ME8493 – Thermal Engineering 1 Mechanical Engineering

Thermal Engineering 1
Unit ii – reciprocating Air compressors
ME8493 – Thermal Engineering 1 Mechanical Engineering

Air Compressor
Air compressor is a device which is used to increase the pressure of gas from low pressure to
high pressure.
Classification compressors
According to number of stages:
 Single stage compressor
 Multi stage compressor
According to number of cylinders:
 Single cylinder compressor
 Multi cylinder compressor
According to method of cooling:
 Air cooled compressor
 Water cooled compressor
According to working:
 Reciprocating compressor
 Rotary compressor
List the types of rotary air compressor.
Positive displacement type
 (a) Screw compressor.
 (b) Vane compressor.
Steady flow type
 (a)Centrifugal compressor.
 (b)Axial flow compressor.
positive displacement compressors
Positive displacement compressor is one in which air is compressed adiabatically. The air is
entrapped in between two sets of engaging surfaces. The pressure rise is either by back flow of
air (as in roots blower) or both by variation in the flow and back flow (as in vane blower).
non-positive displacement compressors
In non-positive displacement compressor, air is not trapped in specific boundaries but it flows
continuously and steadily through the machine (as in centrifugal compressor and axial flow
compressor).
Isothermal efficiency
Isothermal efficiency of the compressor is defined as the ratio of isothermal work input to actual
work input during compression.

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isentropic efficiency
Isentropic efficiency of the compressor is defined as the ratio of isentropic work input to the
actual work input.
theoretical & actual indicator diagram for reciprocating air compressor
a.Theoretical indicator diagram b. Actual indicator diagram

FAD
Free air delivered (FAD) means the actual volume of air delivered by the compressor under
normal temperature and pressure.
Influence of pressure ratio on the volumetric efficiency
The volumetric efficiency of the compressor also depends on the compressor ratio. If the
difference between the suction and the discharge pressure is higher, the compressed air will
remain trapped inside the clearance volume for longer time and prevent the opening of the
suction valve. Thus as the compression ratio of the compressor and the discharge pressure is
increases, its volumetric efficiency and the capacity reduces.
(i) To reduce the temperature of compression from each stage.
(ii) To increase compressor efficiency.
(iii) To condensate from air.
Slip factor
Slip factor is the ratio of whirl velocity of static pressure to tip velocity
pressure coefficient
Pressure coefficient is the ratio of isentropic work of the compressor to the Euler work
Various factors affecting the delivery pressure of the reciprocating

compressor?
The size of the cylinder will be too large for very high pressure.
Due to compression, there will be a rise in the temperature of the air. So the delivery pressure is
limited, so that rise in temperature of air is not going beyond limit and size of cylinder is not too
large.

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Volumetric efficiency of the compressor and How its reduces?

Volumetric efficiency of an air compressor is the ratio of free air delivered to the displacement
of the compressor. Volumetric efficiency = Free air delivered / Displacement volume
As the piston moves downwards the high-pressure gas in the clearance volume reduces due to
expansion, and only when the pressure reaches a certain level does the suction-valve open.
Therefore, this gas used in the piston’s suction stroke goes unused and reduces the volumetric
efficiency of the compressor.
Intercooler, perfect intercooling and its purpose
An intercooler is any mechanical device used to cool a fluid, including liquids or gases, between
stages of a multi-stage heating process, typically a heat exchanger that removes waste heat in
a gas compressor.
When temperature of the air leaving the intercooler is equal to the original temperature of
atmospheric air temperature, then the intercooling is known as perfect intercooling.
Merits of multistage compression?
(i) For each stage, pressures during suction and delivery remain constant.
(ii) The index (n) in polytropic law is same in each stage of compression.
(iii) Intercooling in each stage is done at constant pressure.
(iv) Low pressure and high pressure cylinder handle same mass of air.
(v) There is no inter-stage pressure drop

Why clearance volume is necessary and explain its importance?

In actual compressor, the clearance volume is provided to give cushioning effect otherwise the
piston will strike the other end of the cylinder. It is generally expressed as percentage of piston
displacement.
 To give cushioning effect to the piston.
 To provide space for valve movement.
 The maximum pressure may also be controlled by clearance volume.
 If clearance volume is more, it reduces the volumetric efficiency.
effect of pressure ratio on volumetric efficiency with neat P-V diagram.

Volumetric efficiency increases with

decrease in pressure ratio in compressor.

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intercooler
An intercooler is any mechanical device used to cool a fluid, including liquids or gases, between stages of
a multi-stage heating process, typically a heat exchanger that removes waste heat in a gas compressor.

purpose of intercooling
(i) To reduce the temperature of compression from each stage.
(ii) To increase compressor efficiency.
(iii) To condensate from air.
P-V & T-S diagram for perfect/complete intercooling in multistage compressor

P-V & T-S diagram for imperfect/incomplete intercooling in multistage compressor

condition for minimum work done on multistage compressor for ‘Z’stages.

(i) The pressure ratio of each stage should be the same.
(ii) The pressure ratio of any stage is the square root of overall pressure ratio for a two stage
compressor.
(iii) Air after compression in each stage should be cooled to initial temperature of air intake.
(iv) The work input to each stage is same.
Differentiate centrifugal and axial flow compressors
Centrifugal Compressor Axial flow Compressor
Flow of air is perpendicular to the axis of
The flow of air is parallel to the axis of compressor.
compressor.
It has low manufacturing and running cost. It has high manufacturing and running cost.
It requires low starting torque. It requires high starting torque.
It is not suitable for multi staging. It is suitable for multi staging.
factors affecting the delivery pressure of the reciprocating cpmpressor
The size of the cylinder will be too large for very high pressure.
Due to compression, there will be a rise in the temperature of the air. So the delivery pressure is limited,
so that rise in temperature of air is not going beyond limit and size of cylinder is not too large.

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ME8493 – Thermal Engineering 1 Mechanical Engineering
Single Stage Air Compressor : Find 𝐕̇, 𝐕𝐒 and N : (With Clearance Volume)
Indicated power or Polytrophic Work: V̇Act
n−1 V̇ =
n P
ηvol
n
Ẇ = n−1 ṁRT 1 [(P2 ) − 1] kW V̇Act = VS × N × Number of Acting
1
n−1 Clearance Ratio:
n P n VC
Ẇ = n−1 P1 V̇ [(P2 ) − 1] kW C=
1 VS
Where, Volumetric Efficiency:
1
For compressor without clearance P2 n
ηvol = 1 − C [( ) − 1]
V̇ = V̇1 P1
For compressor with clearance Volume of air delivered
ηvol =
V̇ = V̇1 − V̇4 Volume of air filled in Swept Volume
Isothermal Work V̇
P ηvol =
Ẇ = P1 V̇ ln (P2 ) kW Vs × N × Number of Acting
1 Volumetric Efficiency if consider FAD:
Isothermal Efficiency: FAD
Isothermal Power ηvol =
Vs × N × Number of Acting
ηiso = 𝑇 𝑃 𝑇 𝑃
Polytropic Work FAD = (V̇1 − V̇4 ) 𝑎 1 FAD = V̇ 𝑎 1
𝑇1 𝑃𝑎 𝑇1 𝑃𝑎
Isentropic Work: Where,
γ−1
γ−1 P2 γ
P1 - Pressure of the air at FAD(kN/m2 ),
Ẇ = P1 V̇ [(P ) − 1] kW T1 - Temperature of the air at FAD (K)
γ 1
Pa - Inlet or Suction Pressure of the air (kN/m2 ),
Isentropic Efficiency: Ta - Inlet or Suction Temperature of the air (K)
Isentropic Work
ηisen =
Polytropic work
Multi-Stage Air Compressor:
Power Input to the Compressor:
Power required to drive the compressor:
Indicated Power n−1
WC = n P z×n
Mechanical Efficiency 𝑊̇ = 𝑍 × n−1 P1 V̇ [( PZ+1 ) − 1] kW
1
Power Input to the Motor:
Power input Where,
Wmotor = Z = number of stages
Transmission or motor Efficiency
Where , P1- Inlet Pressure of the air (kN/m2 )
n = Index of Compression, PZ+1- Delivery Pressure of the air (𝑘N/m2 )
P1 V̇ = ṁRT 1 For LP Compressor:
n−1
P1 - Inlet Pressure of the air (kN/m2 ), n P2 n
3
Ẇ𝐿𝑃 = P1 V̇ [( ) − 1]
m n−1 P1
V̇ – Volume flow rate of air (Sec)
kg For LP Compressor:
ṁ – Mass flow rate of air (Sec) n−1
n P3 n
J Ẇ𝐻𝑃 = P2 V̇2 [( ) − 1]
R – Gas Constant (R = 287 kgK ) n−1 P2
T1 - Inlet Temperature of the air (K) Intermediate Pressure:
Swept or Stroke Volume: 1
πD2
P2 P3 P4 P𝑍+1 𝑍
VS = × L, = = =( )
4 P1 P2 P3 P1
Find 𝐕̇, 𝐕𝐒 and N: (Without clearance Volume) To Find Pressure or Temperature: If not given
V̇ = VS × N × Number of Acting P2 T2 𝑛
𝑛−1

