Applied Thermodynamics

Module 6: Reciprocating Compressor

Intoduction

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. 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.

Classification of Compressors

(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.
Positive displacement compressors can be further classified based on the type of mechanism used for
compression.
(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 (one delivery stroke per revolution) or double acting (two delivery strokes per revolution of
crank) compressor.

Rotary compressors employing positive displacement have a rotary part whose boundary causes positive
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
(iii) Screw compressor
(iv) Scroll compressor

Non-positive displacement compressors, also called as steady flow compressors use dynamic action of solid
boundary for realizing pressure rise. Non-positive displacement compressor can be classified depending
upon type of flow in compressor
(i) axial flow type
(ii) centrifugal type

(b) Based on number of stages: Compressors can be single stage or multistage.

(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 (air delivered per unit time) of compressors:
(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: 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.

RECIPROCATING COMPRESSORS

Reciprocating compressor has piston cylinder arrangement as shown in Fig. (1)

Fig. (1) Line diagram of reciprocating compressor

Construction: 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.

Working: 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, 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. 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 sufficient 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.

See the working of reciprocating compressor https://www.youtube.com/watch?v=F5Tcv8VxuG4

https://www.youtube.com/watch?v=bJluUxA7aaY

Thermodynamic Analysis of Reciprocating Compressor

Compression of air in compressor may be carried out in three different ways of thermodynamic processes
such as isothermal compression, polytropic compression or adiabatic compression. Figure (2) shows the
thermodynamic cycle involved in compression. Clearance volume is provided in reciprocating compressor.
Purpose of clearance volume in cylinder is twofold. One is to accommodate valve mechanism and another
one is to prevent collision of piston with cylinder head.

On p-V diagram process 4–1 shows the suction process followed by compression during 1–2, discharge
process 2–3 and expansion of clearane air 3-4 (if clearance volume is provided).

(a) (b)
Fig. (2) Compression cycle on p-V diagram (a) without clearance volume (b) with clearance volume

Air enters compressor at pressure 𝑝1 and is compressed up to 𝑝2 . Compression work requirement can be
estimated from the area bounded by the curves comprising the cycle. Area on p–V diagram shows that work
requirement shall be minimum with isothermal process 1 − 2′′ . Work requirement is maximum with
process 1–2 i.e. adiabatic process. As an engineer one shall attempt to minimise the requirement of
compression-work. Therefore, ideally compression should occur isothermally for minimum work input. In
practice, it is not possible to realise isothermal compression. Reason is maintaining constant temperature
during compression is very difficult. Generally, compressors run at substantially high speed while
isothermal compression requires compressor to run at very slow speed so that heat produced during
compression is dissipated out and temperature remains constant. High running speed of compressor lead
compression process near to adiabatic or polytropic process. 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
(adiabatic or polytropic process) from ideal compression process (isothermal compression process).
Isothermal efficiency is defined as the ratio of isothermal work to actual indicated work in reciprocating
compressor.

𝐼𝑠𝑜𝑡ℎ𝑒𝑟𝑚𝑎𝑙 𝑊𝑜𝑟𝑘
𝐼𝑠𝑜𝑡ℎ𝑒𝑟𝑚𝑎𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝐴𝑐𝑡𝑢𝑎𝑙 𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝑊𝑜𝑟𝑘

Compression process following three different processes is also shown on T-s diagram in Fig. (3).

Fig. (3) Compression process on T-S diagram.

Compression Work, 𝑾𝑪 (without clearance volume)- Assuming compression process follow

polytropic process i.e. 𝑝𝑉 𝑛 = 𝐶
In case of compressor having isothermal compression process, n=1 i.e. 𝑝1 𝑉1 = 𝑝2 𝑉2

In case, compressor follow adiabatic compression process, 𝑛 = 𝛾

Or,

Hence isothermal efficiency

As an engineer one should attempt to design a compressor which efficiency approaches 100%, thereby
meaning that actual work of compression should approach isothermal work of compression. This can be
achieved by adopting following method

I. Provide fins over the surface of cylinder. Fins facilitate quick heat transfer from air (which is
being compressed) to atmosphere.
II. Water jacket may be provided around compressor cylinder so that heat can be picked by cooling water
circulating through water jacket.
III. Water may also be injected at the end of compression process in order to cool the air being
compressed.
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.
All these methods restrict the temperature rise during compression. Hence actual compression process
approaches to isothermal compression.

