Week 10: Gas Compressor (Multi-Stage Compressor)
10
Double Stage Compressor
When high pressure air is required, multiple stage air
compressors are used
It is made up of three components: a high pressure (H.P.)
cylinder, an intercooler, and a low pressure (L.P) cylinder. One
primary mover drives both the pistons (in the L.P. and H.P.
cylinders) through a typical shaft.
After entering the low pressure cylinder, atmospheric air at
pressure (𝑃𝑠 ) is compressed to a high pressure (𝑃𝑑 ). The
pressure between the delivery and the intake is what we
called the intercooler pressure (𝑃𝑖 )
An intercooler then receives the air from the low pressure
cylinder.
Week 10: Gas Compressor (Multi-Stage Compressor)
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Double Stage Compressor
In the intercooler, cold water is circulated to cool the air while
maintaining a steady pressure.
The high-pressure cylinder is then filled with the intercooler's
cooled air.
Air is provided to the air receiver tank in the high-pressure
cylinder after being further compressed to the ultimate
delivery pressure (p3)
Week 10: Gas Compressor (Multi-Stage Compressor)
10
Double Stage Compressor
Week 10: Gas Compressor (Multi-Stage Compressor)
10
Advantage of Multi−Stage Compressor
1. Low Compressor Work: Before the air is introduced to the high-
pressure cylinder, it is cooled in an intercooler. In order to deliver
the same amount of air at the same delivery pressure, a
multistage compressor requires less electricity to operate than a
single stage compressor.
2. Better balancing: When air is compressed in one cylinder, it is
drawn into the other. More uniform torque is produced as a
result. As a result, the flywheel's size is decreased.
3. Better Lubrication and Leakage free: The temperature and
pressure ranges are maintained within acceptable bounds. Due
to the reduced temperature, there is a) less air leakage through
the cylinder's piston and b) effective lubrication.
Week 10: Gas Compressor (Multi-Stage Compressor)
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Advantage of Multi−Stage Compressor
4. More Utilized Volume: The influence of the leftover air's
expansion (high pressure air in the clearance space) is reduced
for small pressure ranges. This means that volumetric efficiency is
increased by increasing the number of steps.
5. High delivery pressure: Air is delivered at a high pressure with
reasonable quantitative effectiveness.
6. Cheaper materials: Lower operating temperatures enable the
use of less expensive building materials.
Week 10: Gas Compressor (Multi-Stage Compressor)
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Advantage of Multi−Stage Compressor
𝑃𝑠 = 𝑃𝑠𝑢𝑐𝑡𝑖𝑜𝑛 𝑃𝑑 = 𝑃𝑑𝑖𝑠𝑐ℎ𝑎𝑟𝑔𝑒
1 2 3 4
Intercooler
𝑄𝑅
𝑊𝐶1 𝑊𝐶2 High Pressure
Low Pressure
Compressor Compressor
Week 10: Gas Compressor (Multi-Stage Compressor)
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Assumptions
1. Work of compression are equal.
2. Energy at suction of compressors are equal.
3. For ideal intercooler, the temperature at the suction
are equal.
4. Pressure ratios in the compressors are equal.
Week 10: Gas Compressor (Multi-Stage Compressor)
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Intercooler Pressure
𝑃𝑖 = 𝑃𝑠 𝑃𝑑
Total Work of Compressor
𝑃 𝑘−1
2𝑘 𝑃𝑑 2𝑘
4 𝑊𝐶 = 𝑃𝑠 𝑉𝑠 −1
𝑃𝑑 𝑘−1 𝑃𝑠
2 Saving of Work:
𝑃𝑖
𝑊𝑆 = 𝑊𝑠𝑖𝑛𝑔𝑙𝑒 𝑠𝑡𝑎𝑔𝑒 − 𝑊𝑑𝑜𝑢𝑏𝑙𝑒 𝑠𝑡𝑎𝑔𝑒
𝑃𝑠
1
𝑉
Week 10: Gas Compressor (Multi-Stage Compressor)
10
Example:
An air compressor has a suction volume of 0.25 𝑚3 /𝑠 at 97 𝑘𝑃𝑎 and
discharge to 650 𝑘𝑃𝑎. Determine:
a. How much power saved by the compressor if there are two stages
b. What is the intercooler pressure in psig?
Given: Vs = 0.25 m3/s n = 1.4 a.
Single stage Wc at single - Wc at double
Ps = 97 kpaa = 8.2 KW
Pd = 650 kpaa
Single Stage compressor
Wc = (nP1V1/n-1)(P2/P1)^ n-1/n - 1 = ((1.4 x 97kpaa x 0.25 m3/s)(1.4-1) ) ((650/97)^ 1.4-1/1.4) - 1
= 61.26 KW KJ/S
Double stage compressor Double stage
Wc = 2nP1V1/n-1 (Pi/Ps)n-1/n -1 Wc = (2x1.4 x 97kpaa x 0.25 m3/s)(1.4-1) ) ((251.098/97)^ 1.4-1/1.4)
Wc = 53.06 Kw
b. Intercooler
Pi = square root of PSxPD
= 251.098kpaa
Pa = Patm - Pg = 149.74kpag = 14.7 / 101.325 = 21.73 psig
Week 10: Gas Compressor (Multi-Stage Compressor)
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Example:
Find the cylinder dimensions of a single cylinder double acting
compressor handling 30𝐿/𝑟𝑒𝑣 of nitrogen 𝑓𝑟𝑜𝑚 100 𝑘𝑃𝑎, 37°𝐶 to 725 𝑘𝑃𝑎𝑎.
Compression and re-expansion are accordance with 𝑛 = 1.35, 𝑐 = 5% and
𝐿/𝐷 = 1.
Wc = (2x1.35 x 100kpaa x 0.03)(1.35-1) ) ((269.26/100)^ 1.35-1/1.35) - 1
Vdisplaced= 30Li/rev = 0.03m3/rev
n= 1.35 Pi = 269.26kpaa
Ps = 100Kpa
Ts = 37C Wc = 3.17kw
Pd = 725 kpa 0.025m3 = 3.1416/4 (D)^2 x D
c = 5% D = 0.32m = L
L/D = 1 Nv = 1+C-C (725/100)^1/1.35
Nv = 1 +5%-5% (725/100)^ 1/1.35
L=D = 0.83
Vcyclinder = 3.1416/4 (D)^2 x L
Vcylinder = Nv x Vd
= 0.83 x 0.03m3
= 0.025 m3
Week 10: Gas Compressor (Multi-Stage Compressor)
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Seatwork:
A double-stage compressor receives 1 kg/min of helium gas at
120 𝑘𝑃𝑎𝑎, 27°𝐶 and delivers it at 6 𝑀𝑃𝑎𝑎.
a. Compressor Work
b. Intercooler pressure
c. The maximum temperature of the system
d. The heat transferred by helium in the intercooler in kW.
e. The mass of the refrigerant 𝑁𝐻3, circulated coolant at −30°𝐶, if its
change in enthalpy is 850 𝑘𝐽/𝑘𝑔 𝑖𝑛 𝑘𝑔/𝑠.