0-1air Theory
0-1air Theory
0-1air Theory
Course Objectives :
2
Objectives & Contents
Table of Contents :
Chapter 1 : Introduction
3
Basics of Air Compressors
1. Introduction
1. Introduction
1.1 What is Air ?
5
1. Introduction
1.1 What is Air ?
–
It contains: N2:78%
78% nitrogen
– 21% oxygen
– 1% others
This composition is relatively constant, from sea
level up to an altitude of 25 kilometers.
Atmospheric air is always more or less contaminated
with solid particles, for example, dust, sand, soot and
O2:21%
salt crystals and also includes water vapor.
6
1. Introduction
1.1 What is Air ?
7
1. Introduction
1.1 What is Air ?
9
1. Introduction
1.2 What is Compressed Air ?
Final volume
The pressure in the balloon is of the balloon
increased due to decrease in the Initial Volume
volume. of the balloon
12
1. Introduction
1.3 Effective Pressure .
Absolute pressure is the total pressure measured from zero (perfect vacuum )
13
1. Introduction
1.3 Effective Pressure .
Pressure ( in bar)
Atmospheric
Plastic ball pressure 1 bar
Absolute pressure is the total pressure measured from zero (perfect vacuum)
Effective pressure is the total pressure measured from the atmosheric pressure.
The effective pressure is the difference between absolute pressure and
atmospheric pressure
Effective pressure = Absolute pressure – Atmospheric pressure
14
1. Introduction
1.3 Effective Pressure .
Effective pressure
The fan does not rotate
Atmospheric
Plastic ball pressure 1 bar
15
1. Introduction
1.3 Effective Pressure .
The absolute pressure in the ball is 2 bar
The effective pressure is 1 bar.
Absolute pressure = 2 bar
1 bar
The fan is rotating
Effective pressure
Atmospheric
Pump Plastic ball pressure 1 bar
16
Basics of Air Compressors
2. Basic Definitions
2. Basic Definitions
18
2. Basic Definitions
19
2. Basic Definitions
2.5 Capacity
Quantity of gas actually delivered, typically referred back to
inlet conditions at pressure, temperature and moisture Nm3/hr,
20
2. Basic Definitions
21
2. Basic Definitions
2.8 Power
Is the total mechanical input required including, compression power
and all frictional losses
22
2. Basic Definitions
2.10 Intercooling*
Cooling of the gas between stages of compression
1. Reducing the temperature
2. Reducing the volume to the succeeding stage
3. Liquefy condensable vapors to reduce power
(all of the above in order to reduce power)
23
Basics of Air Compressors
25
3. Applications of compressed air
3.1 Industrial Applications .
26
3. Applications of compressed air
3.1 Industrial Applications .
Automobile and other manufacturing
Transport
27
3. Applications of compressed air
3.1 Industrial Applications .
Textile Mining
28
3. Applications of compressed air
3.1 Industrial Applications .
Blowing Vacum
29
3. Applications of compressed air
3.3 Compressed Air requirements .
– Pressure
– Flow
– Quality of the air
Oil
Water
Solid particles
– Noise
33
Basics of Air Compressors
4. Types of Compressors
What is an Air Compressor ?
Air compressor is a machine that delivers a certain flow of air to a certain application and converts power ( usually
from an electric motor or a diesel engine) into kinetic energy by compressing and pressurizing air into the application air
net.
A compressor can withstand working against pressure/compression.
Types of air compressors
Based on the operating principle
- Positive-displacement compressor - Dynamic compressor
Compressors
44
4. Types of Compressors
DISPLACEMENT
Displacement compressors work on the
principle of reducing a volume to create
compression.
DYNAMIC
Dynamic compressors work on the
principle of using kinetic energy of the air
mass to create compression.
4. Types of Compressors
4. Types of Compressors
4.1 Dynamic Compressors
47
4. Types of Compressors
4.1 Dynamic Compressors
48
4. Types of Compressors
4.1 Dynamic Compressors
49
4. Types of Compressors
4.2 Positive Displacement Compressors
Inlet valve
Outlet valve
Piston
Inlet valve
Compressing
Outlet valve
Piston
Inlet valve
Compressing
Outlet valve
Piston
50
4. Types of Compressors
4.2 Positive Displacement Compressors
Outlet valve
Pressure
outlet valve are closed. Piston
Volume
51
4. Types of Compressors
4.2 Positive Displacement Compressors
Inlet valve
Outlet valve
Piston
Compression principle: Inlet valve
Compressing
Outlet valve
Piston
Pressure
= compressing
As the piston moves forward the
– During compressing the inlet air gets compressed and reaches
point 2
Volume
52
4. Types of Compressors
4.2 Positive Displacement Compressors
Inlet valve
Compressing
Inlet valve
Pressure
point 3. Discharging
Volume
53
4. Types of Compressors
4.2 Positive Displacement Compressors
Inlet valve
Compression principle: Discharging
Outlet valve Piston
to point 4.
