W = m h2 +
K H 2K
1
1
2
F T + C I – mC F T + C I
GH 2 C JK GH 2 C JK
2 2
2 1
W = mCp 2 p 1
p p

From definition of stagnation temperature,

FT I=T F I =T
GH 2 +
C22
2 Cp JK o2 GH
and T1 +
C12
2 Cp JK 01
732 ________________________________________________________ Applied Thermodynamics

or W = mCp (T02 – T01)

Thus, impeller work can be given by the product of specific heat and change in stagnation tem-
perature from inlet to exit.
LM T - 1OP
NT Q
o2
W = mCp To1
o1

LM F p I g -1
g
OP
MM T H p K PP
02
2
2
W = mCp To1
MM T F p I P
g -1

-1P
g

N HpK Q
o1
1
1

LMF p I g -1
O
- 1P
g

MNH p K PQ
o2
W = m Cp To1
o1

FG p IJ is ratio of stagnation pressure across impeller. For radial flow blades, substituting
Hp K
02
Here,
01
for W,
LMF p I g -1
g
OP
MNH p K -1
PQ
02
mU22 = mCpT01
01

FG p IJ = LM U O
g

+ 1P
2 g -1

H p K NC T Q
02 2
or,
01 p 01
Thus, it shows that stagnation pressure ratio depends on the square of blade tip speed. Here it has
been assumed that in case of radial blades blade tip speed is equal to the whirl velocity component,
which is not valid condition in reference to actual operation.
Actually, due to turbulence and secondary flow effects the Cw2 ¹ U2 and the Cw2 < U2. Difference
between U2 and Cw2 i.e. (U2 – Cw2) is called the slip. This slip is quantified by the parameter called slip
factor. Slip factor is the ratio of actual whirl velocity component to the ideal whirl velocity component.
Cw2 Actual whirl velocity Cw2 a f
Slip factor =
U2
=
Ideal whirl velocity U2 a f
Losses in centrifugal compressor: Centrifugal compressor has losses at inlet. Every compressor
offers its optimum performance at design operation. Any deviation from design condition increases the
different losses occuring in it. Due to friction, turbulence, eddy formation etc. there are flow losses
inside the compressor. These losses are proportional to the square of flow velocity. Compressibility of
fluid at high Mach nos. also offers losses. Losses in diffuser, volute casing are also there due to friction.
Friction and secondary flow losses also cause slip and actual whirl component is less than theoretical
value.

16.10 AXIAL FLOW COMPRESSORS

Axial flow compressors have the fixed blades and moving blades mounted along the axis of compressor.
Air enters axially and leaves axially. It has primarily two components i.e. rotor and casing. The rotor has
Reciprocating and Rotary Compressor ______________________________________________ 733
blades mounted on it constituting moving blade ring. Blades are also mounted on the inner side of casing
thereby constituting stages as fixed blade ring followed by moving blade ring followed by fixed blade
ring, moving blade ring and so on.
Due to the reduction in volume the volume space for compressed air may be gradually reduced.
Gradual reduction in volume can be done by flaring the rotor while keeping stator diameter uniform or
by flaring the stator while keeping rotor diameter constant as shown in fig. 16.21. The pressure of fluid
entering the axial flow compressor increases upon passing through the fixed and moving blades. This
flow of fluid over moving blades is accompanied by enthalpy rise while the fixed blades merely deflect
the fluid so as to facilitate smooth entry into moving blades. Absolute velocity of air increases along axis
of rotor due to work input from the prime mover. Relative velocity of air decreases during its flow
through rotor. Blades have aerofoil section so as to have minimum losses due to turbulence, boundary
layer formation and separation, eddy formation etc.

Fig. 16.21 Axial flow compressor

16.11 SURGING AND CHOKING

Let us look at the variation of theoretical pressure ratio with mass flow rate in case of a centrifugal
compressor running at constant speed, as shown in Fig. 16.22.
734 ________________________________________________________ Applied Thermodynamics
Let the compressor be run with completely closed delivery valve thus the mass flow rate is zero
and pressure ratio available is shown by point a. This operating state of compressor shall not have any
amount of air entering into it instead the air trapped inside the impeller and casing shall be subjected to
impeller action (compression) causing its pressure rise upto the state a. Now upon opening of delivery
valve the flow of air into compressor and its discharge begins. With this gradual opening of delivery
valve the pressure ratio increases, say from state a to b and c along with increase in mass flow rate. The
pressure ratio reaches to some maximum value at point c. Further opening of delivery valve shows that
the mass flow rate increases but the pressure ratio decreases after point c i.e. beyond the point having
maximum pressure ratio. The decrease in pressure ratio is due to the dominance of pressure loss due to
friction etc. over the pressure rise in diffuser. After point c pressure losses are more than the pressure
rise thereby, showing net decrease in pressure ratio as evident from points d and e on the delivery
pressure vs mass flow rate characteristic curve.

Fig. 16.22 Surging and choking

Theoretically, the characteristic curve may be extrapolated and the maximum discharge (mass
flow rate) is evident from point f at which the pressure ratio becomes unity and efficiency is zero.
Maximum efficiency is available at the point (c) corresponding to the maximum pressure ratio. At the
state f all work input to compressor is used in overcoming frictional resistance. In actual case the state
‘e’ shall indicate the maximum mass flow rate practically possible. This maximum mass flow state is
known as choked mass flow. State of operation of compressor at point e is called ‘choking’ of com-
pressor. Choking gives the maximum mass flow from compressor and the pressure ratio corresponding
to this is less than maximum pressure ratio.
Reciprocating and Rotary Compressor ______________________________________________ 735
Let us open delivery valve for increase in mass flow rate from mb to mb1. With this opening of
valve the delivery pressure increases from pb to pb1. At point b1 the pressure on upstream and down
stream do not rise simultaneously instead the pressure at upstream becomes pb1 while in downstream it
remains pb for some time, due to inertia till pressure is not equalized. Since pb < pb1 so there is no
problem in terms of flow reversal. Similarly as the delivery valve is gradually opened up to state c there
is no problem of flow reversal as upstream pressure is always more than downstream pressure up to c.
Upon partly closing the delivery valve, say from b to b2 the mass flow rate decreases from mb to mb2.
This is accompanied by decrease in pressure at both upstream and downstream. Pressure at upstream
gets changed (lowered) from pb to pb2 (pb2 < pb) instantaneously while the downstream pressure remains
equal to pb for some time due to inertia. Pressure gets equalized to pb2 after some time lag. During this
time lag the reversal of flow (stoppage of discharge from compressor) occurs from downstream to
upstream as in transient period downstream pressure pb is more than upstream pressure pb2. Reversed
flow stabilizes to normal flow after the pressure gets equalized. This reversal of flow occurs during part
closing of valve in the operating range from a to c. Reversal of flow causes pulsations to the compressor
and the noise, vibration and, jerks are felt during this transition period. This phenomenon is called
‘surging’. Similar, study of part closing and opening of valve when carried out in between c and e shows
that no such reversed flow is observed. This changed behaviour is seen as even in case of closing of
valve the mass flow rate shall decrease but the pressure ratio increases and in case of opening of valve
the mass flow rate increases although pressure ratio decreases. Region lying between c and e gives the
safe operating zone where surging phenomenon is not observed and also it is within the limits of choking
of compressor. Compressor should be therefore run between c and e for its’ smooth running. The
excessive surging may even lead to failure (fracture) of rotating parts in compressor and is therefore
completely avoided. For every compressor the safe zone for its operation is obtained and compressors
are run in that region.
Surging generally occurs in diffuser passages where the flow is slightly obstructed and gets
retarded due to friction near vanes. Surging tends to increase with increasing number of diffuser vanes
as with large no. of vanes it becomes difficult to divide air equally in all the passages. To avoid this the
number of diffuser vanes is kept less than the impeller blades so that each of diffuser vane passage is
provided with flow from more than one impeller blade channel. Thus, the condition of flow remain
nearly same for all diffuser passages and surging due to flow reversal does not occur.

16.12 STALLING
Stalling refers to the instability in the flow occurring due to flow separation from blade surfaces. Stalling
may occur due to the non-uniform flow passing through the channels/passage between consecutive
blades/vanes. In case of centrifugal compressor the flow output from impeller passes into the diffuser
vanes and subsequently to exit end. In case of breakdown of flow in any one channel in diffuser, which
may be due to reduced angle of incidence/increased angle of incidence, the flow pattern gets disturbed.
For example the Fig. 16.23 shows the reduced angle of incidence in channel B of diffuser section in
centrifugal compressor. Since the diffuser vanes are supposed to handle the similar amount of total flow
therefore, inspite of reduced flow through the channel B (due to reduced angle of incidence) the mass
flow rate does not change. Due to reduced flow through B the remaining channels have to carry
additional flow in order to compensate for flow reduction in one of channels. These different angles of
incidence into different channels result into non-uniform mass of air being handled by these channels.
Such as in present case channel A has higher angle of incidence and channel C has reduced angle of
incidence due to reduced flow through channel B. It results into flow separation due to increase and
decrease in angle of incidence. Flow separation disturbs the flow pattern and results into excessive
736 ________________________________________________________ Applied Thermodynamics
vibrations. This stall phenomenon passes from one channel to the other gradually. Stall may rotate in
direction opposite to that of impeller rotation and is termed as rotating stall.
This phenomenon of flow separation from blade surface, called as stalling also occurs in axial
flow compressors, in the manner similar to that of centrifugal compressor. Stalling results in reduction
of delivery pressure at compressor exit which may eventually lead to reversal of flow or surging.
Stalling also leads to reduction in stage efficiency along with vibrations in compressor which may even
rise upto the level causing failure of compressor parts when frequency matches with natural frequency.