Compression Work, 𝑾𝑪 (with clearance volume)- With clearance volume the cycle is represented on Fig.
(2-b). The work done for compression of air polytropically can be given by the area enclosed in cycle 1–2–3–
4.
 (∵ 𝑝1 = 𝑝4 & 𝑝2 = 𝑝3 )

This (V1 – V4), say 𝑉𝑑 , is actually the volume of air inhaled in the cycle and delivered subsequently.

Assuming air behaves as a perfect gas. Now temperature and pressure can be related as

And

Substituting,

Ideally there shall be no change in temperature during suction and delivery i.e. 𝑇1 = 𝑇4 & 𝑇2 = 𝑇3 . Above
equation can be written as

Or,

Where (𝑚1 − 𝑚2 ) indicates the mass of air sucked or delivered. For unit mass of air delivered the work
done per kg of air can be given as,
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.

Power required to run the compressor

For single acting compressor,

Volumetric Efficiency

It is defined as the ratio of actual volume of air sucked into the cylinder during suction stroke to the piston
displacement (PD) or swept volume (𝑉𝑠 ) of the cylinder. Volumetric efficiency of compressor is often
referred to at free air conditions, i.e., temperature and pressure of the environment, which may be taken as
15℃ & 101.325 kPa, if not mentioned.

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. 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,

Volumetric efficiency referred to free air conditions,

Volumeof air sucked referred to free air conditions (FAD)

𝜂𝑣𝑜𝑙 =
Swept Volume

𝑉1 − 𝑉4
=
𝑉1 − 𝑉3
(𝑉𝑠 + 𝑉𝑐 ) − 𝑉4
=
𝑉𝑠
Here 𝑉𝑐 is clearance volume, 𝑉𝑐 = 𝑉3 and 𝑉𝑠 = 𝑉1 − 𝑉3 .
 𝑉𝑐 𝑉4
𝜂𝑣𝑜𝑙 = 1 + ( ) − ( )
𝑉𝑠 𝑉𝑠
Here,

𝑉
Let the ratio of clearance volume to swept volume be given by clearance, C, i.e. 𝐶 = 𝑉𝑐.
𝑠
𝑉4
𝜂𝑣𝑜𝑙 = 1+𝐶−𝐶( )
𝑉3
1
𝑝 𝑛
Or, 𝜂𝑣𝑜𝑙 = 1 + 𝐶 − 𝐶 ( 2)
𝑝1

Above expression shows that volumetric efficiency decreases with increase in pressure ratio and clearance
as shown in Fig. (4).

Fig. (4) Effect of pressure ratio and clearance on volumetric efficiency

 𝜂𝑣𝑜𝑙

𝑝2
Pressure ratio,
𝑝1
𝑝
Fig. (5) Effect of pressure ratio ( 2⁄𝑝1 ) and index of compression (n) on volumetric efficiency (𝜂𝑣𝑜𝑙 ).

For a given pressure ratio, 𝜂𝑣𝑜𝑙 is zero when the maximum clearance is
1
𝑝2 𝑛
0 = 1 + 𝐶𝑚𝑎𝑥 − 𝐶𝑚𝑎𝑥 ( )
𝑝1
1
𝐶𝑚𝑎𝑥 = 1
𝑝 𝑛
(𝑝2 ) − 1
1
𝜂𝑣𝑜𝑙 decreases with increase in pressure ratio. Thus, maximum pressure ratio that can be attained with
reciprocating cylinder is limited by clearance. Maximum pressure ratio can be determined as

1
𝑝2𝑚𝑎𝑥 𝑛
0 = 1+𝐶−𝐶( )
𝑝1
Or,
𝑝2𝑚𝑎𝑥 1 𝑛
= (1 + )
𝑝1 𝐶

Volumetric Efficiency and control of mass flow rate of air:

𝑚̇𝑣
𝜂𝑣𝑜𝑙 =
𝑃𝐷

Where 𝑚̇ & 𝑣 are mass flow rate and specific volume of air sucked into the cylinder.
𝑃𝐷
𝑚̇ = 𝜂𝑣𝑜𝑙
𝑣
In order to have maximum flow rate of air, 𝑚̇, compressors are built with minimum practical clearance.
But, sometimes, compressors are driven by constant speed motor and it is required to manipulate the flow
rate of air through the compressor. This can be achieved by providing adjustable clearance pocket to the
cylinder head as shown in Fig. (6). By varying the clearance 𝐶, mass flow rate is controlled.

