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In many industries, reciprocating air compressors are the backbone of the operation as they offer efficient and dependable compressed air solutions. Thus, knowing how such machines work will enable one make an appropriate choice when it comes to revolving compressors for varying applications.
In this blog, we will cover the basics of the reciprocating air compressor technology, its uses in many sectors, and most importantly, aid you in finding the right reciprocating air compressor for your needs.
An air compressor that utilizes a reciprocating motion in the piston depressor is called a ‘reciprocating air compressor’. A crankshaft in the air compressor drives several pistons, which in turn compress air within the cylinder. The motion of the pistons within the cylinder compresses air, which is subsequently released and stored in a tank for later use. Most of the ways of air compression technique ,reciprocating machine has been among the oldest and the most popular types and still serves well. This is because they can withstand wear and tear, are very reliable and can work at high pressures.
Positive Displacement Principle: As far as positive displacement goes, the working of reciprocating compressors is based on this principle, where the volume of air in the cylinder is reduced resulting in the increase of pressure. This happens due to the movement of the pistons in a reciprocating manner. The piston pulls air into the cylinder during the intake stroke and compresses this air in the cylinder during the compression stroke.
High Pressure Capabilities: Reciprocating air compressors can generate high discharge pressures, enabling application in areas where the pressure is designed to be sustained up to 6000 psi. This high-pressure capability is possible by reason of having several stages of compression whereby air is compressed in stages to attain such a pressure level.
Wide Capacity Range: Reciprocating compressors come in a variety of sizes, from low output workshop compressors of a few cubic feet per minute (CFM) to large industrial machines capable of hundreds of CFM. This quality gives the ability to use reciprocating compressors in many applications, for example from driving pneumatic tools at a garage to running manufacturing operations in an industrial facility.
Efficiency: Reciprocating compressors are very efficient, particularly in High pressure and low flow rate applications. According to the principle of positive displacement, air is compressed in a definite volume with every stroke of the piston leading to proper compression. But, with an increase in the flow rate of the reciprocating compressor, the efficiency could drop due to the heating and friction caused by the moving parts in the internal system.
The three classified air compressors and widely used in different sectors include: reciprocating air compressors, rotary screw compressors as well as centrifugal compressors. Each of them has its own general features, benefits, and drawbacks. The following comparison is meant to point out the principal distinctions between these types of compressors.
Compression Techniques:
Piston Type Compressors: Crankshaft-driven pistons are used to compress air in back and forth linear movement within cylinders.
Screw Compressors: While rotating, two opposing shafts squeeze and push the air out to maintain constant pressure.
Centrifugal Compressors: Internal blades of the impeller spin fast for the air to be sucked in and forced out as a compressed gas.
Pressure Range:
Reciprocating Compressors: High-pressure linear acting air compressor can generate pressures even up to 6000 psi.
Rotary Screw Compressors: These compressors usually work at a pressure range of 100-200psi to work with compressed air for most industries.
Centrifugal Compressors: These types of compressors are for low pressure applications usually up to 125 psi.
Flow Rate:
Reciprocating Compressors: They work on positive displacement and are suited for very low flow rates-high pressure applications, and provide a compressed air in a pulsating manner.
Rotary Screw Compressors: Supplied with rotary, they have a higher flow rate than the reciprocating compressors, and provide a steady stream of compressed air.
Centrifugal Compressors: These types of compressors are meant for high flow rate applications, and consistently provide high volumes of compressed air.
You can get more information about Rotary Screw vs Piston Air Compressors.
A reciprocating air compressor function due to the principle of positive displacement. The main components of the compressor, in addition to their individual parts, work in a cycle to suck in ambient air, compress it to a higher level and release it either to a storage tank or application or both.
A reciprocating air compressor works through a cyclic process of inhaling the atmospheric air, compressing the air thus received, and finally expelling the compressed air. This basic process which is called the compression cycle is performed every so often in order to ensure that there is compressed air always available. The compression cycle has three cardinal parts:
Intake Stage: In this part known as the anchor part, the piston is drawn down in order to create a vacuum in the cylinder housing that separates the piston from the valve. This vacuum in turn forces the inlet valve to be open as atmosphere air fills the cylinder.