Where, =( )
P1 𝑇1
N – Speed of Compressor (rpm) T2 V1 𝑛−1
=( ) = (rc )𝑛−1
𝑇1 V2
Compression Ratio:
V1 VS + VC
rc = =
V2 VC

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ME8493 – Thermal Engineering 1 Mechanical Engineering

PART – B

1. With a neat sketch, describe the construction of single stage reciprocating air compressor .

 In single stage reciprocating air compressor the entire compression is carried out in a single cylinder.
 If the compression is affected in one end of the piston & cylinder then it is known as single acting & if the
compression is affected in both ends of piston & cylinder then it is known as double acting reciprocating air
compressor.
 The opening & closing of simple check valve (plate or spring valve) is depend upon difference in pressure.
 if mechanically operated valves are used for suction & discharge then their functioning is controlled by
cams.
 The weight of air in the cylinder will be zero when the piston is at top dead center, if we neglect clearance
volume.
 When piston starts moving downwards, the pressure inside the cylinder falls below atmospheric pressure&
suction valve/inlet valve opens. The air is drawn into the cylinder through suction filter element. This
operation is known as suction stroke.
 When piston moves upwards, compresses the air in cylinder & inlet valve closes when pressure reaches to
atmospheric pressure.
 Further compression follows as the piston moves towards the top of its stroke until, when the pressure in the
cylinder exceeds that in the receiver. This is compression stroke of compressor. At the end of this stroke
discharge/delivery valve opens & air is delivered to receiver.
 When it is double acting reciprocating air compressor, suction stroke is in process at one end of piston while
at same time discharge stroke is in process at other end of piston. In simple word we can say that suction &
compression took place on both end of piston & cylinder in double acting reciprocating air compressor.

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2. Derive the work done for single cylinder reciprocating air compressor with and without clearance.

Compressor without clearance: Compressor with clearance volume:

Process 1-2 : Compression

Process 1-2 : Compression
Process 2-3 : Deliver (During compression
Process 2-3 : Deliver (During compression
delivery valve opens)
delivery valve opens)
Process 3-4 : Expansion of high pressure air in the
Process 4-1 : Suction
clearance volume
( P1 = P4 , P2 = P3 )
Process 4-1 : Suction
Work done for single stage air compressor Work done for single stage air compressor
without clearance volume: with clearance volume:

W = Process ( 1234 + 230a − 140b) W = Process ( 1256 − 3564)

P2 V2 − P1 V1 n−1 n−1
W= + (P2 V2 − P3 V3 ) − (P1 V1 − P4 V4 ) n P2 n n P3 n
n−1 W= 𝐏 V̇ [( ) − 1] − 𝐏 V̇ [( ) − 1]
n − 1 𝟏 1 P1 n − 1 𝟒 4 P2
Where, V3 = V4 = 0
P2 V2 − P1 V1 Where,
W= + (P2 V2 − P1 V1 )
n−1 ṁ1 = ṁ2 , ṁ3 = ṁ4 , P1 = P4 , PP2 = PP3
1 2
1 n−1
W = (P2 V2 − P1 V1 ) [ + 1] n P2 n
n−1 W= 𝐏 (V̇ − V̇4 ) [( ) − 1]
n n−1 𝟏 1 P1
𝐖= (P V − P1 V1 )
n−1 2 2 n−1
n n P2 n
𝐖= ṁ R(T2 − T1 ) 𝐖= (ṁ 1 − ṁ 4 ) RT1 [( ) − 1]
n−1 n−1 P1
n T2
𝐖= ṁ RT1 ( − 1) n−1
n−1 T1 n P2 n
𝐖= P1 (V̇ 1 − V̇ 4 ) [( ) − 1] 𝐤𝐖
Where, n−1 P1
n−1
T2 P2 n Note:
=( )
T1 P1
P1 - Inlet Pressure of the air (𝐤𝐍/𝐦𝟐 )
n−1
n P2 n 𝐦 𝟑
𝐖=
n−1
ṁ RT1 [( )
P1
− 1] V̇ = (V̇ 1 − V̇ 4 ) – Volume flow rate of air (𝐒𝐞𝐜)
𝐤𝐠
𝐧−𝟏 ṁ = (ṁ 1̇ − ṁ 4 ) – Mass flow rate of air (𝐒𝐞𝐜)
𝐧 𝐏𝟐 𝐧
𝐖̇ = 𝐏 V̇ [( ) − 𝟏] 𝐤𝐖
𝐧−𝟏 𝟏 𝐏𝟏 𝐤𝐉
R – Gas Constant (𝐑 = 𝟎. 𝟐𝟖𝟕 𝐤𝐠𝐊 )

T1 - Inlet Temperature of the air (K)

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ME8493 – Thermal Engineering 1 Mechanical Engineering
3. Derive the expression for volumetric efficiency of air compressor.
The actual volume sucked in the cylinder during the suction
stroke is always less than the swept volume. It is due to

 The resistance offered by inlet valve to

incoming air
 Temperature of incoming air
 Back pressure of residual gas left in the
clearance volume
In terms of volume ratio:
The volumetric efficiency of air compressor is
defined as the volume of gas delivered as measured
at atmospheric pressure and temperature divided by
swept volume of the cylinder
In terms of mass ratio:
The volumetric efficiency of air compressor is defined as the mass of the gas delivered divided by
mass of gas which would fill the swept volume at atmospheric pressure and temperature.
Mass of the gas delivered
ηvol =
mass of gas which would fill the swept volume at atm cond.
In an indicator diagram for reciprocating air compressor showing effective swept volume and piston
displacement volume.
The volumetric efficiency can be expressed in terms of effective volume and piston displacement
volume.
V1 −V4 Vs +Vc −V4 Vs +Vc −V4 Vc V4
ηvol = ηvol = ηvol = ηvol = 1 + −
V1 −VC Vs +Vc −VC Vs Vs Vs

V
Multiply and divide by VC at last right term, Introducing C = Vc as clearance ratio and using Vc = V3
s

V V V V V V V
ηvol = 1 + Vc − V4 × VC ηvol = 1 + Vc − VC × V4 ηvol = 1 + C − C (V4 )
s s C s s c 3

For expansion of gas in clearance volume

1
P3 V4 n V4 P n
P4
=( )
V V3
= (P3) , where P3 = P2 and P4 = P1
3 4

1 𝟏
P n 𝐏 𝐧
Then, ηvol = 1 + C − C (P2 ) 𝛈𝐯𝐨𝐥 = 𝟏 − 𝐂 [(𝐏𝟐 ) − 𝟏]
1 𝟏

P
The volumetric efficiency decreases with pressure ratio (P2) increases in the compressor,
1

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ME8493 – Thermal Engineering 1 Mechanical Engineering
Problems on Single cylinder reciprocating air compressor without Clearance Volume

1. A single stage single acting reciprocating air compressor takes 1 m3 per minute of air at 1.013 bar and 15

°C and delivers at 7 bar assume that pvn=C where n=1.35. Calcuate Work done or Indicated Power. In

which clearance is negligible.

Given:

𝑚3
V̇1 = 1 P = 1.013 bar, T1 = 15℃, P2 = 7 bar, n=1.35
𝑚𝑖𝑛 1

Solution:

Work Done
n−1 1.35−1
n P n 1.35 1 7 1.35
Ẇ = P1 V̇ [( 2) − 1] Ẇ = × 1.013 × 102 × [( ) − 1]
n−1 P1 1.35−1 60 1.013

𝐖̇ = 𝟒. 𝟐𝟏𝟒𝟓 𝐤𝐖

2. A single acting reciprocating air compressor has cylinder diameter and stroke of 200 mm and 300 mm

respectively. The compressor sucks air at 1 bar and 27 °C and delivers at 8 bar. Speed of the compressor

is 100 rpm. Find (i) Indicated power, (ii) Mass of the air delivered per min and (iii) Temperature of the

air delivered. The compressor follow the law PV1.25=C.