Adjustable clearance
pocket

Fig. (6) A cylinder with adjustable clearance pocket to control volumetric capacity or mass flow rate

Actual Indicator Diagram

Theoretical indicator diagram of reciprocating compressor refers to the ideal state of operation of
compressor.

Fig. (7) 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.
1234 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 22’3.

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 depression 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.

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 next cylinders for further
compression.

Before going into detail of multistaging let us understand it’s necessity. Maximum pressure that can be
achieved economically with single stage reciprocating compressor is 5 bar.

i. First and foremost reason, decrease in volumetric

efficiency with increase in pressure ratio.
1
𝑝2 𝑛
𝜂𝑣𝑜𝑙 = 1+𝐶−𝐶( )
𝑝1
This aspect can also be explained with the help of p-V
diagram as shown in Fig. (8). For the same swept
volume, 𝑉𝑠 , delivery pressure has been increased from
𝑝2 to 𝑝2′ . Suction volume (𝑉1 − 𝑉4′ ) for the cycle 1-
2’-3’-4 is less than the suction volume (𝑉1 − 𝑉4 ) for
the cycle 1-2-3-4. Hence volumetric efficiency
decreases. Fig. (8) Effect of increase in pressure

ii. In order to maintain same discharge at higher pressure 𝑝2′ (cycle 1-2’-3’-4) a large size cylinder
will be required.
iii. Leakage of air past the valves and piston at higher pressure.
iv. Increase in pressure ratio requires sturdy structure, from mechanical strength point of view, to
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. In multistage compression the partly
compressed air leaving first stage is cooled up to ambient air temperature in intercooler and then sent to
subsequent cylinder (stage) for compression as shown in Fig. (9). Fig. (10) shows the p-V diagram of
multistage compression occurring in two stages. Here first stage of compression occurs in cycle 12671.
Thereafter, partly compressed air enters intercooler and subsequently to second stage of compression and
occurs in cycle 2345.
Intercooling is called perfect when temperature at inlet to subsequent stages of compression is reduced to
ambient temperature. 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’–3’. Fig. (11) shows multistage (two stage) intercooled compression.
 Fig. (9) Schematic diagram of two stage compression Fig. (10) Two stage intercooled
with intercooling compression

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 intercooling 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. T–s representation is shown in Fig. (11).

Fig. (11) T-s representation of multistage compression

Optimum Pressure Ratio and Minimum Work for Multistage Reciprocating Compression

Following assumptions are made in mathematical analysis:

i. Index of compression is same in all stages and there is no pressure drop in suction and delivery of
air across any stage.
ii. There is perfect intercooling between compression stages.
iii. Mass handled in different stages is same.
iv. Air behaves as perfect gas during compression.
Total work required in compression is given by

Here 𝑝1 , 𝑇1 and 𝑝2′ are fixed and 𝑝2 is the only variable. Thus, 𝑊𝑐 is a function of 𝑝2 and compressor work
can be optimized with respect to intermediate pressure 𝑝2 .

𝑑𝑊𝑐
=0
𝑑𝑝2

=0

Or,

Or,

Or,

Thus, for minimum work of compression, the intermediate pressure is the geometric mean of suction and
delivery pressure for a two stage compressor.

Pressure ratio in LP stage is equal to pressure ratio in HP stage. Thus, it is established that the compressor
work shall be minimum when the pressure ratio in each stage is equal.

Thus, intermediate pressure that produces minimum work will also result in equal pressure ratios in the two
stages of compression and equal work for two stages. For two stage-compression, the minimum work becomes
In case of multiple stages, say i number of stages, for the delivery and suction pressures of 𝑝𝑖+1 and 𝑝1 the
optimum pressure ratio for each stage shall be,
1
𝑝𝑖+1 𝑖
𝑂𝑝𝑡𝑖𝑚𝑢𝑚 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑟𝑎𝑡𝑖𝑜 = ( )
𝑝1
And minimum work required for i number of stages shall be,

Advantages of multistage compression are:

1. High volumetric efficiency.
2. Reduction in requirement of work input and hence power.
3. Size and strength of cylinders can be adjusted to suit volume and pressure of air.
4. Multi cylinder compressors give more uniform torque and better mechanical balance thus require
smaller flywheel.
5. Since maximum temperature reached during the compression process is greatly reduced by
intercooling, lubrication difficulties and explosion hazards are lessened.
6. Leakage losses are reduced considerably.

