A Review Paper On Reciprocating Air Compressor

International Research Journal of Engineering and Technology (IRJET)

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A Review Paper On Reciprocating Air Compressor Tanmay Chavhan1, Mahesh Jaiswal2, Komal Pawar3 , Ketan Niswade4, Ankit Bhoyar5 1Tanmay Chavhan Dept. Of Mechanical Engineering, Jagadambha College, Maharashtra, India 2Mahesh Jaiswal Dept. Of Mechanical Engineering, Jagadambha College, Maharashtra, India 3Komal Pawar Dept. Of Mechanical Engineering, Jagadambha College, Maharashtra, India

4Ketan Niswade Dept. Of Mechanical Engineering, Jagadambha College, Maharashtra, India 5

Ankit Bhoyar Dept. Of Mechanical Engineering, Jagadambha College, Maharashtra, India ---------------------------------------------------------------------***--------------------------------------------------------------------Applications: Abstract - This review paper provides a comprehensive overview of air compressors, their applications, maintenance procedures, and condition monitoring techniques. It highlights the importance of converting mechanical energy into pneumatic energy, which is accomplished by various types of compressors operating under diverse working principles and conditions. The primary objective of all air compressors is to draw in atmospheric air and generate high-pressure air for a wide range of applications. The research employs a combination of experimental testing, computational fluid dynamics (CFD) simulations, and mathematical modeling to achieve the research objectives.

Key

Reciprocating air compressors find extensive use across diverse industries due to their efficient delivery of highpressure air. Notable applications include: 1. Manufacturing and Industrial Processes: Employed in manufacturing for tasks requiring compressed air, including pneumatic tools, air-powered machinery, and automation systems. Widely utilized in automotive, metalworking, woodworking, and plastics industries.

2. Construction and Mining:

Words:

Compressor, Reciprocating Air Compressor, CFD (Computational Fluid Dynamics).

Extensively used in construction and mining operations to power pneumatic tools such as jackhammers, rock drills, and impact wrenches, facilitating efficient excavation and material handling.

1. INTRODUCTION A reciprocating air compressor employs piston-driven crankshafts to pressurize air and gases, enhancing their density by reducing volume. This compression process proves instrumental in simplifying the storage, transportation, and effective utilization of materials like natural gas.

3. Oil and Gas Industry: Vital in the oil and gas sector for various applications, including gas gathering, transmission, wellhead compression, gas lift systems, and natural gas processing.

Within reciprocating compressors, pistons are housed in cylinders. Each cylinder features a closed end adjacent to the cylinder head and concludes with a movable piston.

Valves, situated at the bottom of the compressor's valve pockets, come into play during the compression stages. In the initial phase, air enters the cylinder through a suction valve activated by the piston's movement, creating a vacuum.

4. Refrigeration and HVAC:

The piston then executes a reciprocating motion, reversing itself and initiating air compression. As the interior pressure of the cylinder surpasses that in the discharge pipes, valves open to release compressed air.

Utilized for packaging, bottling, canning, and processing in the food and beverage sector. Provides compressed air for cleaning, powers pneumatic actuators, and contributes to the control of production lines.

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Applied in refrigeration and air conditioning systems to compress refrigerants, enabling the cooling process and maintaining controlled temperatures in buildings. Found in refrigeration units for food storage and transportation.

5. Food and Beverage Industry:

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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 10 Issue: 12 | Dec 2023

p-ISSN: 2395-0072

www.irjet.net

6. Medical and Dental Applications: Essential in medical and dental facilities for tasks such as operating air-driven surgical tools, powering dental chairs, and supplying clean, dry compressed air for medical equipment.

7. Laboratory and Research Facilities: Applied in laboratories and research facilities for gas chromatography, sample analysis, and experiments requiring precise control of compressed air.

8. Automotive Service and Repair:



Commonly found in automotive service and repair shops to power pneumatic tools like impact wrenches, air ratchets, paint guns, and tire inflators.

Single Acting Compressor

Reciprocating

Reciprocating

Air

A double-acting air compressor, a type within the reciprocating air compressor category, functions differently than its single-acting counterpart. While a single-acting compressor uses only one side of the piston to operate, a double-acting compressor utilizes both sides for air or gas suction and compression. In simpler terms, the piston in a double-acting reciprocating compressor performs suction and compression on both of its sides.

This design makes double-acting compressors a notable choice in positive displacement compressors.