Fig.16.23 Stall propagation

16.13 CENTRIFUGAL COMPRESSOR CHARACTERISTICS

Compressor characteristics are the set of curves obtained between delivery pressure and temperature
plotted against mass flow for different values of rotational speed. Characteristics curves are machine
specific i.e. every compressor shall have its own unique characteristic curves. These characteristic
curves are plotted using non-dimensional parameters. Non-dimensional parameters used as the per-
formance indicator of compressor. depend upon entry pressure, temperature, physical properties of
fluid being compressed, mass flow rate and rotational speed etc. In order to obtain characteristic curve
excessively large number of experimental observations are needed which can not be presented con-
cisely. Use of non-dimensional parameters helps in combining number of parameters in order to get
dimensionless groups which can be used for getting compressor characteristic curves. The non-
p02 T02 m RT01 ND
dimensional groups thus used are, , , , where p, T, m, R, D, N are pressure,
p01 T01 D 2 p01 RT01
temperature, mass flow rate, gas constant, characteristics linear dimension and rotational speed respec-
tively. Here for a particular compressor running with definite fluid the R and D shall be fixed and non-
p02 T02 m T01 N
dimensional groups can be modified as, , , , .
p01 T01 p01 T01
Different non-dimensional groups given here are termed as described below inspite of the fact
that some of these are no more dimensionless due to omission of R and D terms.
p02
= Dimensionless pressure
p01
Reciprocating and Rotary Compressor ______________________________________________ 737
T02
= Dimensionless temperature
T01

m T01
= Dimensionless mass flow
p01
N
= Dimensionless rotational speed
T01
Characteristic curves for centrifugal compressor are obtained by plotting;
FG IJ
p02 m T01 FG IJ
(i) “dimensionless pressure”
H K
p01
with “dimensionless mass flow
p01 H K
relative to design value”

FG IJ relative to design value” and, (ii) “isentropic

N
for different “dimensionless rotational speeds
H K
T01

efficiency” with “dimensionless mass flow G

F m T IJ relative to design value” for different
H p K
01

F N IJ relative to design value.”

01

“dimensionless rotational speeds G

H T K 01

Fig. 16.24 Centrifugal compressor characteristic curve

Figures 16.24 and 16.25 shows the compressor characteristic curves. First curve is plot between
pressure ratio and mass flow rate. Similar type of plot has been referred while discussing surging and
choking. Here only the portion between surge line and choke line has been shown for different dimensionless
rotational speeds relative to design value of 0.6, 0.7, 0.8, 0.9, 1.0. The locus of points having maximum
efficiency is also shown on characteristic curve. This curve identifies the two extreme operating states
between which the compressor runs.
738 ________________________________________________________ Applied Thermodynamics

Fig. 16.25 Isentropic efficiency of a centrifugal compressor (characteristic curve)

Similar to the plot between dimensionless pressure and dimensionless mass flow rate the plot
between dimensionless temperature and dimensionless mass flow rate can be obtained. Using these
patterns the plot between isentropic efficiency and dimensionless mass flow rate for different
dimensionless rotational speeds can be obtained as shown in Fig. 16.25. These characteristic curves
give the operating range of compressor and are also used for matching of compressors with other
devices such as turbine etc. operating together. Characteristics of compressor and turbine operating
together in any plant should be matching else inefficiencies are observed. Looking at the centrifugal
compressor characteristic curves it can be concluded that, “for a given pressure ratio the increase in
speed shows increase in flow rate and simultaneous reduction in efficiency,” “for any particular speed
of compressor the decrease in mass flow rate is accompanied by increase in pressure ratio” and “at all
speeds the compressor operation is limited by surging on one end and choking on other end” etc.
Figure 16.26 shows a typical characteristic curve for some centrifugal compressor.

Fig. 16.26 Typical centrifugal compressor characteristic curve

740 ________________________________________________________ Applied Thermodynamics
Here it may be noted that since axial flow compressor comprises of number of stages so each stage shall
also have its’ own characteristic curve, although stage characteristic curves are similar to over all
characteristic curve but with small pressure ratio. Characteristic curves show that the flow rate does
not change much with increase in pressure ratio near design conditions. The efficiency is seen to
decrease with decrease in flow rate and pressure ratios. Characteristic curves for axial flow compressor
can also be shown as in Fig. 16.28.

Fig. 16.28 Performance characteristic of axial flow compressor

It is evident from characteristic curves that when compressor is run at less than design speed
then rise in pressure and temperature is less than design value and also the choking decides the limiting
operating point for compressor.

16.15 COMPARATIVE STUDY OF COMPRESSORS

Comparative study of different types of compressors is presented below:
(i) Comparison of reciprocating compressors with rotary compressors

Reciprocating compressors Rotary compressors

1. These are suitable for low discharge 1. These are suitable for high discharge
rate at higher delivery pressures. rate at smaller delivery pressures.
Speed of rotation of reciprocating Speed of rotation of rotary compressors
compressors is quite small due to is quite high up to 40,000 rpm.
higher inertia of reciprocating parts.
2. Reciprocating compressor has inter- 2. Rotary compressor has continuous
mittent delivery of high pressure air delivery of high pressure air therefore
thereby requiring receiver for maintain- no receiver is required.
ing continuous delivery.
3. Reciprocating compressors have 3. Rotary compressors have better
balancing problems. balancing as compared to reciprocating
compressors.
(Contd.)
Reciprocating and Rotary Compressor ______________________________________________ 741
Reciprocating compressors Rotary compressors
4. Quality of air delivered from 4. Air delivered is comparatively cleaner.
reciprocating compressors is poor
due to its contamination with
lubricant.
5. Lubrication requirements are severe 5. Lubricating requirements are less
in these compressors. compared to reciprocating compressors.
6. Reciprocating compressors can not be 6. Rotary compressors can be directly
directly coupled to high speed prime coupled to high speed prime movers.
movers such as turbines etc.
7. Reciprocating compressors are desi- 7. Rotary compressors have isentropic
gned to achieve compression close to process ideally but actually the compression
isothermal compression by cooling etc. occurs following polytropic compression
compression process with index more with index more than adiabatic index.

(ii) Comparison between the centrifugal compressor and axial flow compressor is given as under.
Centrifugal Compressor Axial flow compressor
(i) Centrifugal compressors generally (i) Axial flow compressors generally
have stage pressure ratio of aro- have stage pressure around 1.5
und 5 and have radial flow inside and have axial inlet and
with axial entry of fluid. Maxi- axial exit with flow inside
mum pressure up to 400 bar can compressor being parallel to the
be achieved by multistaging, compressor axis. Maximum pressure
although multistaging is slightly up to 10 bar is possible to be achieved
difficult. through multistaging which is very
convenient in axial compressors.
(ii) Centrifugal compressors have (ii) Axial flow compressors have
good part load efficiency and poor part load efficiency and narrow
wide operating range between operating range between surging and
surging and choking limits. choking limits.
(iii) Centrifugal compressors have (iii) Axial flow compressors have large
small starting torque requirement. starting torque requirement.
(iv) Due to large frontal area (iv) Due to small frontal area
these are well suited for land axial flow compressors are well
applications. suited for aviation applications.
(v) These have simple construction (v) These have complex construction
and are comparatively cheap. and are costly.
(vi) These have poor isentropic (vi) These have better isentropic
efficiency (» 70%). Power required efficiency (» 85 to 90%). Power
per kg of air flow rate is more. required per kg of air flow rate is less
in axial flow compressors.
(vii) Efficiency vs. speed characteristics (vii) Efficiency vs. speed characteristics is
for centrifugal compressor is flat. slightly bell shaped. It means higher
It has higher efficiency in large efficiency in narrow range of speed.
speed range.
(viii) Centrifugal compressor’s (viii) Axial compressor’s performance
performance does not alter with deteriorates with any kind of
any kind of deposition on blade deposition on blade surface.
surface.
742 ________________________________________________________ Applied Thermodynamics
EXAMPLES
1. A reciprocating air compressor has cylinder with 24 cm bore and 36 cm stroke. Compressor
admits air at 1 bar, 17°C and compresses it up to 6 bar. Compressor runs at 120 rpm. Considering
compressor to be single acting and single stage determine mean effective pressure and the horse power
required to run compressor when it compresses following the isothermal process and polytropic process
with index of 1.3. Also find isothermal efficiency when compression is of polytropic and adiabatic type.
Solution:
P2
Compression ratio = =6=r
P1
From cylinder dimensions the stroke volume
p
= ´ (0.24)2 ´ (0.36)
4
= 0.01628 m3
Volume of air compressed per minute = 0.01628 ´ 120
= 1.954 m3/min
Let us neglect clearance volume.
Work done in isothermal process
Wiso = P1 V1 ln r
Mean effective pressure in isothermal process
p1V1 ln r
mepiso = = P1 ln r
V1
= 1 ´ 102 ´ ln 6 = 179.18 kPa
Work done in polytropic process with index n = 1.3, i.e. PV 1.3 = C
LMF P I n-1
OP
MNGH P JK
n n
-1
PQ
2
Wpoly = P V
n-1 1 1 1