Pressure
– During this movement, the volume Discharging
Volume
54
4. Types of Compressors
4.2 Positive Displacement Compressors
Outlet valve
Pressure reduction
Piston
Pressure
4 to point 1. Discharging
55
4. Types of Compressors
4.2 Positive Displacement Compressors
Double rotor:
56
4. Types of Compressors
4.2 Positive Displacement Compressors
Piston compressors:
57
4. Types of Compressors
4.3 Comparaison
A Centrifugal compressor is
Pressure
a machine with:
– variable capacity.
– constant pressure.
Centrifugal
compressor
A displacement compressor
is a machine with:
– constant capacity.
Displacement Compressor
– variable pressure.
Flow/capacity
58
4. Types of Compressors
4.4 Oil Injected Compressors
59
4. Types of Compressors
4.5 Oil Free Compressors
60
4. Types of Compressors
4.6 Water Injected Compressors
61
Basics of Air Compressors
5. Working Principals
5. Working Principals
5.1 Screw Compressors
Female rotor
The screw element’s main parts are the male and Male rotor
the female rotors, wich move towards each other
while the volume between them and the housing
decreases.
5. Working Principals
5.1 Screw Compressors
65
5. Working Principals
5.2 Tooth Compressors
– intake : air is drawn into the compression chamber until the rotors block the inlet.
– compression : the drawn in air is in the compression chamber, which gets smaller and
smaller as the rotors move.
Outlet = closed; inlet = open.
66
5. Working Principals
5.3 Scroll Compressors
67
5. Working Principals
5.3 Scroll Compressors
Compression process:
– The moving spiral is driven by a short stroke crankshaft and runs eccentrically around
the centre of the fixed spiral.
– Intake: at the top of the element housing.
– When the moving spiral runs clockwise, air is drawn in, captured in one of the air
pockets and compressed variably in towards the centre
– where the outlet and a non-return valve are situated.
68
5. Working Principals
5.4 Piston Compressons
Compression process:
Compression in a Piston compressor is characterized by enclosing a volume of gas or air and then increasing the pressure by reducing the area of the enclosed
volume.
69
5. Working Principals
A typical characteristic of a vacuum pump is that they work with a very high pressure ratio,
however despite this, multi-stage machines are common. Multi-stage compressed air compressors
can also be used for vacuums within the pressure range 1 bar(a) and 0.1 bar(a).
5. Working Principals
Fixed Speed Compressors
81
5. Working Principals
Variable Speed Drive « VSD » Compressors
82
5. Working Principals
Variable Speed Drive « VSD » Compressors
Frequency Converter
Controller
Set Point
Pressure
Sensor
Air
Net
Free Air Delivery
83
5. Working Principals
Variable Speed Drive « VSD » Compressors
0.6 BAR
84
5. Working Principals
Atlas Copco Offers the Best Technology For the Right Application
scroll 1-15KW
tooth 15-45KW
SPECIFIC ENERGY J/L
centrifugal
450-…KW
FLOW L/s
5. Working Principals
Ex. SOME SELECTION CRITERIA
LOAD
Base = =
Fluctuating = (VSD ++) -
DISCHARGE PRESSURE
Constant - (VSD ++) + (only for CPC)
SPEED FLUCTUATION
6. Air Drying
Composition of air
Air, the medium which we are using in
our products is almost perfect, always
available, not aggressive nor explosive,
at no cost etc.
There is however one disadvantage
with air in the way we use it: it always
contains water.
And water is not wanted in the
compressed air system.
Composition
Nitrogen: 78%
Oxygen: 21%
Others: 1%
Other
Composition of air
Watervapour
Other
Humidity
1000
800
Pws (mbar)
Humidity = the presence of water
600
vapour in air
400
200
Air has the capacity to adsorb water
0
vapour 0 10 20 30 40 50 60 70 80 90 100
Temperature (°C)
200
100%
150 SATURATED
60%
g/m³
100
50
NOT
0
SATURATED
-10 0 10 20 30 40 50 60 70
°C
The Relative Humidity
R.H. is defined as the ratio between the water content to the amount of water the air can
possibly hold at the same temperature .