2. Compressor type 

Double Acting Compressor

Air

A single-acting compressor is like, a type of air compressor which uses, like, only one end of the piston, for the suction and compression purpose. In simple words, the first stroke of the piston sucks the air inside the compressor while the air compression occur, like, in the second stroke. In contrast the piston’s other end is usually free or open. Due to this, we can’t perform any work by the other end of the piston Therefore, only one side of the piston uses for sucking and compressing purposes. In simple wording, the piston upper part uses for air compression while the other side uses to open the crankcase. A single acting compressor uses compressed air to push the piston in one direction and the spring force to send the piston back to its, like, primary position. It can work, like, in the direction of pneumatic actuators. The cylinder of these, uh, reciprocating air compressors uses only one piston for supplying and discharging pressurized gas or air.

2.

Literature Review

2.1 R. C. Wadbudhe, Akshay Diware, and Praful Kale present a case study focusing on a reciprocating air compressor used in a locomotive. The study highlights issues associated with frequent part failures, providing a thorough diagnosis and effective solutions. The proposed maintenance strategies aim to address the challenges encountered during overhauling and repairing processes.

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Volume: 10 Issue: 12 | Dec 2023

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In one aspect of their invention, the authors describe a two-stage reciprocating compressor with specific features.

The compressor includes a casing, housing a first compressing unit and a second compressing unit. The first unit consists of a first piston and a first cylinder, driven by a reciprocating motor to linearly reciprocate the first piston. This motion is utilized to suck in and compress gas.

The second compressing unit, placed in the same casing, comprises a second piston and a second cylinder. In this case, the second unit is driven by the vibration generated by the first compressing unit. The vibration causes the linear reciprocation of the second piston in the second cylinder, facilitating the suction and compression of gas.

Additionally, a vibration transfer member is incorporated to transfer the vibration from the first compressing unit to the second compressing unit.

In contrast, the dual-energy engine caters to both city and open-road driving and is planned to be integrated into all MDI vehicles. This dual-energy engine offers versatility for various driving conditions, providing a solution for both urban and highway use.

2.4 Jitendra Kumar Sasmal, Amit Suhane, and Geeta Agnihotri authored an article that delves into the diverse failure modes experienced by reciprocating compressors under different operational conditions. The article also emphasizes the importance of employing maintenance strategies to effectively diagnose and address these recurring issues. Recognizing the critical role of condition monitoring techniques, the authors highlight their significance in sustaining the normal functioning of equipment. This proactive approach aids in identifying both premature and catastrophic failures, ultimately preventing significant productivity losses.

Notably, the first and second compressing units are arranged to extend in parallel and face each other. This configuration enhances the efficiency and functionality of the two-stage reciprocating compressor.

2.5 Ravishankar, Amit Suhane, and Manish Vishwakarma present a case study specifically focusing on the reciprocating air compressor used in locomotives.

The study addresses associated problems, offers detailed diagnoses, and proposes effective solutions, supported by appropriate maintenance strategies. These strategies aim to tackle the challenges arising from frequent part failures, providing insights into overhauling and repairing.

2.2 S. S. Verma provides a concise overview of recent advancements in compressed-air vehicle technology and addresses associated challenges while proposing solutions.

In the development of compressed-air vehicles, careful control of parameters such as temperature, energy density, input power requirements, energy release, and emission control is crucial. This mastery is essential for creating a compressed air vehicle that is not only safe but also lightweight and cost-effective in the near future.

2.6 Suraj Ghiwe, K.V. Srinivasan, and Kiran Chaudhari explore the impact of temperature on the filter performance of a compressor. The study assesses filter efficiency and pressure drop across the filter under experimental and Computational Fluid Dynamics (CFD) analyses. The research covers a temperature range of 10°C to 35°C, shedding light on how varying temperatures influence the compressor's filter performance.

Compressed air car engines differ from traditional engines, as they are fueled by a tank of compressed air rather than relying on pistons and an ignited fuel-air mixture.

Essentially, these vehicles are powered by the expansion of compressed air. Although the concept of vehicles running on compressed air appears promising, the practical application of this technology on a large scale has faced challenges due to inherent technical issues associated with compressed air.

3.

Advancement And Reciprocating Compressor

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In

With the help of the above findings Computational Fluid Dynamics (CFD) is a powerful tool used in the analysis and design of reciprocating air compressors. Here are some specific applications of CFD in reciprocating air compressor development:

2.3 Gaurav Kumar Tandan unveils the objective of propelling a four-stroke bike using compressed air. The aim is to achieve a speed of 50 km/h with a refilling range for compressed air after covering 70-80 km. These singleenergy engines are intended for deployment in both Minicabs and City cats, designed specifically for urban environments where the maximum speed is 50 km/h.