Mean effective pressure in polytropic process,

F n I PV L
H n - 1 K MF P I - 1OP
1 1
n -1

MNH P K
n

PQ
2
meppoly =
V1 1

F n I P LMF P I - 1OP
n -1

H n - 1 K MNH P K
n

PQ
2
meppoly = 1
1

F 1.3 IJ ´ 1 ´ 10 L(6) - 1O
= G
1. 3 - 1

H 1.3 - 1 K MN 2
PQ 1.3

meppoly = 221.89 kPa

Reciprocating and Rotary Compressor ______________________________________________ 743

Fig. 16.29 p-V representation

g LMF P I g -1
g
OP
MNH P K -1
PQ
2
Work done in adiabatic process, Wadibatic = P V
g -1 1 1 1

Wadiabatic
Mean effective pressure in adiabatic process, mepadiabatic =
V1

g LMF P I g -1
g
OP
MNH P K PQ
mepadiabatic = P 2
-1
g -1 1
1

FG 1.4 IJ ´ 1 ´ 10 L(6) 1. 4 - 1
OP
=
H 1.4 - 1 K MN 2
1. 4 -1
Q
mepadiabatic = 233.98 kPa
Horse power required for isothermal process,
mepiso ´ Volume per minute
HPiso =
0.7457 ´ 60
(As 1 hp = 0.7457 kW)
179.18 ´ 1.954
=
0.7457 ´ 60
HPiso = 7.825 hp
Horse power required for polytropic process,
meppoly ´ Volume per minute
HPpoly =
0.7457 ´ 60
221.89 ´ 1.954
=
0.7457 ´ 60
HPpoly = 9.69 hp
744 ________________________________________________________ Applied Thermodynamics
Horse power required for adiabatic process,
mepadiabatic ´ Volume per minute
HPadiabatic =
0.7457 ´ 60
233.98 ´ 1.954
=
0.7457 ´ 60
= 10.22 hp
Isothermal process power required
Isothermal efficiency =
Actual power required
HPiso 7.825
Isothermal efficiencypoly = = = 0.8075 or 80.75%
HPpoly 9.69
HPadiabatic 7.825
Isothermal efficiencyadiabatic = = = 0.7657 or 76.57%
HPpoly 10.22

mep: 179.18 kPa for isothermal, 221.89 kPa for polytropic process
HP required: 7.825 HP for isothermal, 9.69 HP for polytropic
Isothermal efficiency: 80.75% for polytropic process, 76.57% for adiabatic process Ans.
2. A single stage single acting reciprocating air compressor has air entering at 1 bar, 20°C and
compression occurs following polytropic process with index 1.2 upto the delivery pressure of 12 bar. The
compressor runs at the speed of 240 rpm and has L/D ratio of 1.8. The compressor has mechanical
efficiency of 0.88. Determine the isothermal efficiency and cylinder dimensions. Also find out the rating
of drive required to run the compressor which admits 1 m3 of air perminute.
Solution:
Using perfect gas equation the mass of air delivered per minute can be obtained as,
P1V1
m=
RT1

=
b1 ´ 10 ´ 1g2

( 0.287 ´ 293)
= 1.189 kg/min
Compression process follows PV1.2 = constt.
Temperature at the end of compression;

FPI
n -1

HPK
2 n
T2 = T 1
1

= 293 FH IK
1. 2 - 1
12 1. 2
T2
1
T2 = 443.33 K
Reciprocating and Rotary Compressor ______________________________________________ 745

FG n IJ ´ mR (T – T )
Work required during compression process, W =
H n -1K 2 1

F 1.2 I ´ 1.189 ´ 0.287 (443.33 – 293)

=
H 1.2 - 1 K
307.79
W = 307.79 kJ/min = hp
60 ´ 0.7457
W = 6.88 hp
6.88
Capacity of drive required to run compressor = = 7.82 hp
0.88
Isothermal work required for same compression,
FP I
HPK
2
Wiso = m RT1 ln
1

= (1.189 ´ 0.287 ´ 293) × ln FH 12 IK

1
Wiso = 248.45 kJ/min
Isothermal work 248.45
Isothermal efficiency = = = 0.8072
Actual work 307.79
1
Volume of air entering per cycle = = 4.167 ´ 10–3 m3/cycle
240
p 2
Volume of cylinder = 4.167 ´ 10–3 = D L
4
p
= 4.167 ´ 10–3 = ´ D2 ´ 1.8D
4
Bore, D = 0.1434 m or 14.34 cm
Stroke length L = 1.8 ´ D = 1.8 ´ 14.34 = 25.812 cm

Isothermal efficiency = 80.72 %

Cylinder dimension, D = 14.34 cm
L = 25.812 cm
Rating of drive = 7.82 hp Ans.
3. A reciprocating compressor of single stage, double acting type delivers
20 m3/min when measured at free air condition of 1 bar, 27°C. The compressor has compression ratio of
7 and the conditions at the end of suction are 0.97 bar, 35°C. Compressor runs at 240 rpm with clear-
ance volume of 5% of swept volume. The L/D ratio is 1.2. Determine the volumetric efficiency and
dimensions of cylinder and isothermal efficiency taking the index of compression and expansion as
1.25. Also show the cycle on P-V diagram.
Solution:
P2
P1 = 0.97 bar, T1 = 273 + 35 = 308 K, = 7, N = 240 rpm
P1
746 ________________________________________________________ Applied Thermodynamics
V3 = 0.05 Vs, Vs = V1 – V3, V1 = 1.05 Vs
For free air condition of 1 bar, 27°C the mass of air delivered,
PV 1 ´ 10 2 ´ 20
m= =
RT 0.287 ´ 300
m = 23.23 kg/min

Fig. 16.30 P-V representation

For compression process 1–2, PV 1.25 = Constant

FP I
1. 25 - 1

HPK
1. 25
T2 = T1 ´ 2

1
= 308 ´ (7)0.2
T2 = 454.54 K
For expansion process, 3–4, PV 1.25 = Constant

FPI
1

HP K
1. 25
V4 = V3 ´ 3

4
V4 = 0.05 Vs (7)1/1.25
V4 = 0.273 Vs
V1 – V4 = 1.05 Vs – 0.237 Vs = 0.813 Vs
Volume of air corresponding to the suction conditions can be obtained using the volume of free air
delivered
0.97 ´ 300 0.97 ´ 300
= ´ (V1 – V4) = ´ 0.813 Vs
1 ´ 308 1 ´ 308
= 0.768 Vs
0.768 Vs
Volumetric efficiency = = 0.768 or 76.8%
Vs

Volumetric efficiency = 76.8% Ans.

Reciprocating and Rotary Compressor ______________________________________________ 747
In order to find out the dimension of cylinder the volume of air sucked in one cycle. Volume of air
20
sucked in a cycle = = 0.0208 m3/cycle.
2 ´ 240
Volume per cycle = Swept volume
p 2 p
0.0208 = D ×L= D 2 × (1.2 D)
4 4
Þ D = 0.2805 m or 28.05 cm
L = 33.66 cm

Bore = 28.05 cm
Stroke = 33.66 cm Ans.
Work required in reciprocating compressor
n
W= mR (T2 – T1)
n -1
FG 1.25 IJ ´ 23.23 ´ 0.287 (454.54 – 308)
W=
H 1.25 - 1 K
= 4884.92 kJ/min
4884.92
= , {as 1 hp = 0.7457 kW]
60 ´ 0.7457
W = 109.18 hp

FP I
HPK
2
Work required when compression is isothermal, Wiso = m RT1 ln
1

= 23.23 ´ 0.287 ´ 308 ln (7)

= 3995.81 kJ/min
3995.81
=
60 ´ 0.7457
Wiso = 89.31 hp
Wiso 89.31
Isothermal efficiency = = = 0.8133 or 81.33%
W 109.81

Isothermal efficiency = 81.33% Ans.