Relative humidity is what really matters:
PDP has to be related to ambient temperature to be meaningful
25.00
20.00
PDP (°C)
15.00
RH = 26%
10.00
5.00
0.00
15 25 35 45 55
Ambient Temperature (°C)
Provided the air quality is in the green zone, corrosion is not possible.
Dewpoint
What is dewpoint ?
Dewpoint
= The temperature of the air below which
condensation starts
= The temperature of the air where the air is
saturated
Influence of pressure
The term pressure dew point (PDP) is used to describe the water content in the compressed air. It is the temperature at which
water vapour transforms into water at the current working pressure.
Low PDP values indicate small amounts of water vapour in the compressed air. It is important to remember that atmospheric dew
point can not be compared with PDP when comparing different dryers.
Example, a PDP of +2°C at 7 bar is equivalent to -23°C at atmospheric pressure.
You can select the main type of drying equipment based on the pressure dew point. Seen from a cost point of view, the lower
the dew point required the higher operating costs for air drying.
In principle, there are five methods to remove the moisture from compressed air: Cooling,
overcompression ,combinations ,absorption and adsorption. There is equipment available, based on these methods for different
types of compressed air systems.
Influence of pressure
– Cooling
– Overcompression
– Absorption
– Adsorption
– Combinations
AFTERCOOLER
Dewpoint = limited
= directly related to CW temp.
Air leaving aftercooler is always 100% saturated
Principle: cooling
REFRIGERATION DRYER
Principle: cooling
Aftercooler FD
Air Net
200 l/s 200 l/s 200 l/s
25 ° C 150 ° C 153,36 l/day 35 ° C
0 bar 7 bar 7 bar
RH : 60 % RH : 100 %
PDP : +3°C
Principle: cooling
Aftercooler FD
Air Net
200 l/s 200 l/s 200 l/s
25 ° C 150 ° C 151,8 l/day 35 ° C
0 bar 7 bar 7 bar
RH : 60 % RH : 100 %
PDP : +3°C
EXERCISE
+26°C 24 g/m³
+3°C 6 g/m³ ratio = 24/6 = 4/1
Drying by absorption is a chemical process where the water vapour is bound to the absorption
material by chemical reaction.
Absorption of water vapour can be made with both solid and liquid absorbents. The liquid
absorbents (sulphuric acids, glycerine glycol, etc.) are mostly used for air conditioning.
Absorption by means of solid absorbents is used for compressed air drying. The most common types
of solid absorbents are of the deliquescent type which becomes liquid at the chemical reaction with
the water vapour.
Exchange of absorbent must thus be made periodically.
The continuous consumption of the absorbent results in quite high operating costs for this type of air
drying.
Principle: adsorption
– The most common desiccants are silicagel and activated alumina used for dewpoints down to -50°C to -
60°C.
– If even lower dewpoints are required, molecular sieves can be used.
Principle: adsorption
Activated Alumina
+ Low price
+ Resistant to free water
+ Robust
Silical Gel
- Requires higher reactivation
(regeneration) temperature
+ Low regeneration temp (50 °C
- Less adsorption capacity than lower than Alumina)
Silica gel
+ Better adsorption capacity
(approx +30% than Alumina)
- Expensive.
- Requires much energy for reactivation
Principle: adsorption
Water vapour transfers to This means:
the desiccant
That, the amount of water
being taken out of the air is
because… stable, and therefore a dew
point -40°C is constant from
desiccant has a greater the beginning to the end of
attraction for water than air. the cycle.
Also:
But:
If the dryer vessel continues
The attraction slowly decreases to accept air, the PDP would
as the desiccant gets wet slowly decay. After about 90
minutes it would be around -
20°C. If the PDP becomes
Meaning : positive, the desiccant is
ruined.
that the wet layer slowly rises
Finally:
up the tower, as dry desiccant
is more attractive than wet
For a -70°C PDP, more water
desiccant. After the half cycle
attractive desiccant is
time, the wet layer is almost at
needed.
the top of the dryer.
Principle: adsorption
Things To Remember: Crucial Parameters
Examples:
Tower dryers:
X
+
Principle: osmosis
OSMOSIS/MEMBRANE TECHNOLOGY
Water
air
molecular
membrane
Atlas Copco dryer families
7- Air Filtration
Introduction
What is A line Filter ??
A filter is...
A product which removes contaminants from the air, like solids, liquids
and vapors.
Why filtration?
