Introduction Reciprocating Compressor

Introduction
A reciprocating compressor or piston compressor is a positive-

displacement compressor that uses pistons driven by a crankshaft to
deliver gases at high pressure.
The intake gas enters the suction manifold, then flows into the
compression cylinder where it gets compressed by a piston driven in a
reciprocating motion via a crankshaft, and is then discharged.
Applications include oil refineries, gas pipelines, chemical
plants, natural gas processing plants and refrigeration plants. One
specialty application is the blowing of plastic bottles made
of polyethylene terephthalate (PET).
In the ionic liquid piston compressor many seals and bearings were
removed in the design as the ionic liquid does not mix with the
gas. Service life is about 10 times longer than a regular diaphragm
compressor with reduced maintenance during use, energy costs are
reduced by as much as 20%. The heat exchangers that are used in a
normal piston compressor are removed as the heat is removed in the
cylinder itself where it is generated. Almost 100% of the energy going
into the process is being used with little energy wasted as reject heat.
Working principle of reciprocating compressor
Piston type compressors are the oldest and most commonly used
compressor in the pneumatic industry because of its flexibility, high
pressure capability, ability to rapidly dissipate heat of compression
and oil free. They are built for either stationary or portable services.
A. SINGLE CYLINDER COMPRESSOR
Piston compressors are available as single or double acting, oil
lubricated or oil free with different number of cylinders in
different configurations. With the exception of really small
compressors with vertical cylinders, the V configuration is the
most common for small compressors. On double acting, large
compressors the L type with vertical low pressure cylinder and
horizontal high pressure cylinder, offer immense benefits and is
why this the most common design. The construction and
working of a piston type reciprocating compressor is very much
similar to that of an internal combustion engine.
a) Construction: Piston type compressor consists of cylinder,

cylinder head, and piston with piston rings, inlet and outlet
spring loaded valves, connecting rod, crank crankshaft and
bearings.
b) Operation
Compression is accomplished by the reciprocating movement

of a piston within a cylinder. This motion alternately fills the
cylinder and then compresses the air. A connecting rod
transforms the rotary motion of the crankshaft into the
reciprocating motion of piston in the cylinder. Depending on
the application, the rotating crank (or eccentric) is driven at
constant speed by a suitable prime mover (usually electric
motor). Schematic diagram of single cylinder compressor.
Inlet stroke: -suction or inlet stroke begins with piston at top
dead centre (a position providing a minimum or clearance
volume). During the downward stroke, piston motion reduces
the pressure inside the cylinder below the atmospheric pressure.
The inlet valve then opens against the pressures of its spring and
allows air to flow into the cylinder. The air is drawn into the
cylinder until the piston reaches to a maximum volume position
(bottom dead centre).The discharge valve remains closed during
this stroke.
Outlet stroke: During compression stroke piston moves in the

opposite direction (Bottom dead centre to top dead centre),
decreasing the volume of the air. As the piston starts moving
upwards, the inlet valve is closed and pressure starts to increase
continuously until the pressure inside the cylinder is above the
pressure of the delivery side which is connected to the receiver.
Then the outlet valve opens and air is delivered during the
remaining upward motion of the piston to the receiver.
Types of reciprocating compressors:
 High speed (separable)

 Low speed (integral)
 Single acting
 Double Acting
Separable compressors
The term “separable” is used because this category of reciprocating
compressors is separate from its driver. Either an engine or an electric
motor usually drives a separable compressor. Often a gearbox is
required in the compression train. Operating speed is typically
between 900 and 1,800 rpm.
Separable units are skid mounted and self-contained. They are easy to
install, offer a relatively small initial cost, are easily moved to
different sites, and are available in sizes appropriate for field
gathering—both onshore and offshore. However, separable
compressors have higher maintenance costs than integral
compressors.
Integral compressors
The term “integral” is used because the power cylinders that drive the
compressor are mounted integrally with the frame containing the
compressor cylinders. Integral units run at speeds of between 200 and
600 rpm. They are commonly used in gas plants and pipeline service
where fuel efficiency and long life are critical. Integral compressors
may be equipped with two to ten compressor cylinders with power
ranging from 140 to 12,000 hp.
Integral compressors offer high efficiency over a wide range of
operating conditions and require less maintenance than the separable
units. However, integral units usually must be field-erected and
require heavy foundations and a high degree of vibration and
pulsation suppression. They have the highest initial installation cost.
Single-acting
A single-acting cylinder in a reciprocating engine is a cylinder in
which the working fluid acts on one side of the piston only. A single-
acting cylinder relies on the load, springs, other cylinders, or the
momentum of a flywheel, to push the piston back in the other
direction. Single-acting cylinders are found in most kinds of
reciprocating engine. They are almost universal in internal
combustion engines (e.g. petrol and diesel engines) and are also used
in many external combustion engines such as Stirling engines and
some steam engines. They are also found in pumps and hydraulic
rams.
Double-acting
A double-acting cylinder is a cylinder in which the working fluid
acts alternately on both sides of the piston. In order to connect the
piston in a double-acting cylinder to an external mechanism, such as
a crank shaft, a hole must be provided in one end of the cylinder for
the piston rod, and this is fitted with a gland or "stuffing box" to
prevent escape of the working fluid. Double-acting cylinders are
common in steam engines but unusual in other engine types. Many
hydraulic and pneumatic cylinders use them where it is needed to
produce a force in both directions. A double-acting hydraulic cylinder
has a port at each end, supplied with hydraulic fluid for both the
retraction and extension of the piston. A double-acting cylinder is
used where an external force is not available to retract the piston or it
can be used where high force is required in both directions of travel.
Single‐Acting, Air‐Cooled Reciprocating Air Compressors

Advantages include:
• Small size and weight
• Generally can be located close to point‐of‐use avoiding lengthy
piping runs and pressure drops
• Do not require separate cooling systems
• Simple maintenance procedures.
Disadvantages include:
• Lubricant carryover as piston rings wear, which should be avoided
• Relatively high noise
• Relatively high cost of compression
• Generally are designed to run not more than 50 percent of the time,
although some can be at 80 percent
• Generally compress and store the air in a receiver at a pressure
higher than required at the point‐of use. The pressure then is reduced
to the required operating pressure but without recovery of the energy
used to compress to the higher pressure. Operating Efficiency: 22 to
24 kW/100 cfm*
Double‐Acting,Water‐Cooled Reciprocating Air Compressors
Advantages include:
• Efficient compression, particularly with multi‐stage compressors
• Three‐step (0‐50‐100 percent) or five‐step (0‐25‐50‐ 75‐100 percent)
capacity controls, allowing efficient part‐load operation
• Relatively routine maintenance procedures.
Disadvantages include:
• Relatively high first cost compared with equivalent rotary air
compressors
• Relatively high space requirements
• Lubricant carryover on lubricant cooled units Relatively high
vibrations require high foundation costs Seldom sold as complete
independent packages Require flywheel mass to overcome torque and
current pulsations in motor driver
• Repair procedures require some training and skills. Operating
Efficiency: 15 to 16 kW/100 cfm*

Introduction Reciprocating Compressor

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Introduction Reciprocating Compressor

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What are the main types of reciprocating compressors?

What are the main components of a reciprocating compressor?

Introduction

A reciprocating compressor or piston compressor is a positive-

a) Construction: Piston type compressor consists of cylinder,

Compression is accomplished by the reciprocating movement

Outlet stroke: During compression stroke piston moves in the

Types of reciprocating compressors:

 High speed (separable)

Single‐Acting, Air‐Cooled Reciprocating Air Compressors

Efficiency: 15 to 16 kW/100 cfm*

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