4. A reciprocating compressor of single stage and double acting type is running at 200 rpm with
mechanical efficiency of 85%. Air flows into compressor at the rate of 5 m3/min measured at atmos-
pheric condition of 1.02 bar, 27°C. Compressor has compressed air leaving at 8 bar with compression
following polytropic process with index of 1.3. Compressor has clearance volume of 5% of stroke
volume. During suction of air from atmosphere into compressor its temperature rises by 10°C. There
occurs pressure loss of 0.03 bar during suction and pressure loss of 0.05 bar during discharge passage
through valves. Determine the dimensions of cylinder, volumetric efficiency and power input required to
drive the compressor if stroke to bore ratio is 1.5.
748 ________________________________________________________ Applied Thermodynamics
Solution:
Considering the losses at suction and discharge, the actual pressure at suction and delivery shall be
as under.
Atmospheric pressure, Pa = 1.02 bar, Ta = 273 + 27 = 300 K, Va = 5 m3/min
Pressure at suction, P1 = 1.02 – 0.03 = 0.99 bar
T1 = 300 + 10 = 310 K
Pressure at delivery, P2 = 8 + 0.05 = 8.05 bar
Volume corresponding to suction condition of P1, T1,
Pa × T1 × Va 1.02 ´ 310 ´ 5
V1 = = = 5.32 m3/min
P1 × Ta 0.99 ´ 300
Therefore, work required for compression,
LMF P I n-1
OP
MNH P K
n n
-1
PQ
2
W= P V
n -1 1 1 1

FG 1.3 IJ ´ 0.99 ´ 10 ´ 5.32 LMF 8.05 I

2 0 .3
OP
H 1.3 - 1 K MNH 0.99 K
1.3
-1
=
60 PQ
= 23.66 kW or 31.73 hp
31.73
Power input required = = 37.33 hp
0.85

Power input = 37.33 hp Ans.

P1Ta LM P F I OP
1

H K PQ
n
Volumetric efficiency, hvol =
Pa T1 MN
1+ C - C 2
P1

0.99 ´ 300 LM1 + 0.05 - 0.05F 8.05 I 1

OP
C = 0.05, so hvol
H 0.99 K
1.3
Here, =
1.02 ´ 310 MN PQ
= 0.7508 or 75.08%
5
Stroke volume per cycle = = 0.0125 m3/cycle
2 ´ 200
0.0125
Actual stroke volume taking care of volumetric efficiency =
0.7508
= 0.0167 m3/cycle
p 2
Stroke volume = D L = 0.0167
4
p 2
D ´ 1.5D = 0.0167
4
D = 0.2420 m or 24.20 cm
Stroke L = 1.5 D = 36.3 cm
Reciprocating and Rotary Compressor ______________________________________________ 749

Cylinder dimensions = bore of 24.20 cm, stroke of 36.3 cm. Ans.

Volumetric efficiency = 75.08%
5. In a reciprocating air compressor the air is compressed at the rate of 4 m3/min at 1 bar, 27°C up
to the pressure of 8 bar following index of compression as 1.2. The compression occurs in two stages with
intercooling at optimum intercooler pressure and perfect intercooling. Compare the work input required
if the same compression occurs in single stage. Also compare the work input if same compression occurs
in two stages with imperfect intercooling up to 30°C at the optimum intercooling pressure. Consider
Cp = 1.0032 kJ/kg × K and R = 0.287 kJ/kg × K.
Solution:
Mass of air compressed per minute;
1 ´ 10 2 ´ 4
m= = 4.65 kg/min
0.287 ´ 300

Fig. 16.31 P-V diagram

Different types of compression are shown on P–V diagram
For single stage compression from 1 bar to 8 bar, process 1–2–3, PV 1.2 = Constt.
LMF P I n -1
OP
MNH P K
n n
-1
PQ
3
Work input, WI = PV
n-1 1 1 1

F 1.2 IJ ´ 1 ´ 10
= G
L8 O
´ 4 M FH IK
- 1P
1. 2 - 1

H 1.2 - 1 K MN 1
PQ
2 1.2

F 994.113 IJ = 22.22 hp
W = 994.113 kJ/min or G
I H 60 ´ 0.7457 K
Optimum intercooling pressure = 8 ´ 1 = 2.83 bar
For two stage compression with perfect intercooling;
LMF P I n -1
OP
MNH P K
n 2n
= 2´ -1
PQ
3
Work input, WII, I/C PV
n -1 1 1 1
750 ________________________________________________________ Applied Thermodynamics

F 1.2 IJ ´ 1 ´ 10
= 2´G
L8
´ 4 ´ M FH IK
1. 2 - 1
OP
H 1.2 - 1 K MN 1 PQ
2.4
2 -1

WII, I/C = 908.19 kJ/min or 20.29 hp

When there is two stage compression with imperfect intercooling:
Intercooler pressure, P2 = 2.83 bar, T2¢ = 273 + 30 = 303 K
P1V1 T2 ¢
Volume of air at inlet of HP cylinder, V2¢ = ´
T1 P2
1 ´ 4 ´ 303
V2¢ = = 1.43 m3/min
300 ´ 2.83
Hence, work required for two stage compression,
W¢II,I/C = W¢HP + W¢LP
L n R|F P I n -1
U|O L n R|F P I U|O n -1

= M - 1V P + M - 1VP
MN n - 1 P V ST|H P K P V¢ S
W|PQ MN n - 1 T|H P K
n n

W|PQ
2 3
1 1 2 2
1 2

= LM F
1.2 I
´ 4 {( 2.83) - 1}OP
(1. 2 - 1)

NH 1.2 - 1 K ´ 1 ´ 10 Q
2
W¢II,I/C 1. 2

LF 1.2 I ´ 2.83 ´ 10 ´ 1.43 ´ R|F 8 I 1. 2 - 1

U|OP
+ MG
MNH 1.2 - 1 JK S|H 2.83 K -1V|P
2 1.2

T WQ
= [454.3] + [459.2] = 913.5 kJ/min or 20.42 hp
% saving in work when compression occur with perfect intercooling as compared to single stage
compression
FG W - W IJ
H W K
I II , I / C
= 100 ´
I
= 8.69% Ans.
% excess work to be done when two stage compression occurs with imperfect intercooling as
compared to two stage compression with perfect intercooling:
F W¢ - WII , I / C I
= 100 ´ GH II , I / C

W ¢ II , I / C JK
= 0.636% Ans.
6. A reciprocating air compressor has four stage compression with 2 m3/min of air being delivered
at 150 bar when initial pressure and temperature are 1 bar, 27°C. Compression occur polytropically
following polytropic index of 1.25 in four stages with perfect intercooling between stages. For the
optimum intercooling conditions determine the intermediate pressures and the work required for driving
compressor.
Solution:
Here there is four stage compression with perfect intercooling at optimum intercooling conditions.
So optimum stage pressure ratio = (150 )1/ 4 = 3.499 » 3.5
Reciprocating and Rotary Compressor ______________________________________________ 751
Intermediate pressure shall be as follows:
Between Ist and IInd stage = 3.5 bar
Between IInd and IIIrd stage = 12.25 bar
Between IIIrd and IVth stage = 42.87 bar

Intermediate pressure: 3.5 bar, 12.25 bar, 42.87 bar Ans.

Since it is perfect intercooling so temperature at inlet of each stage will be
300 k.

FPI
n -1

HPK
n
So temperature at the end of fourth stage, T = T1 ´ 2
1

= 300 ´ ( 3.5) H
F 1. 25 - 1 IK
1. 25
T = 385.42 K
PV 150 ´ 10 2 ´ 2
Mass of air, kg/min, m = = = 271.21 kg/min
RT 0.287 ´ 385.42
Work required for driving compressor,

F n IJ m RT LMF P I - 1OP ´ 4
W= G
n-1

H n -1K MNH P K
n

PQ
2
1
1

=G
F 1.25 IJ ´ 271.21 ´ 0.287 ´ 300 L(3.5) - 1O ´ 4
(1.25 - 1)

H 1.25 - 1 K NM QP 1. 25

= 132978.04 kJ/min or 2972.11 hp F =

132978.04 I
H 60 ´ 0.7457 K
. Work input = 2972.11 hp Ans.
7. A two stage reciprocating compressor has air entering at 1 bar, 17°C into LP compressor and
leaving HP stage at 16 bar. An intercooler working at 4 bar pressure is provided between the HP and LP
stages. The compression process follows the process given by PV1.3 = constant. The bore diameters of
HP and LP cylinder are 6 cm and 12 cm respectively while stroke lengths are equal. For perfect intercooling
determine the work done in compressing per unit mass of air. Also state whether the intercooler pressure
will rise, fall or no change if the volumetric efficiency is taken as 0.90 for LP cylinder. Neglect clear-
ance volumes.
Solution:
For perfect intercooling the amount of work required shall be;
LMF P I n -1
FPI
n -1
OP
MNGH P JK +G J
n´m n n

HP K -2
PQ
2 3
W= RT1
n -1 1 2

LM 1. 3 - 1
OP
1.3 ´ 1
e j
(1.3 - 1) 16
´ 0.287 ´ (273 + 17) ( 4 ) 1. 3 + 1.3
-2
=
1.3 - 1 MN 4 PQ
752 ________________________________________________________ Applied Thermodynamics
= 271.94 kJ/kg

. Work = 271.94 kJ/kg Ans.