Given:

D=200mm, L=300mm, P1 = 1 bar, T1 = 27℃, P2 = 8 bar, N=100rpm, n=1.25

Solution:

Work Done
n−1 1.25−1
n P n 1.25 8 1.25
Ẇ = n−1 P1 V̇ [(P2 ) − 1] Ẇ = 1.25−1 × 1 × 102 × 0.01 × [(1.) − 1] 𝐖̇ = 𝟐. 𝟓𝟖 𝐤𝐖
1

Stroke Volume:
πD2 π×0.22
VS = 4
×L VS = 4
× 0.3 𝐕𝐒 = 𝟗. 𝟒𝟐 × 𝟏𝟎−𝟑 𝐦𝟑

Volume of air sucked:

m3 𝐦𝟑
V̇ = VS × N V̇a = 𝟗. 𝟒𝟐 × 𝟏𝟎−𝟑 × 100 V̇a = 0.9 min
𝐕̇𝐚 = 𝟎. 𝟎𝟏 𝐒𝐞𝐜

Mass of the air delivered per min:

P1 V̇ 1×102 ×0.9 𝒌𝒈
P1 V̇ = ṁ1 RT1 ṁ1 = ṁa = 𝐦̇𝐚 = 𝟏. 𝟎𝟓
RT1 0.287×300 𝒎𝒊𝒏

Temperature of the air delivered:

n−1 n−1 1.25−1
T2 P 𝑛 P 𝑛 8 1.25
T1
= (P2 ) T2 = (P2 ) × T1 = (1) × 300 𝐓𝟐 = 𝟒𝟓𝟒. 𝟕𝑲
1 1

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3. A single stage single acting reciprocating air compressor has air entering at 1 bar, 20°C and compression
occurs following polytrophic process with index 1.2 up to 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 per minute.
Given:
𝐿 𝑚3
P1 = 1 bar, T1 = 20℃, n=1.2, P2 = 12 bar, N=240rpm, 𝐷 = 1.8, 𝜂𝑚𝑒𝑐ℎ = 0.88, V̇1 = 1 𝑚𝑖𝑛

Solution:
Isothermal Work:
P 1 12
Ẇiso = P1 V̇ ln (P2 ) Ẇiso = 1 × 102 × 60 ln ( 1 ) 𝐖̇𝐢𝐬𝐨 = 𝟒. 𝟏𝟒𝐤𝐖
1

Work Done
n−1 1.2−1
n P n 1.2 1 12 1.2
Ẇ = n−1 P1 V̇ [(P2 ) − 1] Ẇ = 1.2−1 × 1 × 102 × 60 × [( 1 ) − 1] 𝐖̇ = 𝟓. 𝟏𝟑 𝐤𝐖
1

Isothermal Efficiency:
Ẇiso 4.14
ηiso = Ẇ
ηiso = 5.13 𝛈𝐢𝐬𝐨 = 𝟖𝟎. 𝟕%

Capacity to Drive required to run compressor:

W ̇ 5.13
ẆAct = 𝜂 ẆAct = 0.88 𝐖̇𝐀𝐜𝐭 = 𝟓. 𝟖𝟑 𝐤𝐖
𝑚𝑒𝑐ℎ

Stroke Volume:
V̇a 1
V̇ = VS × N VS = N
VS = 240 𝐕𝐒 = 𝟎. 𝟎𝟎𝟒𝟐 𝐦𝟑
𝜋𝐷2 π×D2
𝑉𝑆 = 4
×𝐿 0.042 = 4
× 1.8D 𝐃 = 𝟎. 𝟏𝟒𝟑 𝐦
L
D
= 1.8 L = 1.8 × 0.143 𝐋 = 𝟎. 𝟐𝟖𝟓 𝐦

Problems on Single cylinder reciprocating air compressor with Clearance Volume

1. A single stage single acting air compressor delivers 0.6 kg of air per minute at 6 bar. The temperature
and pressure at the end of suction stroke are 30°C and 1 bar. The bore and stroke of the compressors are
100mm and 150mm respectively. The clearance is 3% of the swept volume. Assuming the index and of
compression and expansion to be 1.3, find: i) power required if the mechanical efficiency is 85%, ii)
volumetric efficiency of the compressor, and iii) the speed of compressor.
Given:
𝑘𝑔
ṁ1 = 0.6 , P2 = 6 bar, P1 = 1 bar, T1 = 30℃, D=100mm, L=150mm, Vc = 0.03VS ,
𝑚𝑖𝑛
Vc
C= = 0.03, n=1.3, 𝜂𝑚𝑒𝑐ℎ = 0.85,
VS

Solution:
Volume of the air delivered per min:
ṁ RT 06×0.287×303 𝒎𝟑
P1 V̇ = ṁ1 RT1 V̇ = 1P 1 ṁa = 𝐕̇ = 𝟎. 𝟓𝟐𝟐 𝒎𝒊𝒏
1 1×102

Work Done
n−1 1.3−1
n P n 1.3 0.522 6 1.3
Ẇ = n−1 P1 V̇ [(P2 ) − 1] Ẇ = 1.3−1 × 1 × 102 × 60 × [(1) − 1] 𝐖̇ = 𝟏. 𝟗𝟑 𝐤𝐖
1

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Capacity to Drive required to run compressor:
W ̇ 1.93
ẆAct = 𝜂 ẆAct = 0.85 𝐖̇ 𝐀𝐜𝐭 = 𝟐. 𝟐𝟕 𝐤𝐖
𝑚𝑒𝑐ℎ

Volumetric Efficiency of compressor:

1 1
P n 6 1.3
ηvol = 1 − C [(P2 ) − 1] ηvol = 1 + 0.03 [(1) − 1] 𝛈𝐯𝐨𝐥 = 𝟗𝟏. 𝟎𝟗%
1

Actual Volume of the air delivered per min:

𝐕̇ 𝟎.𝟓𝟐𝟐 𝒎 𝟑
𝐕̇𝒂𝒄𝒕 = 𝐕̇𝒂𝒄𝒕 = 𝐕̇𝒂𝒄𝒕 = 𝟎. 𝟓𝟕𝟑 𝒎𝒊𝒏
𝛈𝐯𝐨𝐥 𝟎.𝟗𝟏𝟎𝟗
Stroke Volume:
πD2 π×0.12
VS = ×L VS = × 0.15 𝐕𝐒 = 𝟏. 𝟏𝟖 × 𝟏𝟎−𝟑 𝐦𝟑
4 4
Volume of air sucked:
0.573
V̇act = VS × N N= 𝐍 = 𝟒𝟖𝟓. 𝟔𝟏 𝐫𝐩𝐦
1.18×10−3
2. A single stage single acting air compressor delivers 15 m3 of air per minute from 1 bar to 8 bar. The speed
of compressor is 300 rpm. Assuming that compression and expansion follow the law PV 1.3=Constant. The
clearance is 1/16th of swept volume find the diameter and stroke of the compressor, if L/D=1.5. The
temperature and pressure of air at suction is 20°C and 1bar respectively. Also Determine the mean
effective pressure and the power required to drive the compressor.
Given:
𝑚3 1
𝑉̇ = V̇1 − V̇4 = 15 , P1 = 1 bar, P2 = 8 bar, N=300, Vc = V,
𝑚𝑖𝑛 16 S
Vc L
C= = 0.0625, n=1.3, = 1.5, T1 = 20℃,
VS 𝐷

Solution:

Work Done or Indicated Power

n−1 1.3−1
n P n 1.3 15 8 1.3
Ẇ = P V̇ [( 2 ) − 1] Ẇ = × 1 × 102 × × [( ) − 1] 𝐖̇ = 𝟔𝟔. 𝟕𝟐 𝐤𝐖
n−1 1 P1 1.3−1 60 1

Volumetric Efficiency of compressor:

1 1
P n 8 1.3
ηvol = 1 − C [(P2 ) − 1] ηvol = 1 − 0.0625 [(1) − 1] 𝛈𝐯𝐨𝐥 = 𝟖𝟏. 𝟓𝟓%
1

Actual Volume of the air delivered per min:

V̇ 15 𝒎 𝟑
V̇𝑎𝑐𝑡 = V̇𝑎𝑐𝑡 = 𝐕̇𝒂𝒄𝒕 = 𝟏𝟖. 𝟑𝟗 𝒎𝒊𝒏
ηvol 0.8155
Stroke Volume:
V̇act 18.39
V̇𝑎𝑐𝑡 = VS × N VS = VS = 𝐕𝐒 = 𝟎. 𝟎𝟔𝟏𝟑 𝐦𝟑
N 300

Cylinder Dimentions:
𝜋𝐷2 π×D2
𝑉𝑆 = ×𝐿 0.0613 = × 1.5D 𝐃 = 𝟎. 𝟑𝟕𝟑𝐦
4 4
L
= 1.5 L = 1.5 × 0.373 𝐋 = 𝟎. 𝟓𝟓𝟗𝟓 𝐦
D

Mean Effective Pressure

Ẇ Ẇ ̇
66.72 𝐤𝐍
PMEP = V̇ PMEP = 𝑵 PMEP = 𝟑𝟎𝟎 𝐏𝐌𝐄𝐏 = 217.68 𝒎𝟐
S 𝐕𝐒 × 𝟎.𝟎𝟔𝟏𝟑×
𝟔𝟎 𝟔𝟎

(OR)
π×0.3732 300 𝐤𝐍
IP = PBMEP LAnk 66.72 = PMEP × 0.5595 × × ×1 𝐏𝐌𝐄𝐏 = 218.26 𝒎𝟐
4 60

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ME8493 – Thermal Engineering 1 Mechanical Engineering
3. The free air delivery of a single cylinder, single stage reciprocating air compressor is 2.5 m 3/min. The

ambient air is at STP condition. The delivery pressure is at 7 bar. The clearance volume is 5 percent of

law stroke volume. Both compression and expansion are according to the law PV1.25 = constant. Stroke

length is 20% more than that of the bore. Compressor runs at 150 rpm. Determine the mass of air per

second, indicated power, indicated mean effective pressure, bore and stroke of cylinder.