Video links for further help on reciprocating compressor

https://www.youtube.com/watch?v=ORelNtfyVLA&list=PL6HQVc8_tFGLgI-L-aAKct4RUGTKY-Bfb
https://www.youtube.com/watch?v=ExQjuiqShcE&list=PL6HQVc8_tFGLgI-L-aAKct4RUGTKY-
Bfb&index=2
https://www.youtube.com/watch?v=TfArKLk0G4I&list=PL6HQVc8_tFGLgI-L-aAKct4RUGTKY-
Bfb&index=3
https://www.youtube.com/watch?v=NtatA5544n8&list=PL6HQVc8_tFGLgI-L-aAKct4RUGTKY-
Bfb&index=4
https://www.youtube.com/watch?v=4yUU3ln1S-0&list=PL6HQVc8_tFGLgI-L-aAKct4RUGTKY-
Bfb&index=5
 Module 6: Assignment
Note:
1. Solution is to be shared with me and not in group.
2. Those who will share in the group will be awarded zero marks
3. You must write your name, registration number and roll number before and
then share the solution.

1. Consider the following factors:

1. Cylinder size 2. Clearance ratio
3. Delivery pressure 4. Compressor shaft power
The factors which affect the volumetric efficiency of a single-stage reciprocating air compressor
would include
(a) 1 and 2 (b) 3 and 4 (c) 2 and 3 (d) 1 and 4
2. A large clearance volume in a reciprocating compressor results in
(a) Reduced volume flow rate (b) Increased volume flow rate
(c) Lower suction pressure (d) Lower delivery pressure
3. Which of the following statements are correct for multi staging in a reciprocating air compressor?
1.It decreases the volumetric efficiency.
2.The work done can be reduced.
3. small high-pressure cylinder is required.
4.The size of flywheel is reduced.
Select the correct answer using the codes given below
(a) 1, 2 and 3 (b) 2, 3 and 4 (c) 1, 3 and 4 (d) 1, 2 and 4
4. The suction pressure is 1 bar and delivery pressure is 125 bar. What is the ideal intermediate
pressure at the end of first stage for a 3-stage air compressor?
(a)25 bar (b) 5 bar (c) 10 bar (d) 20 bar
5. Consider the following statements:
1. Reciprocating compressors are best suited for high pressure and low volume capacity.
2. The effect of clearance volume on power consumption is negligible for the same volume of
discharge
3. While the compressor is idling, the delivery valve is kept open by the control circuit.
4. Inter-cooling of air between the stages of compression helps to minimize losses.
Of these statements:
(a) 1 and 2 are correct (b) 1 and 3 are correct
(c) 2 and 4 are correct (d) 3 alone is correct
6. Assertion (A): The isothermal efficiency of a reciprocating compressor becomes 100% if perfect
cooling of the fluid during compression is attained.
Reason (R): Work done in a reciprocating compressor is less if the process of compression is
isothermal rather than polytropic.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false(d) A is false but R is true
7. Assertion (A): A reciprocating air compressor at sea level would deliver a greater mass of air than
a compressor on a mountain.
Reason (R): The compressor ratings are given for “free air”.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
8. Which one of the following statements is correct? In reciprocating compressors, one should aim
at compressing the air
(a) Adiabatically (b) Isentropically (c) Isothermally (d) Poly
tropically
9. Reciprocating compressors are provided with
(a) Simple disc/plate valve (b) Poppet valve
(c) Spring-loaded disc valve (d) Solenoid valve
10. Which of the following statements does NOT apply to the volumetric efficiency of a
reciprocating air compressor?
(a)It decreases with increase in inlet temperature
(b)It increases with decrease in pressure ratio
(c)It increases with decrease in clearance ratio
(d)It decreases with increase in clearance to stroke ratio