The ratio of volumes handled by HP and LP stages. Using the perfect intercooling.

Fig. 16.32 Two stage compression on P-V diagram

State at inlet of LP cylinder = P1 V1
State at inlet of HP cylinder = P2 V2¢
Since state 2¢ lies on isothermal compression process line so, P1 V1 = P2 V2¢ or,
V1
=
P2
= FH 4 IK = 4
V2¢ P1 1

Volume at inlet to LP
= 4
Volume at inlet to HP
From given cylinder dimensions, for given bore diameters and common stroke length,
Effective volume of LP cylinder
Ratio of effective cylinder volumes =
Effective volume of HP cylinder
p 2
0.90 ´ D ×L
= 4 LP
p 2
D ×L
4 HP
0 .9 ´ ( 0.12 ) 2
= = 3.6
( 0.06 ) 2
Theoretically, the volume ratio is 4 while considering volumetric efficiency the ratio of effective
cylinder volumes comes out to be 3.6 which is less than the theoretical volume ratio. Therefore, it can
be concluded that less amount of air is given into HP cylinder than its’ capacity. Thus, the HP cylinder
would inhale volume equal to its’ capacity and since it has larger capacity than volume available so the
pressure of intercooler shall drop.
8. In a two stage reciprocating air compressor running at 200 rpm the air is admitted at 1 bar, 17°C
and discharged at 25 bar. At low pressure stage suction conditions the rate of air flow is 4 kg/minute.
The low pressure cylinder and high pressure cylinders have clearance volumes of 4% and 5% of respec-
tive cylinder stroke volumes. The index for compression and expansion processes in two stages are same
Reciprocating and Rotary Compressor ______________________________________________ 753
as 1.25. Considering an optimum and perfect intercooling in between two stages determine the power
required, isothermal efficiency, free air delivered, heat transferred in each cylinder and the cylinder
volumes.
Solution:
25
For the optimum intercooling the pressure ratio in each stage = =5
1

Fig. 16.33 P-V representation

P2 P
= 6 =5
P1 P5
Perfect intercooling indicates, T1 = T5 = 273 + 17 = 290 K

FG P IJ
n -1
n

HPK
2
T2 = T1 = 400.12 K
1

FG P IJ
n -1
n

HPK
6
T6 = T5 = 400.12 K
5
Actual compression work requirement,
W = WHP + WLP

F n IJ m RT LMFG P IJ - 1OP
n-1

= 2G
H n -1K
n

MNH P K PQ
2
1
1

= 2´G
F 1.25 IJ ´ 4 ´ 0.287 ´ 290 L(5) (1.25 - 1)
OP
H 1.25 - 1 K NM 1. 25 -1
Q
W = 1264.19 kJ/min or 28.25 hp
Work requirement if the process is isothermal compression,
FG P IJ = 4 ´ 0.287 ´ 290 ln (25)
HPK
6
Wiso = m RT1 ln
1
Wiso = 1071.63 kJ/min
754 ________________________________________________________ Applied Thermodynamics
Wiso
Isothermal efficiency = = 0.8477 or 84.77%
W
mRT1 4 ´ 0.287 ´ 290
Free air delivered = = = 3.33 m3/min
P1 1 ´ 10 2
Heat transferred in HP cylinder = Heat transferred in LP cylinder = Q
(Due to optimum and perfect intercooling)

Q= FH W IK – m C (T – T )
p 2 1
2

= FH
1264.19 I
2 K – 4 ´ 1.0032 ´ (400.12 – 290)
Q = 190.21 kJ/min

PT LM P F I OP
1

H K PQ
n

Pa × T1 MN
Volumetric efficiency, hvol = 1 a 1 + C - C 2
P1

Here the ambient conditions and suction conditions are same so expression gets modified as,

FP I
1

= 1+C–CG J
n
hvol
HPK
2

1
Volumetric efficiency of HP,

FG P IJ
1
n
hvol,
HP K
6
HP = 1 + CHP – CHP
5
CHP = 0.04
= 1 + 0.04 – 0.04 (5)1/1.25
hvol, HP = 0.895 or 89.5%
Volumetric efficiency of LP,

FG P IJ
1
n
hvol,
HPK
2
LP = 1 + CLP – CLP
1
CLP = 0.05
= 1 + 0.05 – 0.05 (5)1/1.25 = 0.8688 or 86.88%
Free air delivery
Stroke volume of HP cylinder =
Pressure ratio ´ speed ´ h vol, HP

3.33
Vs, = = 3.721 ´ 10–3 m3
HP
5 ´ 200 ´ 0.895
Clearance volume, Vc, HP = 0.05 ´ 3.721 ´ 10–3 = 1.861 ´ 10–4 m3
Total HP cylinder volume, VHP = Vs, HP + Vc, HP = 3.907 ´ 10–3 m3 ;
Vc, HP = Clearance volume of HP
Free air delivery 3.33
Stroke volume of LP cylinder = =
Speed ´ h vol, LP 200 ´ 0.8688
Reciprocating and Rotary Compressor ______________________________________________ 755
Vs, LP = 0.01916 m3
Clearance volume, Vc, LP = 0.04 ´ Vs, LP = 7.664 ´ 10–4 m3
Total LP cylinder volume, VLP = Vs, LP + Vc, LP = 0.019926 m3
Power required = 28.25 hp, Ans.
Isothermal efficiency = 84.77%
Free air delivered = 3.33 m3/min,
Heat transfer in HP cylinder = 190.21 kJ/min
Heat transferred in LP cylinder = 190.21 kJ/min,
HP cylinder volume = 3.907 ´ 10–3 m3
LP cylinder volume = 0.019926 m3
9. A two stage double acting reciprocating air compressor running at 200 rpm has air entering at
1 bar, 25°C. The low pressure stage discharges air at optimum intercooling pressure into intercooler after
which it enters at 2.9 bar, 25°C into high pressure stage. Compressed air leaves HP stage at 9 bar. The
LP cylinder and HP cylinder have same stroke lengths and equal clearance volumes of 5% of respective
cylinder swept volumes. Bore of LP cylinder is 30 cm and stroke is 40 cm. Index of compression for both
stages may be taken as 1.2. Determine,
(i) the heat rejected in intercooler,
(ii) the bore of HP cylinder,
(iii) the hp required to drive the HP cylinder.
Solution:
Optimum intercooling pressure = 9 = 3 bar
LP stage pressure ratio = HP stage pressure ratio = 3
From the given dimensions of LP cylinder, the volume of LP cylinder, in m3/min
p
VLP = ´ (0.30)2 ´ (0.40) ´ 200 ´ 2
4
VLP = 11.31 m3/min
Volumetric efficiency of LP compressor, here ambient and suction conditions are same,

FPI
= 1+C–CG J
1
F FH 3 IK IJ
1

GH
n
hvol, LP
HPK
1. 2

K
2
= 1 + 0.05 – 0.05
1 1
hvol, LP = 0.9251 or 92.51%

Fig. 16.34 P-V diagram

756 ________________________________________________________ Applied Thermodynamics
Volume of air inhaled in LP stage = VLP ´ hvol, LP
= 11.31 ´ 0.9251
= 10.46 m3/min
P1V1
Mass of air per minute, m=
RT1
1 ´ 10 2 ´ 10.46
= = 12.23 kg/min
0.287 ´ 298
Temperature after compression in LP stage,

FPI
n -1

= T ´G J
n

HPK
2
T2 1
1

= 298 ´ FH IK
1. 2 - 1
3 1. 2
1
T2 = 357.88 K
Volume of air going into HP cylinder
mRT5
V5 =
P5
After intercooling, T5 = 298 K, P5 = 2.9 bar,
12.23 ´ 0.287 ´ 298
V5 =
2.9 ´ 10 2
V5 = 3.61 m3/min
Since the clearance volume fraction and pressure ratio for both HP and LP stages are same so the
volumetric efficiency of HP stage referred to LP stage suction condition shall be same
hvol, HP = hvol, LP = 0.9251
V5 3.61
Hence, the volume of HP cylinder/min = = = 3.902 m3/min
h vol,HP 0.9251
Let bore of HP cylinder be DHP,
p
3.902 = ´ (DHP)2 ´ 0.40 ´ 2 ´ 200
4
DHP = 0.1762 m or 17.62 cm
Heat rejected in intercooler, Q = mCp (T2 – T5)
= 12.23 ´ 1.0032 ´ (357.88 – 298)
= 734.68 kJ/min