Given:

𝑚3 Vc
𝑉̇ = V̇1 − V̇4 = 2.5 , P1 = 1 bar, T1 = 20℃, P2 = 7 bar,Vc = 0.05VS , C = = 0.05,
𝑚𝑖𝑛 VS

n=1.25, N=150rpm, L=1.2D.

Solution:

Work Done or Indicated Power

n−1 1.25−1
n P n 1.25 2.5 7 1.25
Ẇ = P V̇ [(P2 )
n−1 1
− 1] Ẇ = 1.25−1
× 2
1 × 10 × 60
× [(1) − 1] 𝐖̇ = 𝟗. 𝟗𝟏 𝐤𝐖
1

Volumetric Efficiency of compressor:

1 1
P n 7 1.25
ηvol = 1 − C [(P2 ) − 1] ηvol = 1 − 0.05 [(1) − 1] 𝛈𝐯𝐨𝐥 = 𝟖𝟏. 𝟐𝟓%
1

Actual Volume of the air delivered per min:

V̇ 2.5 𝒎 𝟑
V̇𝑎𝑐𝑡 = V̇𝑎𝑐𝑡 = 𝐕̇𝒂𝒄𝒕 = 𝟑. 𝟎𝟖 𝒎𝒊𝒏
ηvol 0.8125

Stroke Volume:

V̇act 3.08
V̇𝑎𝑐𝑡 = VS × N VS = VS = 𝐕𝐒 = 𝟎. 𝟎𝟐𝟎𝟓 𝐦𝟑
N 150

Cylinder Dimentions:

𝜋𝐷2 π×D2
𝑉𝑆 = ×𝐿 0.0205 = × 1.2D 𝐃 = 𝟎. 𝟐𝟕𝟗𝐦
4 4

L
= 1.2 L = 1.2 × 0.373 𝐋 = 𝟎. 𝟑𝟑𝟓 𝐦
D

Mean Effective Pressure

Ẇ Ẇ 9.91 𝐤𝐍
PMEP = V̇ PMEP = 𝑵 PMEP = 𝟏𝟓𝟎 𝐏𝐌𝐄𝐏 = 193.37 𝒎𝟐
S 𝐕𝐒 × 𝟎.𝟎𝟐𝟎𝟓×
𝟔𝟎 𝟔𝟎

4. 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 clearance
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.

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ME8493 – Thermal Engineering 1 Mechanical Engineering
Given:
𝐦𝟑
V̇ = V̇ 1 − V̇ 4 = 20 , Pa = 1 bar, Ta = 27℃, 𝑟𝑐 = 7,N=240rpm,
𝒎𝒊𝒏
Vc
Vc = 0.05VS , C = = 0.05, L/D=1.2,
VS

P1 = 0.95 bar, T1 = 35℃, n=1.2 , ηMech = 85%

Solution:

Deliver pressure:

P2 v 𝑛
= (V1 ) = (𝑟𝑐 )𝑛 P2 = (𝑟𝑐 )𝑛 × P1 P2 = (7)1.25 × 0.95 𝐏𝟐 = 𝟏𝟎. 𝟖𝟏 𝐛𝐚𝐫
P1 2

Volumetric Efficiency of compressor:

1 1
P n 10.81 1.25
ηvol = 1 − C [(P2 ) − 1] ηvol = 1 − 0.05 [( 1 ) − 1] 𝛈𝐯𝐨𝐥 = 𝟕𝟏. 𝟒𝟐%
1

Actual Volume of the air delivered per min:

V ̇ 20 𝒎 𝟑
V̇𝑎𝑐𝑡 = η V̇𝑎𝑐𝑡 = 0.7142 𝐕̇𝒂𝒄𝒕 = 𝟐𝟖 𝒎𝒊𝒏
vol

Stroke Volume:

V̇act 28
V̇𝑎𝑐𝑡 = VS × N VS = N
VS = 240 𝐕𝐒 = 𝟎. 𝟏𝟏𝟕 𝐦𝟑

Cylinder Dimensions:

𝜋𝐷2 π×D2
𝑉𝑆 = ×𝐿 0.117 = × 1.2D 𝐃 = 𝟎. 𝟒𝟗𝟖𝐦
4 4

L
D
= 1.2 L = 1.2 × 0.477 𝐋 = 𝟎. 𝟓𝟗𝟖 𝐦

Free Air Deliver:

𝑇𝑎 𝑃 300 0.95 𝐦𝟑
FAD = (V̇1 − V̇4 ) × × 𝑃1 FAD = 20 × 308 × 𝐅𝐀𝐃 = 𝟏𝟖. 𝟓 𝒎𝒊𝒏
𝑇1 𝑎 1

Actual Volumetric Efficiency Due to FAD:

FAD 18.5
ηvol = ηvol = 𝛈𝐯𝐨𝐥 = 𝟔𝟓. 𝟖𝟖%
VS ×N 0.117×240

Work Done or Indicated Power

n−1 1.25−1
n P n 1.25 20 10.81 1.25
Ẇ = n−1 P1 V̇ [(P2 ) − 1] Ẇ = 1.25−1 × 0.95 × 102 × 60 × [( 1 ) − 1] 𝐖̇ = 𝟗𝟓. 𝟓𝟒 𝐤𝐖
1

Isothermal Work:

P 20 10.81
Ẇiso = P1 V̇ ln (P2 ) Ẇiso = 0.95 × 102 × 60 ln ( 1 ) 𝐖̇𝐢𝐬𝐨 = 𝟕𝟓. 𝟑𝟖𝐤𝐖
1

Isothermal Efficiency:

Ẇiso 75.38
ηiso = Ẇ
ηiso = 95.54 𝛈𝐢𝐬𝐨 = 𝟕𝟖. 𝟖𝟗%

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ME8493 – Thermal Engineering 1 Mechanical Engineering
5. A single acting air compressor takes in air at 1 bar 27°C and delivers at 1.4 MPa running at 300 rpm and
has cylinder dia of 160 mm and stroke 200 mm. clearance volume is 4% of stroke volume. If the pressure
and temperature at the end of the suction stroke is 100 KPa, 47°C and compression and expansion takes
places by polytropic process (n=1.2), find 1. Mass of air delivered per minute 2. Volumetric efficiency 3.
Driving power required if mechanical efficiency is 85%.
Given:

P1 = 1 bar, Ta = 27℃, P2 = 1.4MPa = 14bar,N=300rpm,

Vc
Vc = 0.04VS , C = = 0.04, L=200mm, D=160mm,
VS

P1 = 1 bar, T1 = 47℃, n=1.2 , ηMech = 85%

Solution:

Stroke Volume:

𝜋𝐷2 π×0.162
𝑉𝑆 = 4
×𝐿 𝑉𝑆 = 4
× 0.2 𝐕𝐒 = 𝟎. 𝟎𝟎𝟒 𝐦𝟑

𝐦𝟑
V̇𝑎𝑐𝑡 = VS × N V̇𝑎𝑐𝑡 = 0.004 × 300 𝐕̇𝒂𝒄𝒕 = 𝟏. 𝟐𝟏 𝒎𝒊𝒏

Volumetric Efficiency of compressor:

1 1
P n 14 1.2
ηvol = 1 − C [(P2 ) − 1] ηvol = 1 − 0.04 [( 1 ) − 1] 𝛈𝐯𝐨𝐥 = 𝟔𝟕. 𝟗𝟑%
1

Volume of the air delivered per min:

V̇ 𝒎𝟑
V̇𝑎𝑐𝑡 =
ηvol
V̇ = V̇𝑎𝑐𝑡 × ηvol V̇ = V̇𝑎𝑐𝑡 × ηvol V̇ = 𝟎. 𝟖𝟐
𝒎𝒊𝒏
= (V̇ 1 − V̇ 4 )

Mass of the air delivered per min:

P1 ×V̇ 1×102 ×0.769 𝐤𝐠

P1 × V̇ = ṁ1 RT1 ṁ1 = ṁa = 𝐦̇𝐚 = 𝟎. 𝟖𝟗𝟑
RT1 0.287×300 𝐦𝐢𝐧

Free Air Deliver:

𝑇𝑎 𝑃 300 1 𝐦𝟑
FAD = (V̇1 − V̇4 ) × × 𝑃1 FAD = 0.82 × 320 × 1 𝐅𝐀𝐃 = 𝟎. 𝟕𝟔𝟗 𝒎𝒊𝒏
𝑇1 𝑎

Actual Volumetric Efficiency of compressor due to FAD:

FAD 0.769
ηvol = ηvol = 𝛈𝐯𝐨𝐥 = 𝟔𝟒. 𝟎𝟖%
VS ×N 0.004×300

Work Done or Indicated Power

n−1 1.2−1
n P n 1.2 0.82 14 1.2
Ẇ = n−1 P1 V̇ [(P2 ) − 1] Ẇ = 1.2−1 × 1 × 102 × 60 × [( 1 ) − 1] 𝐖̇ = 𝟒. 𝟓𝟑 𝐤𝐖
1

Capacity to Drive required to run compressor:

W ̇ 4.53
ẆAct = 𝜂 ẆAct = 0.6408 𝐖̇𝐀𝐜𝐭 = 𝟕. 𝟎𝟕 𝐤𝐖
𝑚𝑒𝑐ℎ

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ME8493 – Thermal Engineering 1 Mechanical Engineering

Multi-Stage Air Compressor:

1. Explain with neat sketch the working principle of multistage reciprocating compressor and discuss the
perfect cooling with inter cooler.
 The compression of air in two or more cylinders in series is called multistage compression.
 The compressor requires minimum work input with isothermal compression but the delivery temperature
increases with pressure ratio and the volumetric efficiency decreases as pressure ratio increases.
 The work input can be reduced to minimum level by compressing the air in more than one cylinders with
intercooler between stages for same compression ratio.
 Air cooling between the stages provides the means to achieving an appreciable reduction in the compressor
work and maintain the air temperature within safe operating limits.

Advantages of multistage compressor

1. The gas can be compressed to a sufficiently high pressure
2. Cooling of air is more sufficient with intercoolers and cylinder walls surface
3. By cooling the air between the stages of compression can be brought to isothermal and power input to
the compressor can be reduced considerably
4. By multi-staging, the pressure ratio of each stage is lowered. The air leakage past the piston in the
cylinder is also reduced
5. The low pressure ratio in the cylinder improve volumetric efficiency
6. Due to low pressure ratio in stages, the compressor speed could be higher for the same isothermal
efficiency,
7. low working temperature in each stage help to sustain better lubrication
8. The low pressure cylinder is made lighter and high pressure cylinder made smaller for reduced pressure
ratio in each stage

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
leaving first stage is cooled up to ambient air temperature in intercooler and then sent to subsequent
cylinder (stage) for compression Intercoolers when put between the stages reduce the compression
work and compression is called intercooled compression. Intercooling is called perfect when
temperature at inlet to subsequent stages of compression is reduced to ambient temperature.

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ME8493 – Thermal Engineering 1 Mechanical Engineering
2. In a two stage compressor in which inter-cooling is perfect, prove that the work done in the compressor is
minimum when the pressure in the inter-cooler is geometric mean between the initial and final pressure.
Draw the P-V & T-S Diagram for two stage compression.
The value chosen for the intermediate pressure p2 influences the work to be
done on the gas and its distribution between the stages. The condition for the
work done to be a minimum will be proved for two-stage compression but
can be extended to any number of stages.
Total work= LP stage work + HP stage work
𝑛−1 𝑛−1
𝑛 𝑃2 𝑛 𝑛 𝑃3 𝑛
Total power = 𝑚𝑅
̇ 𝑇 1 [( ) − 1] + 𝑚𝑅
̇ 𝑇 1 [( ) − 1]
𝑛−1 𝑃1 𝑛−1 𝑃2

It is assumed that intercooling is perfect and therefore the temperature at the start of each stage is 𝑇1 = 𝑇𝑖
𝑛−1 𝑛−1
𝑛 𝑃2 𝑛 𝑃3 𝑛
Total power = 𝑚𝑅
̇ 𝑇 1 {[( ) − 1] + [( ) − 1]}
𝑛−1 𝑃1 𝑃2

If P1, T1 and P2 are fixed, then the optimum value of Pi which makes the power a minimum can be obtained by
equating d(power)/dpi to zero, that is optimum value of pi when

𝑛−1 𝑛−1
𝑑 𝑃2 𝑛 𝑃3 𝑛
{[( ) − 1] + [( ) − 1]} =0
𝑑𝑝𝑖 𝑃1 𝑃2
𝑛−1 𝑛−1
𝑑 1 𝑛 𝑛−1 𝑛−1 1 𝑛
{( ) 𝑃2 𝑛 + 𝑃3 𝑛 ( ) − 2} =0
𝑑𝑝𝑖 𝑃1 𝑃2

Therefore
−(
𝑛−1𝑛 − 1 (𝑛−1−1)
)
𝑛−1 𝑛−1 −(
𝑛−1
−1)
𝑃1 𝑛 ×
𝑃2 𝑛 + 𝑃3 𝑛 × (− ) 𝑃2 𝑛 =0
𝑛 𝑛
−(
𝑛−1
) 𝑛 − 1 (𝑛−1−𝑛) 𝑛−1 𝑛−1 (
−𝑛+1−𝑛
)
𝑃1 𝑛 × 𝑃2 𝑛 + 𝑃3 𝑛 × (− ) 𝑃2 𝑛 =0
𝑛 𝑛
−(
𝑛−1
) 𝑛 − 1 −1 𝑛−1 𝑛 − 1 (1−2𝑛)
𝑃1 𝑛 × 𝑃2 𝑛 = 𝑃3 𝑛 × 𝑃2 𝑛
𝑛 𝑛
Therefore
2(𝑛−1) 𝑛−1
𝑃2 𝑛 = (𝑃1 𝑃3 ) 𝑛

2
𝑃2 = 𝑃1 𝑃3
𝑃2 𝑃3
=
𝑃1 𝑃2
The pressure ratio is same for each stage
Total minimum power = 2 X (power required for one stage)
𝑛−1
𝑛 𝑃 𝑃
where, 𝑃2 2 = 𝑃1 𝑃3
𝑛
=2X 𝑛−1
̇ 𝑇 1 [(𝑃2 )
𝑚𝑅 − 1] 𝑃2 = √𝑃1 𝑃3 = √𝑃3
1 1
𝑛−1
𝑛 𝑃3 2𝑛
= 2 X 𝑛−1 𝑚𝑅
̇ 𝑇 1 [(𝑃 ) − 1]
1

This can be shown to extend to Z stages giving in general

𝑛−1
𝑛 𝑃 𝑧𝑛
̇ 𝑇 1 [(𝑃2 )
Total minimum power = Z X 𝑛−1 𝑚𝑅 − 1]
1
1
𝑃 𝑍
Also the pressure ratio for each stage =(𝑃2 )
1

Hence the condition for minimum work is that the pressure ratio in each stage is the same and the
intercooling is complete.

