Compressors , Fans & Blowers

INTRODUCTION

The main use of the fans, compressors and blowers is the transportation of gases The main item of most processes is the compressor selection There are wide variety of compressors so it is crucial to define the operating conditions before selection

Major Factors During Selection

Head or Pressure Rise Flow Rate Temperature Limitations Consumption of Power Cost

The pressure rise which is the main difference between fans, compressors and blowers can be stated as follows: P(psig) Fans Blowers Compressors 2 2-10 >10

Compressors & Gas Compression

Categories and Types Compression Process Compressor Characteristics Key Design Parameters Calculation Methods Specification Data Sheet Selection Guidelines Control Systems Typical operating Problems

Compressor Application and Classification

Compressors are used in a variety of applications

Example: In natural gas plants, compressors are used to establish feed gas process pressures. Compressors also provide clean, dry air for instruments and control devices In a refinery or chemical plant, compressors are used to compress gases such as light hydrocarbons, nitrogen, hydrogen, carbon dioxide, and chlorine These gases are sent to headers, from which they are distributed

Classification of Compressors
There are three basic designs for compressors : i) Dynamic ii) Positive displacement iii) Thermal. Dynamic compressors include centrifugal (radial flow) and axial (straight-line) flow compressors. Dynamic compressors accelerate airflow by drawing air in axially and spinning it outward (centrifugal compressors) or in a straight line (axial flow compressors).

 Positive displacement compressors include rotary and reciprocating compressors. Positive displacement compressors compress gas into a smaller volume and discharge it at higher pressures. Thermal compressors use ejectors to direct highvelocity gas or steam into the process stream, entraining the gas, then converting the velocity into pressure in a diffuser assembly.

Compressors Family Tree

Compressors & Gas Compression

Categories and Types

The principles of compression are:

Gases and vapors are compressible. Compression decreases volume. Compression moves gas molecules close together. Compressed gases will resume their original shape when released. Compressed gases produce heat because of molecular friction. The smaller the volume, the higher the pressure. Force area = Pressure. Gas volume varies with temperature and pressure. Liquids and solids are not compressible (except under tremendous pressures).

Dynamic Compressors
@ Centrifugal Compressor

Gas enters a centrifugal compressor at the suction inlet and is accelerated radially by moving impellers. Centrifugal compressors have one moving element, the drive shaft and impeller. The impeller discharges into a circular, narrow chamber called the diffuser More sensitive to density and fluid characteristics Designed to operate at speeds in excess of 3000 rpm Can be single stage or multistage Single stage designed for high gas flow rates and low discharge pressure Multi stage designed for high gas flow rates and high discharge pressure

The advantages of centrifugal compressors can be classified as;

They are more efficient than reciprocating ones They provide high flowrates They are compact, less site area They need lower maintainance requirements They are tolerant to liquid carry

Centrifugal Compressor

Compressors & Gas Compression

Centrifugal Compressor

Single-stage Centrifugal Compressor Multi-stage Centrifugal Compressor

Dynamic Compressors
@ Axial Flow Compressor

Normally used for jobs where highest flow and pressure required Request twice as many stages as centrifugal perform (8% to 10%) Primary application of axial compressors involves transfer of clean gas such as air Internal component are sensitive to corrosion, pitting and deposits More lighter, more efficient and smaller than centrifugal pumps Main purpose is in gas turbine applications

The advantages of axial compressors

-

They have higher efficiency They have higher capacity (flow rate) They are in smaller size

The disadvantages of axial compressors

-

They limited operating range They are more subjected to corrosion They are subjected to deposits They have higher capital costs They have lower heads

Axial Flow Compressor

Compressors & Gas Compression

Axial Compressor

Combined Axial and Radial Compressor Applications

They have flow rates ranging from 50,000 to 690,000m3/hr They have pressure ratio ranging from 5.8 to 12.5

POSITIVE DISPLACEMENT COMPRESSORS

Positive Displacement Compressors

Reciprocating Compressors

Rotary Compressors

RECIPROCATING COMPRESSORS

They are the oldest type of compressors They have higher maintainance costs and lower capacity than dynamic compressors They are widely used in industry They have cylinders which are equipped with suction and delivery valves Compression cycle is composed of 3 cycles which are intake, compression and discharge

They intake gas by the help of cylinders The pistons motion is reversed and the gas which taken in is compressed The gas is expelled during the delivery stroke

In multistage reciprocating compressors; The gas is compressed to an intermediate pressure The other cylinders raise the pressure to the end pressure There also exist intercoolers

Positive Displacement Compressors @ Reciprocating piston Compressor

Work by tapping and compressing specific amount of gas between a piston and cylinder wall The back and forth motion incorporated by a reciprocating compressor pull gas on the suction and discharge on the other Spring loaded suction and discharge valves work automatically as piston moves up and down Have a flexible pressure range and overall capacity, low power cost high efficiency rating

Reciprocating Piston Compressor

ROTARY COMPRESSORS

The two rotating components confine a volume of gas The volume of the pocket decreases in rotation so pressure increases

The rotary compressors have high range of capacity and compression ratio The rotary compressors are classified as; Lobed, Helical Screw, Sliding Vane

Positive Displacement Compressors @ Rotary Compressor (Sliding Vane)

Use off center rotor with sliding vane to compress gases body (cast iron or steel), rotor and shaft ( high strength alloy steel), sliding vanes (asbestosphenolic resin, metal) Does not use suction or discharge valve because it is

 Positive Displacement Compressors @ Rotary Compressor (Lobe) Characterized by the two kidney bean shape impellers Used to trap and transfer gases Two impellers move on opposite direction during operation Designed to have constant volume discharge pressure and constant speed drives Can be used in wet and

Positive Displacement Compressors

@ Rotary Compressor (Liquid Ring) Unusual compressor design (combines centrifugal action, with positive displacement and rotary action) May be found in the following application : Hazardous gases Toxic gases Hot gases and vapor

Screw Compressor

HELICAL SCREW COMPRESSORS

There are mainly two screws which are called male and female The gas is compressed between the lobes of the screw and move along the axis to an outlet port

These units can be; oil flooded and dry The contamination of oil is prevented by dry compressors Oil flooded units are used in refrigeration systems and plant air service

FANS & BLOWERS

Blower and Fans

Simple devices typically classified as compressors two basic design (axial flow and centrifugal flow) mostly are single stage devices. - centrifugal blower (low pressure air systems, refrigeration unit or laboratory hoods) - fan (direct airflow into or out of ind. equipment such as cooling tower, boilers or HVAC system) centrifugal fan to move gases over a wide range of conditions