FG IJ
n -1
FH 9 IK
1. 2 - 1
T6 P6 n
H K
1.2
In HP stage, = Þ T6 = 298 ´
T5 P5 2.9
T6 = 359.91 K
Reciprocating and Rotary Compressor ______________________________________________ 757
FG n IJ mR (T
Work input required for HP stage, WHP =
H n -1K 6 – T5)

FG 1.2 IJ ´ 12.23 ´ 0.287 × (359.9 – 298)

=
H 1.2 - 1 K
WHP = 1303.62 kJ/min
or WHP = 29.14 hp
Heat rejected in intercooler = 734.68 kJ/min Ans.
Bore of HP cylinder = 17.62 cm
Horse power required to drive HP stage = 29.14 hp
10. During an experiment on reciprocating air compressor the following observations are being
taken;
Barometer reading = 75.6 cm Hg, Manometer reading across orifice = 13 cm Hg.
Atmospheric temperature = 25°C. Diameter of orifice = 15 mm.
Coefficient of discharge across the orifice = 0.65
Take density of Hg = 0.0135951 kg/cm3
Determine the volume of free air handled by compressor in m3/min.
Solution:
p
Cross-sectional area of orifice, A= ´ (15 ´ 10–3)2 = 1.77 ´ 10–4 m2
4
Atmospheric pressure = 75.6 ´ 0.0135951 ´ 9.81 ´ 104 ´ 10–3
= 100.83 kPa
Specific volume of air per kg at atmospheric conditions,
RT 1 ´ 0.287 ´ 298
v= = = 0.848 m3/kg
P 100.83
Density of air = 1 = 1.18 kg/m3
v
Pressure difference across orifice = 13 ´ 0.0135951 ´ 9.81 ´ 104 ´ 10–3
= 17.34 kPa
Height of air column for pressure difference across orifice.
ra ´ ha ´ g = 17.34 ´ 103
Put, ra = 1.18 kg/m3 Þ ha = 1497.95 m
Free air delivery = Cd × A × 2gha
= 0.65 ´ 1.77 ´ 10–4 2 ´ 9.81 ´ 1497.95
= 0.01972 m3/s or 1.183 m3/min

. Free air delivery = 1.183 m3/min Ans.

11. During a trial on single acting single stage compression the following observations are made;
Dimensions of cylinder: 10 cm bore and 8 cm stroke.
Speed of rotation: 500 rpm.
758 ________________________________________________________ Applied Thermodynamics
Barometer reading: 76 cm Hg
Atmospheric temperature: 27°C
Delivery air temperature = 130°C
Free air delivery = 15 m3/hr
Spring balance of dynamometer type (electric motor) reading: 10 kg
Radius of arm of spring balance: 30 cm
Take mechanical efficiency = 0.90.
Determine the volumetric efficiency, shaft output per m3 of free air per minute.
Solution:
Free air delivery = 15 m3/hr = 0.25 m3/min
p
Volume of cylinder = ´ (0.10)2 ´ (0.08) = 6.28 ´ 10–4 m3
4
(15 60)
Volumetric efficiency =
b
6.28 ´ 10 - 4 ´ 500 g
= 0.7962 or 79.62% Ans.

2p NT
Shaft output =
60
2 ´ p ´ 500 ´ 10 ´ 9.81 ´ 0.30 ´ 10 - 3
Shaft output =
60
= 15.41 kJ/s or 20.66 hp
20.66
Shaft output per m3 of free air per minute =
0.25
= 82.64 hp per m3 of free air per minute. Ans.
12. Determine the minimum number of stages required in an air compressor which admits air at 1
bar, 27°C and delivers at 180 bar. The maximum discharge temperature at any stage is limited to 150°C.
Consider the index for polytropic compression as 1.25 and perfect and optimum intercooling in between
the stages. Neglect the effect of clearance.
Solution:
Let there be ‘i’ number of stages. So the overall pressure ratio considering inlet state as Pa and Ta
and delivery state pressure as Pi.
Pi P P P P
= 1 × 2 × 3 × ⋅⋅⋅× i
Pa Pa P1 P2 Pi − 1

When perfect and optimum intercooling is considered then pressure ratio in each stage will be
same.
P1 P P P
= 2 = 3 =¼= i =r
Pa P1 P2 Pi - 1

Pi
= (r)i, for any stage, say second stage,
Pa
T1 = 273 + 27 = 300 K
Reciprocating and Rotary Compressor ______________________________________________ 759
and T2 = 273 + 150 = 423 K

FG T IJ FG T IJ
n in
P2 n -1 P n -1

HT K , i = (r)i =
HT K
2 2
and =
P1 1 Pa 1

FH 180 IK = FH 423 IK
i ´ 1. 25
1. 25 - 1
, Taking log for solving,
1 300

ln 180 = FH 1.25i IK ln FH 423 IK

0.25 300
Upon solving, i = 3.022 » say 3 stages

3 stages Ans.
13. In a triple stage reciprocating compressor of single acting type the air enters at 1 bar, 27°C.
The compressor has low pressure cylinder with bore of 30 cm and stroke of 20 cm. Clearance volume of
LP cylinder is 4% of the swept volume. The final discharge from compressor takes place at 20 bar. The
expansion and compression index may be taken uniformly as 1.25 for all the stages. The intercooling
between the stages may be considered to be at optimum intercooling pressure and perfect intercooling.
Determine, the interstage pressures, effective swept volume of low pressure cylinder, temperature and
volume of air delivered in each stroke and the work done per kg of air.
Solution:
Here P1 = 1 bar, T1 = 300 K, C = 0.04, P10 = 20 bar, n = 1.25, See Fig. 16.35
For optimum and perfect intercooling,

FH 20 IK
1
P2 P P
= 6 = 10 = 3
= 2.714
P1 P2 P6 1
P2 = 2.714 bar, T5 = T1 = 300 K
P6 = 7.366 bar T9 = T1 = 300 K
Volumetric efficiency of LP stage,

FP I
1

= 1+C–CG J
1. 25
hvol, LP
HPK
2

1
= 1 + 0.04 – 0.04 (2.714)1/1.25
= 0.9511 or 95.11%
p 2 p
LP swept volume, V1 – V3 = D L= ´ (0.30)2 ´ 0.20 = 0.01414 m3
4 4
Effective swept volume of LP cylinder, V1 – V4 = hvol, LP ´ (V1 – V3)
V1 – V4 = 0.9511 ´ 0.01414 = 0.01345 m3

F P IJ
1. 25 - 1

´G
1. 25 (1.25 - 1)

HPK = 300 ´ ( 2.714 )

10
Temperature of air delivered, T10 = T9 1. 25
6
= 366.31 K
760 ________________________________________________________ Applied Thermodynamics

Fig. 16.35 P-V representation

For the compression process of air as perfect gas;
a
P1 ´ V1 - V4 f= a
P10 ´ V10 - V11 f
T1 T10

V10 – V11 =
aV - V f ´ T
1 4 10 ´ P1
T1 ´ P10
0.01345 ´ 366.31 ´ 1 ´ 10 2
=
300 ´ 20 ´ 10 2
Volume of air delivered = V10 – V11 = 8.2115 ´ 10–4 m3
Total Work done per kg air,
R| n F F P I I U|
1. 25 - 1

W= 3 ´ S G
RT G J
G H K
2
- 1J V
1.25

JK |W
|T n - 1
H
1
P 1

= 3 ´ RSF IK UV
1.25 I F (1. 25 - 1)

TH 1.25 - 1 K ´ 0.287 ´ 300 ´ H (2.714) 1.25 -1

W
= 285.44 kJ/kg of air

Intermediate pressure = 2.714 bar, 7.366 bar Ans.