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ME8493 – Thermal Engineering 1 Mechanical Engineering
3. A single acting two stage compressor with complete inter cooling delivers 6 kg/min of air at 16 bar (1.6
MPa). Assuming an intake at 1 bar (100 kPa) and 15ºC and compression and expansion with the law pV1.3
= C. Calculate : (i) Power required to run the compressor (ii) Isothermal efficiency (iii) Free air delivered
per sec. (iv) If clearance ratios for LP and HP cylinder are 0.04 and 0.06, Calculate volumetric efficiency
and swept volume for each cylinder. Assume R = 0.287 kJ/kg ºK, Cv = 0.71 kJ/kg ºK.
Given:
𝑘𝑔
𝑚̇ = 0.6 , P1 = 1 bar, T1 = 15℃, P2 = 16bar, C𝐿𝑃 = 0.04, C𝐻𝑃 = 0.06,
𝑚𝑖𝑛

pV1.3 = C
R = 0.287 kJ/kg ºK
Cv = 0.71 kJ/kg ºK
Solution:
Volume of the air delivered per min:
ṁ RT 6×0.287×288 𝐦𝟑
P1 V̇ = ṁ1 RT1 V̇ = 1 1
P1
V̇ = 2 𝐕̇ = 𝟒. 𝟗𝟔
𝐦𝐢𝐧
1×10

Power required to drive the compressor:

n−1 1.3−1
n
Ẇ = Z × P1 V̇ [(P3 )z×n − 1]
1.3
Ẇ = 2 × 1.3−1 × 1 × 10 × 2 4.96
[(
16 2×1.3
) − 1] 𝐖̇ = 𝟐𝟕𝐤𝐖
n−1 P1 60 1

Isothermal Work:
P 0.496 16
Ẇiso = P1 V̇ ln (P2 ) Ẇiso = 1 × 102 × 60 × ln ( 1 ) 𝐖̇𝐢𝐬𝐨 = 𝟐𝟐. 𝟗𝐤𝐖
1

Isothermal Efficiency:
Ẇiso 2.29
ηiso = Ẇ
ηiso = 2.7
𝛈𝐢𝐬𝐨 = 𝟖𝟒. 𝟖𝟗%

For perfect Intercooler:

P2 = √P1 P3 P2 = √1 × 16 𝐏𝟐 = 𝟒 𝐛𝐚𝐫
For LP Cylinder:
1 1
P n 4 1.3
ηVLP = 1 − C [( 2) − 1] ηVLP = 1 − 0.04 [( ) − 1] 𝛈𝐕𝐋𝐏 = 𝟗𝟐. 𝟑𝟖%
P1 1

Volume of LP cylinder:
V̇ FAD 4.96
ηVLP = VSLP = VSLP = 𝐕𝐒𝐋𝐏 = 𝟎. 𝟎𝟏𝟕𝟗𝐦𝟑
VSLP ×N ηVLP ×N 0.9238×300

For HP Cylinder:
1 1
P n 16 1.3
ηVHP = 1 − C [( 3) − 1] ηVHP = 1 − 0.06 [( ) − 1] 𝛈𝐕𝐇𝐏 = 𝟖𝟖. 𝟓𝟕%
Pi 4

Volume Flowrate for HP Cylinder:

Volume of the air delivered per min:
ṁ RT 6×0.287×288 𝐦 𝟑
P1 V̇ = ṁ1 RT1 V̇ = 1P 1 V̇HP = 2 𝐕̇𝐇𝐏 = 𝟏. 𝟐𝟒 𝐦𝐢𝐧
1 4×10

Volume of HP cylinder:
̇ V̇ HP 1.24
ηVHP = V VHP×N VSHP = VSHP = 𝐕𝐒𝐇𝐏 = 𝟎. 𝟎𝟎𝟒𝟔𝟕𝐦𝟑
SHP ηVHP ×N 0.8857×300

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ME8493 – Thermal Engineering 1 Mechanical Engineering
4. In a single acting two stage reciprocating air compressor 4.5 kg of air per min are compressed from 1.013
bar and 15°C through a pressure ratio of 9 to 1. Both stages have the same pressure ratio and the law of
compression of both compression and expansion follows the law PV 1.3 = C calculate i) Indicated power ii)
the cylinder swept volume required. Assume that the clearance volume of both the cylinder are 5% of
their respective swept volume and that the compressors runs at 300 rpm.
Given:
𝑘𝑔 P3
𝑚̇ = 4.5 , P1 = 1.013 bar, T1 = 15℃, = 9 bar, V𝐶 = 0.05V𝑆 ,
𝑚𝑖𝑛 P1

pV1.3 = C, R = 0.287 kJ/kg ºK

Solution:
Volume of the air delivered per min:
ṁ RT 4.5×0.287×288 𝐦𝟑
P1 V̇ = ṁ1 RT1 V̇ = 1P 1 V̇ = 2 𝐕̇ = 𝟑. 𝟔𝟕𝟐 𝐦𝐢𝐧
1 1.013×10

Power required to drive the compressor:

n−1 1.3−1
n P z×n 1.3 3.672 9 2×1.3
Ẇ = Z × n−1 P1 V̇ [(P3 ) − 1] Ẇ = 2 × 1.3−1 × 1.013 × 102 × 60 [(1) − 1]
1

𝐖̇ = 𝟏𝟓. 𝟒𝟕 𝐤𝐖
For perfect Intercooler:
𝐏𝟐
P2 = √P1 P3 P2 = √P1 × P1 × 9
𝐏𝟏
= 𝟑 𝐛𝐚𝐫

For LP Cylinder:
1 1
P n 3 1.3
ηv = 1 − C [( 2) − 1] ηv = 1 − 0.05 [( ) − 1] 𝛈𝐯 = 𝟗𝟑. 𝟒%
P1 1

For LP Cylinder:
Volume of LP cylinder:
V̇ V̇ 3.672
ηvol = VSLP = VSLP = 𝐕𝐒𝐋𝐏 = 𝟎. 𝟎𝟏𝟑𝟏𝐦𝟑
VSLP ×N ηvol ×N 0.934×300

For HP Cylinder:
Volume of the air delivered per min:
ṁ RT 4.5×0.287×288 𝐦 𝟑
P1 V̇ = ṁ1 RT1 V̇HP = 1P 1 V̇HP = 2 𝐕̇𝐇𝐏 = 𝟏. 𝟐𝟐𝟒 𝐦𝐢𝐧
1 3.039×10

Volume of HP cylinder:
V̇ HP V̇ HP 1.224
ηvol = VSHP = VSHP = 𝐕𝐒𝐇𝐏 = 𝟎. 𝟎𝟎𝟒𝟑𝟕𝐦𝟑
VSHP ×N ηvol ×N 0.934×300

5. A two stage Compressor delivers 2 m3 of free air per minute. He temperature and pressure of air at

suction is 27°C and 1bar. The pressure at the delivery is 50bar. The clearance is 5% of the respective

stroke in L.P cylinder as well as H.P cylinder. Assuming perfect inter cooling between the two stages find

the minimum power required to run the compressor at 200 rpm. also find the diameter and stroke of the

compressor and assuming both are equal for two cylinders. Assume L/D=1.5

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Given:
𝑚3
𝑉̇ = 2 , P1 = 1 bar, T1 = 27℃, P2 = 50bar, V𝐶 = 0.05V𝑆
𝑚𝑖𝑛

N=200 rpm, L/D = 1.5

Solution:

Power required to drive the compressor:

n−1 1.3−1
n P z×n 1.3 2 50 2×1.3
Ẇ = Z × n−1 P1 V̇ [(P3 ) − 1] Ẇ = 2 × 1.3−1 × 1 × 102 × 60 [( 1 ) − 1] 𝐖̇ = 𝟏𝟔. 𝟒𝟕𝐤𝐖
1

For perfect Intercooler:

P2 = √P1 P3 P2 = √1 × 50 𝐏𝟐 = 𝟕. 𝟎𝟕 𝐛𝐚𝐫
Volumetric Efficiency:
1 1
P n 7.07 1.3
ηVLP = 1 − C [( 2) − 1] ηVLP = 1 − 0.05 [( ) − 1] 𝛈𝐕𝐋𝐏 = 𝟖𝟐. 𝟓%
P1 1

Volume of LP cylinder:
V̇ V̇ 2
ηVLP = VSLP = VSLP = 𝐕𝐒𝐋𝐏 = 𝟎. 𝟎𝟏𝟐𝟏𝐦𝟑
VSLP ×N ηVLP ×N 0.825×200

Stroke Volume:
𝜋𝐷2 π×D2
𝑉𝑆 = ×𝐿 0.0121 = × 1.5D 𝐃 = 𝟎. 𝟐𝟏𝟕 𝐦
4 4
𝐿
𝐷
= 1.5 𝐿 = 1.5 × 0.217 𝐋 = 𝟎. 𝟑𝟐𝟔

6. 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.
Given:
N=200rpm, P1 = 1 bar, T1 = 25℃, P2 = 2.9 bar, T2 = 25℃, P3 = 9 bar, V𝐶 =
1.2
0.05V𝑆 , D=30cm, L=40cm,pV = C,

Solution:
Stroke Volume:
𝜋𝐷2 π×0.32
𝑉𝑆 = 4
×𝐿 𝑉𝑆 = 4
× 0.4 𝐕𝐒 = 𝟎. 𝟎𝟐𝟖𝟑 𝐦𝟑
𝐦𝟑
V̇𝑎𝑐𝑡 = VS × N × 2 V̇𝑎𝑐𝑡 = 0.0283 × (200 × 2) 𝐕̇𝒂𝒄𝒕 = 𝟏𝟏. 𝟑𝟐 𝒎𝒊𝒏