Motor Development International (MDI) envisions a future in cities where pollution will be restricted, facilitated by the use of compressed air technology, which boasts a zeropollution level.

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Development

Flow Analysis: CFD allows for detailed analysis of the fluid flow within the compressor, including the intake and discharge processes. It provides insights into flow patterns, pressure distribution, velocity profiles, and turbulence characteristics. This information helps optimize the compressor's performance, efficiency, and overall design.

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International Research Journal of Engineering and Technology (IRJET)

e-ISSN: 2395-0056

Volume: 10 Issue: 12 | Dec 2023

p-ISSN: 2395-0072

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4. CONCLUSIONS

Valve Dynamics: Valves play a crucial role in reciprocating compressors, controlling the flow of air during the intake and discharge strokes. CFD can simulate the valve dynamics, considering factors such as valve lift, timing, and geometry. By studying valve behavior, CFD can optimize valve designs, improve sealing performance, and minimize pressure losses.

Researchers have been urging the need to understand how heat transfer affects reciprocating compressors for over 25 years, but not enough attention has been given to it.

Instead, the focus has been on developing new materials for reliability. We lack proper understanding of how heat transfer works in compressors and how it affects their performance. In two-stage reciprocating air compressors, different cooling methods have been found to reduce the energy needed for compression. This can lower the power required to run the compressor by about 1-2%.To improve compressor performance, we can use a computer simulation called Computational Fluid Dynamics (CFD). It helps us study the airflow and heat transfer in compressors to optimize their design and efficiency. And using CFD can lead to better and more efficient compressors.

Heat Transfer Analysis: CFD can simulate the heat transfer phenomena within the compressor, including heat generation from compression and dissipation to the surrounding components. This analysis helps in evaluating the cooling requirements, identifying hot spots, and optimizing cooling systems to prevent overheating and improve overall system efficiency.

Piston-Cylinder Interaction: CFD enables the analysis of the interaction between the piston and cylinder, considering factors such as clearances, lubrication, and friction. It helps in understanding the dynamic behavior, efficiency, and wear characteristics of the piston-cylinder assembly. This information is essential for optimizing the design, materials, and lubrication systems for improved performance and durability.

REFERENCES 1) R.C.Wadbudhe, Akshay Diware, Praful kale, International Journal of Research In Science & Engineering, Volume: 3 Issue: 2 March-April 2017,pp 272-279.

Acoustic Analysis: CFD can simulate the acoustic behavior of reciprocating compressors, predicting noise generation and propagation within the system. By analyzing the noise sources and propagation paths, CFD can assist in the design of noise reduction measures and optimize the acoustic performance of the compressor.

2) S. S.Verma, Global journal of Research in Engineering, Volume xiii, ISSN: 2249-4596, issue 1, year 2013, pp 15-23.

3) Gaurav Kumar Tandan, International Journal of Science, Engineering and Technology Research (IJSETR), Volume 4, Issue 11, November 2015, ISSN: 2278 – 7798 pp 3770-3774

Design Optimization: CFD can be utilized as a virtual testing tool to evaluate and compare different design variations and configurations. By running simulations with various parameters, such as geometry, valve timing, and operating conditions, CFD helps identify optimal design choices that maximize performance, efficiency, and reliability.

4) Jitendra Kumar Sasmal, Amit Suhane, Geeta Agnihotri, International Journal of Science and Research, ISSN (Online): 2319-7064, Volume 4 Issue 6, June 2015,pp 2596-2601.

Performance Prediction: CFD simulations can provide valuable insights into the expected performance of reciprocating air compressors under different operating conditions. It enables the prediction of important performance parameters, such as flow rates, pressure ratios, power consumption, and efficiency, facilitating compressor selection and system integration.

5) Ravi Shankar, Amit suhane, Manish vishwakarma,International Research Journal of Engineering and Technology, Volume: 03 Issue: 04,year 2016, e-ISSN: 2395 -0056,pp 653-664.

6) Suraj Ghiwe, K.V. Srinivasan, Kiran Chaudhari, International Journal of Scientific Engineering and Applied Science,Volume-1, Issue-2, year 2015, NISS: 2395-3470,pp297-302

The use of CFD in reciprocating air compressor development allows for a deeper understanding of the complex fluid dynamics and thermal phenomena involved.

It aids in optimizing the design, improving performance, reducing energy consumption, and enhancing the overall reliability and efficiency of reciprocating air compressors.

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