Effective swept volume of LP cylinder = 0.01345 m3
Temperature of air delivered = 366.31 K
Volume of air delivered = 8.2115 ´ 10–4 m3
Work done = 285.44 kJ/kg of air
14. A two stage reciprocating air compressor has air being admitted at 1 bar, 27°C and delivered
at 30 bar, 150°C with interstage pressure of 6 bar and intercooling up to 35°C. Compressor delivers at
the rate of 2 kg/s. Clearance volumes of LP and HP cylinders are 5% and 7% of stroke volume respec-
tively. The index of compression and expansion are same throughout. Determine the swept volume of
both cylinders in m3/min, amount of cooling required in intercooler and total power required. Also
estimate the amount of cooling required in each cylinder.
Reciprocating and Rotary Compressor ______________________________________________ 761
Solution:
Given: P1 = 1 bar, T1 = 300 K, P2 = 6 bar, P6 = 30 bar,
T6 = 273 + 150 = 423 K, T5 = 273 + 35 = 308 K, CLP = 0.05, CHP = 0.07, m = 2 kg/s

Fig. 16.36 P-V representation

For process 5–6, P2 = P5

FG T IJ
n
P6 n -1

HT K
6
=
P5 5

FH 30 IK = FH 423 IK
n
n -1
Þ
6 308
Taking log of both sides,
n
Þ ln (5) = ln (1.3734)
n -1
Upon solving we get,
n = 1.245
Volumetric efficiency of LP cylinder,

FP I
1

= 1+C –C G J
1. 245
hvol, LP
HPK
2
LP LP
1

= 1 + 0.05 – 0.05 FH IK
1
6 1. 245
1
= 0.8391 or 83.91%
Volumetric efficiency of HP cylinder,

FPI
1

= 1+C –C G J
1. 245
hvol, HP
HPK
6
HP HP
5

= 1 + 0.07 – 0.07 F
H IK
1
30 1. 245
6
hvol, HP = 0.815 or 81.50%
762 ________________________________________________________ Applied Thermodynamics
For suction of LP cylinder
P1 × (V1 – V4) = mRT1
2 ´ 0.287 ´ 300
(V1 – V4) = = 1.722 m3/s or 103.32 m3/min
1 ´ 10 2
V1 - V4
hvol, LP = = 0.8391 Þ (V1 – V3)
V1 - V3
103.32
= = 123.13 m3/min
0.8391

Swept volume of LP cylinder = 123.13 m3/min Ans.

For HP cylinder, P2 ´ (V5 – V8) = m RT5
mRT5
Þ (V5 – V8) =
P2
2 ´ 0.287 ´ 308
= = 0.2946 m3/s or 17.676 m3/min
6 ´ 10 2
V5 - V8 17.676
hvol, HP = Þ (V6 – V7) = = 21.69 m3/min
V6 - V7 0.815

Swept volume of HP cylinder = 21.69 m3/min Ans.

For compression in LP stage,
n −1
P  n
T2 = T1  2 
 P1 

FH 6 IK
1. 245 - 1

= 300 ´ 1. 245
1
T2 = 426.83 K
Cooling required in intercooler, QI/C = m ´ Cp ´ (T2 – T5)
= 2 ´ 1.0032 ´ (426.83 – 308)
QI/C = 238.42 kJ/s

Heat picked in intercooler = 238.42 kW Ans.

Work input required = WLP + WHP

LMF P I n-1
O n LMF P I n -1
OP
- 1P +
MNGH P JK MNGH P JK
n n n

PQ n - 1 m RT -1
PQ
2 6
= m RT1
n -1 1
5
5

L R|F P I n-1
U| R|F P I n -1
U|O
mR M T S - 1V + T SG J - 1V P
MN |TH P K |W |TH P K
n n n

|WPQ
2 6
=
n -1
1 5
1 5
Reciprocating and Rotary Compressor ______________________________________________ 763

FG 1.245 IJ ´ 2 ´ 0.287 LM300R|SF 6 I 1. 245 - 1

U| R| 30 I
- 1V + 308 SFH
1.245 - 1
U|OP
=
H 1.245 - 1 K MN |TH 1 K
1.245

|W |T 6 K
1. 245
-1V|P
WQ
= 704.71 kJ/s

Total work required = 704.71 kW Ans.

Heat transferred in LP cylinder = Amount of cooling required in LP cylinder
F g - n I ´ C ´ (T – T )
QLP = m
H n -1 K v 2 1

= 2´G
F 1.4 - 1.245 IJ ´ 0.72 ´ (426.83 – 300)
H 1.245 - 1 K
= 115.55 kJ/s

. Amount of cooling required in LP cylinder = 115.55 kW Ans.

Heat transferred in HP cylinder = Amount of cooling required in HP cylinder

F g - n I ´ C ´ (T – T )
QHP = m
H n -1 K v 6 5

= 2´G
F 1.4 - 1.245 IJ ´ 0.72 ´ (423 – 308)
H 1.245 - 1 K
= 104.77 kJ/s

Amount of cooling required in HP cylinder = 104.77 kW Ans.

15. A roots blower handles free air of 0.5 m3/s at 1 bar and 27°C and delivers air at pressure of
2 bar. Determine indicated power required to drive compressor and isentropic efficiency.
Solution:
Indicated power required = (P2 – P1) ´ V1
Wroots = (2 – 1) ´ 102 ´ 0.5 = 50 kJ/s
Wroots = 50 kW or 67.05 hp
Indicated power when isentropic compression occurs,
R|F P I U|
( g - 1)

Wisentropic =
g
´ P1 V1 S|H P K
2 g
V| -1
g -1
T 1
W
F 1.4 IJ ´ 1 ´ 10
= G
R| 2
´ 0.5 SFH IK
1. 4 - 1
U|
H 1.4 - 1 K
1. 4
-1V|
T| 1
2

W
= 38.33 kW or 51.4 hp

Fig. 16.37
764 ________________________________________________________ Applied Thermodynamics

Wisentropic 38.33
Isentropic efficiency of roots blower = = = 0.7666 or 76.66%
Wroots 50

Indicated power of roots blower = 67.05 hp, Ans.

Isentropic efficiency = 76.66%
16. A vaned compressor handles free air of 0.6 m3/s at 1 bar and compresses up to 2.3 bar. There
occurs 30% reduction in volume before the back flow occurs. Determine the indicated power required
and isentropic efficiency.
Solution:
Here on P–V diagram the state 2 indicates the point at which delivery occurs. While 2¢ is the point
up to which air is compressed inside. V2 = 0.7 ´ V1
P2 F V I = FG V IJ
g 1. 4

H V K H 0.7 V K
1 1
=
P1 2 1

= 1 ´ FH
1 I 1. 4

0. 7 K
Þ P2 = 1.65 bar

Fig. 16.38 P-V diagram

Indicated power required for vaned compressor

F g I P V R|SF P I - 1U|V + (P
g -1
g

H g - 1K T|H P K
– P2) ´ V2
2

W|
Wvane = 1 1 2¢
1

=G
F 1.4 IJ ´ 1 ´ 10 ´ 0.6 {(1.65) (1. 4 - 1)
}
H 1.4 - 1 K - 1 + (2.3 – 1.65) ´ 102 ´ (0.7 ´ 0.6)
2
1. 4

= 59.60 kJ/s or 79.925 hp

Power requirement when compression occurs isentropically,
R|F P I g -1
U|
Wisentropic =
g
P V S|H P K
2¢ g
-1 V|
g -1 1 1
T 1
W
Reciprocating and Rotary Compressor ______________________________________________ 765

F 1.4 IJ ´ 1 ´ 10
=G
R| 2.3 I
´ 0.6 SFH
1. 4 - 1
U|
H 1.4 - 1 K
2
|T 1 K
1. 4
-1V|
W
= 56.42 kJ/s or 75.66 hp
Wisentropic 75.66
Isentropic efficiency of Vane compressor = =
Wvane 79.925
= 0.9466 or 94.66%

Indicated power required = 79.925 hp, isentropic efficiency = 94.66% Ans.

17. A centrifugal compressor delivers free air of 18 kg/min. Air is sucked at static states of 1 bar,
27°C with inlet velocity of 50 m/s. The total head pressure ratio is 4 and isentropic efficiency of
compressor is 0.75. The mechanical efficiency of motor attached to it is 0.90. Determine total head
temperature of air at exit of compressor and brake power required to drive compressor.
Solution:
V12
Stagnation temperature at inlet, T01= T1 +
2Cp

( 50 ) 2
T01 = 300 + = 301.25 K
2 ´ 1.0032 ´ 10 3
Isentropic efficiency of compressor,
T02 ¢ - T01
hisen =
T02 - T01
For process 1–2,

FG P IJ
g -1
T02 ¢ g
HP K
02
=
T01 01
(1. 4 - 1 )
Þ T02¢ = T01 ´ ( 4 ) 1. 4

T02¢ = 301.25 ´ ( 4 ) 0 . 4/1. 4 = 447.66 K

Fig. 16.39
Substituting temperature values in expression of isentropic efficiency,
766 ________________________________________________________ Applied Thermodynamics

T02 =
aT
02 ¢ - T01 f +T
h isen 01

( 447.66 - 301.25)
= + 301.25
0.75
T02 = 496.46 K
Total head temperature at exit = 496.46 K Ans.

Brake power of drive required =

m ´ C p ´ T02 - T01 a f
h mech
18 ´ 1.0032 ´ ( 496.46 - 301.25)
=
60 ´ 0.9
= 65.28 kW or 87.54 hp

Brake power required = 87.54 hp Ans.