Volumetric Efficiency:
1 1
P n 2.9 1.2
ηv = 1 − C [( 2) − 1] ηv = 1 − 0.05 [( ) − 1] 𝛈𝐯 = 𝟗𝟐. 𝟖𝟓%
P1 1

Volume of the air delivered per min:

V ̇ 𝐦𝟑
V̇𝑎𝑐𝑡 = η V̇ = V̇𝑎𝑐𝑡 × ηv V̇ = 11.32 × 0.9285 𝐕̇ = 𝐕̇ 𝟏 − 𝐕̇ 𝟒 = 𝟏𝟎. 𝟓𝟏 𝒎𝒊𝒏
v

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ME8493 – Thermal Engineering 1 Mechanical Engineering
Mass of the air delivered per min:
P1 ×V̇ 1×102 ×10.51 𝐤𝐠
P1 × V̇ = ṁ1 RT1 ṁ1 = ṁa = 𝐦̇𝐚 = 𝟏𝟐. 𝟐𝟗
RT1 0.287×298 𝐦𝐢𝐧

Heat rejected to the intercooler:

𝑛−1 𝑛−1 1.2−1
T2 𝑃2 𝑛 𝑃2 𝑛 2.9 1.2
= (𝑃 ) T2 = (𝑃 ) × T1 T2 = ( 1 ) × 298 𝐓𝟐 = 𝟑𝟓𝟓. 𝟖𝟔𝐊
T1 1 1

𝐤𝐉
𝑄𝑅 = ṁ a 𝐶𝑃 (T2 − T1 ) 𝑄𝑅 = 12.29 × 1.005(355.86 − 298) 𝑸𝑹 = 𝟕𝟏𝟒. 𝟔𝟓 𝐦𝐢𝐧
For HP Cylinder:
Volume of the air delivered per min:
ṁ RT 12.29×0.287×298 𝐦 𝟑
Pi V̇ = ṁ1 RTi V̇HP = 1P i V̇HP = 2 𝐕̇𝐇𝐏 = 𝟑. 𝟔𝟐 𝐦𝐢𝐧
i 2.9×10

Volume of HP cylinder:
V̇ HP V̇ HP 3.62
ηvol = VSHP = VSHP = 𝐕𝐒𝐇𝐏 = 𝟎. 𝟎𝟎𝟗𝟕𝟓𝐦𝟑
VSHP ×N ηvol ×N 0.9285×200×2

Bore of HP Cylinder:
𝜋𝐷2 π×D2
𝑉𝑆𝐻𝑃 = 4
×𝐿 0.00975 = 4
× 0.4 𝐃 = 𝟎. 𝟏𝟕𝟔 𝐦

Power required to drive the HP compressor:

n−1 1.2−1
n P3 n 1.2 3.62 9 1.2
ẆHP = n−1 P2 V̇ [(P ) − 1] ẆHP = 1.2−1 × 2.9 × 10 × 2
[(2.9) − 1]
2 60

𝐖̇𝐇𝐏 = 𝟐𝟐 𝐤𝐖
7. A two stage air compressor having 3 cylinders having same bore and stroke. The delivery pressure is 7
bar and free air delivered is 4.3 m3/min. Air is drawn at 1 bar and 15°C and intercool the air at 38°C. The
index for compression is 1.3 for all the cylinders. Neglecting clearance find 1. Intermediate pressure, 2.
Power required to drive compressor, 3. Isothermal efficiency.
Given:
m3
Z=2, V̇ = 4.3 min
P1 = 1 bar, T1 = 15℃, P3 = 7 bar, Ti = 38℃, pV1.3 = C,

Solution:

Intermediate Pressure:
1 1 1
P2 P 𝑍 P2 P 𝑍 7 2
= ( P𝑍+1 ) = (P3 ) P2 = (1) ×1 𝐏𝟐 = 𝟐. 𝟔𝟓 𝐛𝐚𝐫
P1 1 P1 1

Power required to drive the compressor:

n−1 1.3−1
n P z×n 1.3 4.3 7 2×1.3
Ẇ = Z × n−1 P1 V̇ [( PZ+1 ) − 1] Ẇ = 2 × 1.3−1 × 1 × 102 × 60 [(1) − 1]
1

𝐖̇ = 𝟏𝟓. 𝟔𝟒 𝐤𝐖
Isothermal Work:
P 4.3 7
Ẇiso = P1 V̇ ln (P3 ) Ẇiso = 1 × 102 × 60 ln (1) 𝐖̇𝐢𝐬𝐨 = 𝟏𝟑. 𝟗𝟓𝐤𝐖
1

Isothermal Efficiency:
Ẇiso 13.95
ηiso = ηiso = 𝛈𝐢𝐬𝐨 = 𝟖𝟗. 𝟏𝟕%
Ẇ 15.64

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8. A three stage air compressor with perfect intercooling takes 15 m3 of air per minute at 95 KPa and 27°C
and delivers at 3.5 MPa and compression takes place by polytropic process (n= 1.3), find 1. Power
required if mechanical efficiency is 90% 2. Heat rejected in intercoolers per minute 3. Isothermal
efficiency.
Given:
𝐦𝟑
Z=3, V̇ = 15 ,P
𝐦𝐢𝐧 1
= 95KPa, T1 = 27℃, PZ+1 = 3.5 MPa, pV1.3 = C, ηmach = 90%

Solution:
Power required to drive the compressor:
n−1 1.3−1
n P z×n 1.3 15 35 3×1.3
Ẇ = Z × n−1 P1 V̇ [( PZ+1 ) − 1] Ẇ = 3 × 1.3−1 × 0.95 × 102 × 60 [(0.95) − 1]
1

𝐖̇ = 𝟗𝟖. 𝟕𝟐 𝐤𝐖
Capacity to Drive required to run compressor:
W ̇ 98.72
ẆAct = 𝜂 ẆAct = 0.90 𝐖̇𝐀𝐜𝐭 = 𝟏𝟎𝟗. 𝟔𝟗 𝐤𝐖
𝑚𝑒𝑐ℎ

Intermediate Pressure:
1 1 1
P2 P 𝑍 P2 P 𝑍 35 3
P1
= ( P𝑍+1 ) P1
= (P4 ) P2 = (0.95) × 0.95 𝐏𝟐 = 𝟑. 𝟏𝟔 𝐛𝐚𝐫
1 1

1 1 1
P3 P 𝑍 P3 P 𝑍 35 3
P2
= ( P𝑍+1 ) P2
= (P4 ) P3 = (0.95) × 3.16 𝐏𝟑 = 𝟏𝟎. 𝟓𝟏 𝐛𝐚𝐫
1 1

Heat rejected to the intercooler:

𝑛−1 𝑛−1 1.3−1
T2 𝑃 𝑛 𝑃 𝑛 3.16 1.3
T1
= (𝑃2 ) T2 = (𝑃2 ) × T1 T2 = (0.95) × 300 𝐓𝟐 = 𝟑𝟗𝟓. 𝟖𝟗𝐊
1 1

Mass of the air delivered per min:

P1 ×V̇ 0.95×102×15 𝐤𝐠
P1 × V̇ = ṁ1 RT1 ṁ1 = ṁa = 𝐦̇𝐚 = 𝟏𝟔. 𝟓𝟓
RT1 0.287×300 𝐦𝐢𝐧
𝐤𝐉
𝑄12 = ṁa 𝐶𝑃 (T2 − T1 ) 𝑄12 = 16.55 × 1.005(395.89 − 300) 𝑸𝟏𝟐 = 𝟏𝟓𝟗𝟒. 𝟗𝟔 𝐦𝐢𝐧

Heat rejected to the intercooler:

𝑛−1 𝑛−1 1.3−1
T3 𝑃 𝑛 𝑃 𝑛 10.51 1.3
T𝑖
= (𝑃3 ) T3 = (𝑃3 ) × T𝑖 T3 = ( 3.16 ) × 300 𝐓𝟑 = 𝟑𝟗𝟓. 𝟖𝟖𝐊
2 2

Mass of the air delivered per min:

Pi ×V̇ 3.16×102 ×15 𝐤𝐠
Pi × V̇ = ṁi RTi ṁi = RTi
ṁa = 0.287×300
𝐦̇𝐚 = 𝟓𝟓. 𝟎𝟓 𝐦𝐢𝐧
𝐤𝐉
𝑄𝑖3 = ṁa 𝐶𝑃 (T2 − T1 ) 𝑄𝑖3 = 55.05 × 1.005(395.88 − 300) 𝑸𝒊𝟑 = 𝟓𝟑𝟎𝟒. 𝟖 𝐦𝐢𝐧