When the compressed air is not filtered, and led as such to for example construction equipment,
industrial end-products, medical applications, etc., the contaminants may damage the customer’s instruments,
27
Filtration of compressed air
QDT PDp
oil vapor dust
OIS
DD PD
Major contaminants in compressed
oil aerosol oilair
aerosol
28
ISO 8573-1:2010
Purity classes
For example:
class 1.4.1 means
Dirt: max 20.000 particles in the range of 0.1-0.5 µm, 400 particles of 0.5-1 µm and 10 of 1-5 µm
Water: max 3°C PDP
Oil: max 0,01 mg/m³
class 2.4.2 means
Dirt: max 400.000 particles in the range of 0.1-0.5 µm, 6.000 particles of 0.5-1 µm and 100 of 1-5 µm
Water: max 3°C PDP
Oil: max 0,1 mg/m³
29
ISO 8573-1:2010
Typical installations
1:2:1
1:-:2
2:-:3 1:4:1
1:2:1
1:4:1
and WSD
30
Performance/types
DD filter:
• The DD filter is a general-purpose protection and liquid removal filter, the IDD filter is a DD filter modified
to be integrated in a compressor. The filters are equipped with an electronic water drain.
•the operating pressure is 7 bar(e) (100 psig) and the oil concentration at the inlet of the filter is below 3
mg/m3. The maximum inlet temperature is 66 ˚C (150 ˚F).
DDp filter:
•The DDp filter is a dust filter.
•The element traps the solid particles down to 1 micrometer for 100 %, down to 0.01
micrometer for 99.9 %.The maximum inlet temperature is 66 ˚C (150 ˚F).
31
Performance/types
PD filter:
•The PD filter is a high-efficiency dust, liquid and aerosol removal filter for compressed air. The filters are
equipped with an electronic water drain.
•The filter element traps the solid particles down to 0.01 micrometer. The oil/water aerosols liquefy and the
so-formed drops collect and are removed by the automatic drain. The maximum remaining oil content in the
outgoing compressed air is 0.01 mg/m3 at a compressed air temperature of 20 ˚C (68 ˚F) and an operating
pressure of 7 bar(e) (100 psig). The maximum inlet temperature is 66 ˚C (150 ˚F).
PDp filter:
•The PDp filter is a high-efficiency dust filter.
•The filter element traps the solid particles down to 0.01 micrometer. The element traps the solid particles
down to 1 micrometer for 100 %, down to 0.01 micrometer for 99.9 %. The maximum inlet temperature is
66 ˚C (150 ˚F).
QD filter:
•The QD filter is an oil vapour and odour removal filter up to a remaining oil content of maximum 0.003
mg/m3 at a compressed air temperature of 20 ˚C (68 ˚F) and an operating pressure of 7 bar(e) (100
psig).The air flows through the activated carbon, which is contained in the filter element. The maximum
inlet temperature is 35 ˚C (95 ˚F).
32
Performance/types
34
Components
35
Function
36
Function
• Dust particles enters the element from out side, particles can easily be drained via the bottom valve
•all DDp filters are as standard equipped with a manual drain valve at the bottom of the filter housing.
37
Function
PD
Purpose: High performance oil filtration PDp
Performance:Oil aerosol down to Purpose: High performance particle filtration
0,01mg/m3 (and particles down to 0,01 Performance: Particles down to 0,01 micron.
micron.
Pressure drop: 0,08 bar
Pressure drop (wet): 0,2 bar in
DD DDp
Purpose: General performance oil
Purpose: General performance particle
filtration
filtration
Performance:Oil aerosol down to
Performance: Particles down to 1 micron.
0,1mg/m3 (and particles down to 1
micron. Pressure drop: 0,05 bar
Pressure drop (wet): 0,12 bar
38
UD PLUS
The Nautilus Filter Technology is the heart of the UD+ filter
+ =
Best-in-class efficiency
Line Filter Cartridge Service Interval: No compromise on performance
Coalescing filters: 4000 running hours Or 1 year of
installation
39
Service intervals
new filter elements
Replace DD+ and PD+ after … (whatever comes first)
– 4000 operating hours
– one year
• Ventilation air should be taken from outdoors, preferably without using long ducting.
• The intake should be placed as low as possible.
• The ventilation fan/fans should be placed high up on one of the room’s end walls.
• the air intake placed on the opposite wall.
• The air velocity at the ventilation inlet opening should not exceed 4 m/s.
• The quantity of ventilation air must be sufficient to limit the temperature increase in the room to 7–
10°C.
43
Committed to sustainable
productivity.
45