18. A double-acting single cylinder reciprocating air compressor has a piston displacement of
0.015 m3 per revolution, operates at 500 r.p.m. and has a 5% clearance. The air is received at 1 bar and
delivered at 6 bar. The compression and expansion are polytropic with n = 1.3. Determine,
(i) the volumetric efficiency
(ii) the power required
(iii) the heat transferred and its direction, during compression if inlet temperature of air is 20°C.
[U.P.S.C., 1998]
Solution:
V = 0.015 m3 per revolution, N = 500 r.p.m., C = 5% or 0.05, n = 1.3, P1 = 1 bar, P2 = 6 bar,
T1 = 20°C

FP I
1

=1+C–CG J
n
Volumetric efficiency, hvol
HPK
2

FH 6 IK
1
1.3
= 1 + 0.05 – 0.05
1
= 0.8516 or 85.16%

Ans. Volumetric efficiency = 85.16%

LMF P I n-1
OP
MNGH P JK
n n
-1
PQ
2
Power required = P1V1
n-1 1

Here swept volume in cylinder = Vs = V ´ 2N

= 0.015 ´ 2 ´ 500
Vs = 15 m3/min
Actual air inhaled = V1 = 15 ´ 0.85
V1 = 12.75 m3/min
Reciprocating and Rotary Compressor ______________________________________________ 767
P1V1 1 ´ 10 2 ´ 12.75
Mass of air entering, m = = = 15.16 kg/min.
RT1 0.287 ´ 293

(1.3) LMF 6 I 1.3 - 1

OP
´ 1 ´ 102 ´ 12.75
MNH 1 K PQ
1.3
Power required = -1
(1.3 - 1)
= 2829.21 kJ/min

Ans. Power required = 2829.21 kJ/min

Heat transferred during compression, (this is heat rejected), for a polytropic process
F g - n I (T
Q = m Cv ×
H n -1 K 2 – T1)

During compression process

FG P IJ
n -1
T2 n

HPK
2
=
T1 1

= 298 ´ FH IK
1.3 - 1
6 1. 3
T2
1
T2 = 450.59 K
Substituting in heat transferred Q,
FG 1.4 - 1.3 IJ (450.59 – 293)
Q = 15.16 ´ 0.718 ´
H 1.3 - 1 K
Q = 571.78 kJ/min

Heat rejected during compression = 571.78 kJ/min Ans.

-:-4+15-
16.1 Classify the compressors.
16.2 Discuss the applications of compressed air to highlight the significance of compressors.
16.3 Describe the working of single stage reciprocating compressor.
16.4 Discuss the indicator diagram for reciprocating compressor. Also describe the factors responsible
for deviation of hypothetical indicator diagram to actual indicator diagram.
16.5 Obtain the volumetric efficiency of single stage reciprocating compressor with clearance volume
and without clearance volume.
16.6 Discuss the effects of clearance upon the performance of reciprocating compressor.
16.7 Define isothermal efficiency. Also discuss its significance.
16.8 What do you understand by multistage compression? What are its’ merits over single stage
compression?
16.9 Show that the volumetric efficiency with respect to free air delivery is given by,
 1

P1T a   P2  n 
hvol. = 1+ C − C  
Pa ⋅ T1   P1  

 
where all the terms of expression have their usual meanings.
768 ________________________________________________________ Applied Thermodynamics
16.10 Discuss the significance of intercooling upon the performance of multi-stage compression.
16.11 What is the optimum pressure ratio for perfect intercooling in between two stages of compression?
The inlet and outlet pressures may be taken as P1 and P3.
16.12 Discuss the control of reciprocating air compressor.
16.13 Discuss the working of positive displacement rotary compressors.
16.14 Describe the working of centrifugal compressors.
16.15 What do you understand by surging and choking phenomenon?
16.16 Explain the stalling and its effect on the compressor performance.
16.17 Describe the characteristics of centrifugal compressor.
16.18 Compare the axial flow compressor with centrifugal compressors.
16.19 Show that the heat rejected in each stage of a reciprocating compressor with perfect intercooling
is given by,

  γ − n 
Q =  C p + Cv    (T2 – T1)
  n − 1 
16.20 Write short notes on the following:
(i) Free air delivery
(ii) Volumetric efficiency
(iii) Axial flow compressors
(iv) Air flow rate measurement in reciprocating compressors.
16.21 A single stage single cylinder reciprocating compressor has 60 m3/hr air entering at 1.013 bar, 15°C
and air leaves at 7 bar. Compression follows polytropic process with index of 1.35. Considering
negligible clearance determine mass of air delivered per minute, delivery temperature, indicated
power and isothermal efficiency. [1.225 kg/min, 202.37°C, 4.23 kW, 77.1%]
16.22 A reciprocating compressor of single stage and double acting type has free air delivered at 14
m3/min measured at 1.013 bar, 288 K. Pressure and temperature at suction are 0.95 bar and 305
K. The cylinder has clearance volume of 5% of swept volume. The air is delivered at pressure of
7 bar and expansion and compression follow the common index of 1.3. Determine the indicated
power required and volumetric efficiency with respect to free air delivery. [63.55 kW, 72.4%]
16.23 A single stage double acting reciprocating compressor delivers 14 m3/min measured at suction
states of 1 bar and 20°C. Compressor runs at 300 rpm and air is delivered after compression with
compression ratio of 7. Compressor has clearance volume of 5% of swept volume and compression
follows polytropic process with index 1.3. Determine the swept volume of cylinder and indicated
power in hp. [0.028 m3, 76.86 hp]
16.24 A single stage single acting reciprocating air compressor handles 0.5 m3/min of free air measured
at 1 bar. Compressor delivers air at 6.5 bar while running at 450 rpm. The volumetric efficiency
is 0.75, isothermal efficiency is 0.76 and mechanical efficiency is 0.80. Determine indicated mean
effective pressure and power required to drive the compressor. [0.185 MPa, 3.44 hp]
16.25 A single stage single acting reciprocating air compressor compresses air by a ratio of 7. The
polytropic index of both compression and expansion is 1.35. The clearance volume is 6.2% of
cylinder volume. For volumetric efficiency of 0.8 and stroke to bore ratio of 1.3 determine the
dimensions of cylinder. [14.67 cm and 19.08 cm]
16.26 A single stage single acting reciprocating air compressor runs with air entering at 1 bar and
leaving at 7 bar following PV1.3 = constant. Free air delivery is 5.6 m3/minute and mean piston
1
speed is 150 m/min. Take stroke to bore ratio of 1.3 and clearance volume to be th of swept
15
Reciprocating and Rotary Compressor ______________________________________________ 769
volume per stroke. The suction pressure and temperature are equal to atmospheric air pressure
and temperature. Determine volumetric efficiency, speed of rotation, stroke and bore. Take mean
piston speed = 2 ´ stroke ´ rpm. [76.88%, 164 rpm, 45.7 cm, 35.1 cm]
16.27 A reciprocating compressor of single acting type has air entering at 1.013 bar, 15°C and leaving
at 8 bar. Compressor is driven by electric motor of 30.84 hp and the mechanical efficiency is 0.87.
The clearance volume is 7% of swept volume and the bore is equal to stroke. The compression
and expansion follow PV1.3 = constant. Determine (i) free air delivered in m3/min, (ii) volumetric
efficiency, and (iii) cylinder dimensions. [4.47 m3/min, 72.68%, L = D = 29.7 cm]
16.28 A reciprocating compressor has two stages with inlet air going into LP stage at 1 bar, 16°C and
at the rate of 12 m3/min. Air is finally delivered at 7 bar and there is perfect intercooling at optimum
pressure between the stages. The index for compression is 1.25 and compressor runs at 600 rpm.
Neglecting clearance volume determine intermediate pressure, total volume of each cylinder and
total work required. [2.645 bar, 0.02 m3, 0.0075 m3, 57.6 hp]
16.29 A two stage reciprocating air compressor delivers 4.2 kg of free air per min at 1.01325 bar and 15°C.
The suction conditions are 0.95 bar, 22°C. Compressor delivers air at 13 bar. Compression
throughout occurs following PV1.25 = C. There is optimum and perfect intercooling between the
two stages. Mechanical efficiency is 0.75. Neglecting clearance volume determine
(i) the heat transfer in intercooler per second.
(ii) the capacity of electric motor.
(iii) the % saving in work if two stage intercooling is compared with single stage compressor
between same limits. [7.6 kJ/s, 44.65 hp, 13%]
16.30 A single acting reciprocating air compressor has two stages with the optimum and perfect
intercooling in between. Compressor has air sucked at 1 bar and at the rate of 2.4 m3/min when
measured at 1.013 bar, 288 K. Compressor delivers air at 70 bar. Temperature at the end of suction
stroke is 32°C. The compression and expansion follows polytropic process PV1.25 = C uniformly.
The clearance volume is 3% of swept volume in each HP and LP cylinder. Compressor runs at
750 rpm. If the mechanical efficiency is 0.85 then determine the power of drive required, swept
volumes of each cylinder, % saving in power as compared to single stage compression within
limits. [35.8 hp, 3963 cm3, 473 cm3, 20.89%]