9. 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.
Given:
𝐦𝟑
Z=4, V̇ = 2 , P1 = 1 bar, T1 = 27℃, PZ+1 = 150 bar, pV1.25 = C,
𝐦𝐢𝐧

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Solution:

Intermediate Pressure:
1 1 1
P2 P 𝑍 P2 P 𝑍 150 4
= ( 𝑍+1 ) = ( 5) P2 = ( ) ×1 𝐏𝟐 = 𝟑. 𝟓 𝐛𝐚𝐫
P1 P1 P1 P1 1

1 1 1
P3 P 𝑍 P3 P 𝑍 150 4
= ( P𝑍+1 ) = (P5 ) P3 = ( 1 ) × 3.5 𝐏𝟑 = 𝟏𝟐. 𝟐𝟓 𝐛𝐚𝐫
P2 1 P2 1

Power required to drive the compressor:

n−1 1.25−1
n P z×n 1.3 2 50 4×1.25
Ẇ = Z × P V̇ [( PZ+1 ) − 1] Ẇ = 4 × 1.3−1 × 1 × 10 × 2
[( 1 ) − 1]
n−1 1 1 60

𝐖̇ = 𝟏𝟗. 𝟎𝟏𝟖 𝐤𝐖
10. Difference between Reciprocating and Rotary Compressor.
S. No Reciprocating Compressor Rotary Compressor
The maximum delivery pressure may be as
1. The maximum delivery pressure is 10 bar only
high as 1000 bar
The maximum free air discharge is about The maximum free air discharge is as high as
2.
300 m3/min 3000 m3/min
They are suitable for large discharge of air at
They are suitable for low discharge of air
3. low
at very high pressure pressure
4. The speed of air compressor is low The speed of air compressor is high
5. The air supply is intermittent The air supply is continuous.
The size of air compressor is large for the The size of air compressor is small for the
6.
given discharge same discharge.
7. The balancing is a major problem There is no balancing problem.
8. The lubricating system is complicated The lubricating system is simple.
The air delivered is less clean, as it comes The air delivered is more clean, as it does not
9.
in contact with the lubricating oil come in contact with the lubricating oil.
Isothermal efficiency is used for all sorts of Isentropic efficiency is used for all sorts of
10.
calculations calculations.

11. Explain the construction and working principle of Rotary air compressor.

1. Roots blower compressor;

2. Vane blower compressor;
3. Centrifugal blower compressor
4. Axial flow compressor.
The first two compressors are popularly known as positive displacement compressors, whereas the last
two as non-positive displacement. We shall discuss all the above mentioned rotary compressors one by
one.
Note: The positive displacement compressors (i.e. roots blower and vane blower) are not very popular
from the practical point of view. However, they have some academic importance. The only important
rotary compressor is the centrifugal blower compressor.

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Roots Blower Compressor:
A roots blower compressor, in its simplest form, consists of two rotors with lobes rotating in an air
tight casing which has inlet and outlet ports. Its action resembles with that of a gear pump. There are
many designs of wheels, but they generally have two or three lobes (and sometimes even more). In all
cases, their action remains the same as shown in Fig. The lobes are so designed that they provide an air
tight joint at the point of their contact.

The mechanical energy is provided to one of the rotors from some external source, while the other is gear
driven from the first. As the rotors rotate, the air, at atmospheric pressure, is trapped in the pockets
formed between the lobes and casing. The rotary motion of the lobes delivers the entrapped air into the
receiver. Thus more and more flow of air into the receiver increases its pressure. Finally, the air at a
higher pressure is delivered from the receiver. It will be interesting to know that when the rotating lobe
uncovers the exit port, some air (under high pressure) flows back into the pocket from the receiver. It is
known as backflow process. The air, which flows from the receiver to the pocket, gets mixed up with the
entrapped air. The backflow of air continues, till the pressure in the pocket and receiver is equalised. Thus
the pressure of air entrapped in the pocket is increased at constant volume entirely by the back flow of air.
The backflow process is shown in Fig. Now the air is delivered to the receiver by the rotation of the lobes.
Finally, the air at a higher pressure is delivered from the receiver.
Vane Blower Compressor
A vane blower, in its simplest form, consists of a disc rotating eccentrically in an air tight casing with
inlet and outlet ports. The disc has a number of slots (generally 4 to 8) containing vanes: When the rotor
rotates the disc, the vanes are pressed against the casing, due to centrifugal force, and form air tight
pockets. The mechanical energy is provided to the disc from some external source. As the disc rotates, the
air is trapped in the pockets formed between the vanes and casing.

First of all, the rotary motion of the vanes compresses the air. When the rotating vane uncovers the exit
port, some air (under high pressure) flows back into the pocket in the same way as discussed in the ease
of roots blower compressor. Thus the pressure of air, entrapped in the pocket, is increased first by
decreasing the volume and then by the backflow of air as shown in Fig. Now the air is delivered to the
receiver by the rotation of the vanes. Finally, the air at a high pressure is delivered from the receiver.

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12. Explain the construction and working principle of centrifugal compressor and axial flow compressor with
neat sketches.
Centrifugal Compressor:

A centrifugal compressor is a radial flow rotodynamic fluid machine that uses mostly air as the
working fluid and utilizes the mechanical energy imparted to the machine from outside to increase the
total internal energy of the fluid mainly in the form of increased static pressure head.
During the second world war most of the gas turbine units used centrifugal compressors. Attention was
focused on the simple turbojet units where low power-plant weight was of great importance. Since the
war, however, the axial compressors have been developed to the point where it has an appreciably
higher isentropic efficiency. Though centrifugal compressors are not that popular today, there is
renewed interest in the centrifugal stage, used in conjunction with one or more axial stages, for small
turbofan and turboprop aircraft engines.
A centrifugal compressor essentially consists of three components.
1. A stationary casing
2. A rotating impeller as shown in Fig. which imparts a high velocity to the air. The impeller may
be single or double sided as show in Fig. but the fundamental theory is same for both.
3. A diffuser consisting of a number of fixed diverging passages in which the air is decelerated with
a consequent rise in static pressure.

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Principle of operation: Air is sucked into the impeller eye and whirled outwards at high speed by the
impeller disk. At any point in the flow of air through the impeller the centripetal acceleration is obtained
by a pressure head so that the static pressure of the air increases from the eye to the tip of the impeller.
The remainder of the static pressure rise is obtained in the diffuser, where the very high velocity of air
leaving the impeller tip is reduced to almost the velocity with which the air enters the impeller eye.
Usually, about half of the total pressure rise occurs in the impeller and the other half in the diffuser.
Owing to the action of the vanes in carrying the air around with the impeller, there is a slightly higher
static pressure on the forward side of the vane than on the trailing face. The air will thus tend to flow
around the edge of the vanes in the clearing space between the impeller and the casing. These results in a
loss of efficiency and the clearance must be kept as small as possible. Sometimes, a shroud attached to the
blades as shown in Figure. May eliminate such a loss, but it is avoided because of increased disc friction
loss and of manufacturing difficulties.
The straight and radial blades are usually employed to avoid any undesirable bending stress to be set up in
the blades. The choice of radial blades also determines that the total pressure rise is divided equally
between impeller and diffuser.
Before further discussions following points are worth mentioning for a centrifugal compressor.
(i) The pressure rise per stage is high and the volume flow rate tends to be low. The pressure rise per
stage is generally limited to 4:1 for smooth operations.
(ii) Blade geometry is relatively simple and small foreign material does not affect much on operational
characteristics.
(iii) Centrifugal impellers have lower efficiency compared to axial impellers and when used in aircraft
engine it increases frontal area and thus drag. Multistaging is also difficult to achieve in case of
centrifugal machines.
Advantages Of Centrifugal Compressor

1. Wide Operating ranges

2. Very high reliability
3. Low maintenance costs
4. Low initial cost
5. Medium Capacity storage
6. High efficiency
Disadvantages of Centrifugal Compressor

1. Very unstable when the flow is reduced.

2. Sensitive to changes in gas compositions
3. Limited compression ratios
4. Limited turn downs
5. Periodic replacement is necessary for proper functioning

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Axial Flow Compressors:

An axial flow compressor, in its simplest form, consists of a number of rotating blade rows fixed to a

rotating drum. The drum rotates inside an air tight casing to which are fixed stator blade rows, as shown

in Fig. The blades are made of aerofoil section to reduce the loss caused by turbulence and boundary

separation.

The mechanical energy is provided to the rotating shaft, which rotates the drum. The air enters from the

left side of the compressor. As the drum rotates the airflows through the alternately arranged stator and

rotor. As the air flows from one set of stator and rotor to another, it gets compressed. Thus successive

compression of the air, in all the sets of stator and rotor, the air is delivered at a high pressure at the outlet

point.

Page 27