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Energy Conservation in Reciprocating Compressor

This document discusses energy conservation measures for reciprocating compressors. It begins with an introduction to reciprocating compressors, describing their basic design and uses. It then provides details on single stage and multi-stage compressor diagrams. Finally, it lists 12 specific energy conservation measures that can be implemented, such as ensuring cool air intake, regular filter cleaning, valve maintenance, minimizing low-load operation, installing regenerative dryers, periodic cleaning of intercoolers, and considering multi-stage compression.

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Ruturaj Umaranikar
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151 views5 pages

Energy Conservation in Reciprocating Compressor

This document discusses energy conservation measures for reciprocating compressors. It begins with an introduction to reciprocating compressors, describing their basic design and uses. It then provides details on single stage and multi-stage compressor diagrams. Finally, it lists 12 specific energy conservation measures that can be implemented, such as ensuring cool air intake, regular filter cleaning, valve maintenance, minimizing low-load operation, installing regenerative dryers, periodic cleaning of intercoolers, and considering multi-stage compression.

Uploaded by

Ruturaj Umaranikar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Name- Ruturaj Arvind Umaranikar

Reg no.- 200979009

Energy conservation Measures in Reciprocating Compressor

Introduction-

A reciprocating compressor is a positive-displacement device that


uses a cylinder and piston arrangement to compress a gas and deliver it at high
pressure.

They are often some of the most critical and expensive systems at a
production facility, and deserve special attention. Gas transmission pipelines,
petrochemical plants, refineries and many other industries all depend on this
type of equipment.

Reciprocating compressors are typically used where high


compression ratios (ratio of discharge to suction pressures) are required per
stage without high flow rates, and the process fluid is relatively dry.

Figure 1
Fig. 1 shows reciprocating compressor working strokes that include
suction, compression and delivery stroke.

From the number of compression cylinders one can easily count the
number of stages of compression. Piston is driven by prime mover to
compress the gas or air. Depending on the design of cylinder we can say
whether it is single acting or double acting.

In double acting cylinder compression and delivery occurs from both


ends of piston.

They are often some of the most critical, less efficient and expensive
systems at a production facility, and deserve special attention.

P-V Diagrams of single and multi-stage reciprocating compressors-

Single stage reciprocating compressor-


Multi-stage reciprocating compressor-

So, in order to conserve energy and improve efficiency of cycle following are
the measures we can follow:

Energy conservation measures in reciprocating compressor-

1. Ensure air intake to compressor is not warm and humid by locating


compressors in well-ventilated area or by drawing cold air from
outside.

Every 40°C rise in air inlet temperature will increase power


consumption by 1 percent.

2. Clean air-inlet filters regularly.

Compressor efficiency will be reduced by 2 percent for every 250


mm WC pressure drop across the filter.

3. Keep compressor valves in good condition by removing and inspecting


them once every six months.

Worn-out valves do not provide reasonable closing and opening of


suction and delivery valves. They even cause delivery even before
completion of suction stroke. Worn-out valves can reduce compressor
efficiency by as much as 50 percent.

4. Install manometers across the filter and monitor the pressure drop.

Reason being to check the loss of pressure across the filtering stage
so as to ensure cleaning of filters.

5. Minimize low-load compressor operation

If air demand is less than 50 percent of compressor capacity,


consider change over to a smaller compressor or reduce compressor speed
appropriately (by reducing motor pulley size) in case of belt driven
compressors.

6. Consider the use of regenerative air dryers

Regenerative air dryers use the heat of compressed air to remove


moisture.

7. Fouled inter-coolers reduce compressor efficiency and cause more


water condensation in air receivers and distribution lines resulting in
increased corrosion. Periodic cleaning of inter-coolers must be
ensured.

8. Compressor free air delivery test (FAD) must be done periodically

To check the present operating capacity against its design capacity


and corrective steps must be taken if required.

9. If more than one compressor is feeding to a common header,


compressors must be operated in such a way that only one small
compressor should handle the load variations whereas other
compressors will operate at full load.
10.The possibility of heat recovery from hot compressed air to generate
hot air or water for process application must be economically analysed
in case of large compressors.

Large compressors require more power to compress the air which in


turn requires more fuel consumption which means increases cost of
compression. And to use such high cost compressed air must be utilized
carefully.

11.Consideration should be given to two-stage or multistage compressor


as it consumes less power for the same air output than a single stage
compressor.

Multi-stage compression uses intercoolers to reduce temperature


after every stage compression which reduces the work of compression.

12.Reduce compressor delivery pressure, wherever possible, to save


energy.

Compressor work depends on outlet pressure so it reduces with lesser


outlet pressure.

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