Compression Stage: While the crankshaft keeps turning, the piston has already started advancing upward, thereby compressing the air within the cylinder walls. The inlet valve snaps shut to stop the air from leaking back into the atmosphere. The movement of the piston creates a situation in which the free volume of the cylinder is decreasing, thereby resulting in the rise of the pressure of the air contained within the cylinder.
Discharge Stage: In the case where the piston has to go to the extreme end position towards the top of its stroke, the pressure associated with the compressed air becomes greater than that encountered in the discharge line. The difference in pressure is what forces the discharge valve to open thus enabling the compressed air to exit from the casing to the storage tank or to the distribution system. After this discharge stage, the piston goes down again, while the same cycle commences.
The air compressor that uses a reciprocating system comprises of several components that are important in the process of compression. These components are the cylinder, the piston, the valves and the crankshaft, and each of them has its importance in the functioning of the compressor. Let us examine these major components in detail:
Cylinder: The cylinder is the primary air holding component of the compressor. It is mostly constructed from either cast iron or aluminum since they are able to withstand very high pressures.
Piston: A piston is a stipulating part inside the cylinder that going to be moving up and down. A crankshaft is attached to its upper portion at an angle via a connecting rod which below the piston compresses air when the piston is going down in the cylinder.
Valves: Two types of valves are used in reciprocating compressors namely inlet valves and discharge valves. The intake valves permit the cylinder to draw ambient air into it at the intake stage while the discharge valves permit the outflow of the pressurized air from the cylinder at the discharge stage.
Crankshaft: The crankshaft is also part of the compress motor assembly, but in this case, it is used to change the rotational motion of the motor into the linear motion of the pistons. It has connecting rods which connect to the pistons.
Reciprocating air compressors are terminologically divided into two classes based on the number of compression stages used, single-stage or multi-stage compressors:
Single Stage Compressors: A single stage reciprocating air compressor uses only one cylinder to complete the entire compression process, this means the air will be compressed all the way from atmospheric pressure to the discharge pressure in one stage. Single-stage compressors are normally used for applications with relatively lower pressure ratings (150 psi and below), they also have lower compression ratios.
Multi-Stage Compressors: Multi-stage reciprocating air compressors consist of two or more cylinders for compressing air in stages. Initially, the air is compressed in a low-pressure cylinder and is cooled before entering the high-pressure cylinder or cylinders for further compression. This method of compression enables higher final discharge pressure ratings of over 6000 psi and efficiency since the amount heat generated during compression is lower.
More deails about Single Stage vs Tow-Stage Compressor.
Reciprocating air compressors are one of the most common tools used in various industries for quite a long time owing to their inherent features and capabilities. Nevertheless, like any other compressor, recips have their own pros and cons that are important to take into account while choosing the most appropriate compressor for a particular application.
High Pressure Capabilities:
A major benefit of the use of reciprocating compressors is the high discharge pressures that can be attained. Compressors of even small sizes can deliver air up to about 6000 psi, thus such wet or dry air compressor high pressure applications include gas compression, pressure or Hydrostatic testing, and boosting.
Wide Capacity Range:
Air compressors with reciprocating mechanism come in an array of sizes and capacities ranging from small workshop ones that produce a few CFM to big industrial kinds that are able to supply even hundreds of CFM. This flexibility offers the user the chance to pick a compressor that matches their air supply demand.
Efficiency:
Reciprocating compressing machines are very efficient especially for operations that require pressurization but with very low flow rates. This is enhanced by the positive displacement mechanism that ensures that the entire volume of air compressed in a piston up stroke is the same with the size of the piston after that stroke causing effective compression. Furthermore, more efficient multi-stage reciprocating compressors do this even more efficiently by cooling the compressed air between its compression spaces as this reduces the work done on the gas within the system.
Durability:
Reciprocating type air compressors are also very dependable as well as all other employing this technology. These types of compressors have been in service for quite a long time and have quite impressed many for their sturdiness for such operating climate control equipment. Provided that they receive the required care and timely servicing, reciprocating compressors will be able to function without problems for a long time, thereby preventing breakdowns and providing the delivery of air in a compressed manner without interruptions.
Noise Level:
Reciprocating compressors have a high noise level among other city compressor types. This type is also quite noisier surrounding due to the motion of pistons and opening and closing of valves. This creates a challenge especially in places where noise is a concern. Most of the times, this problem is resolvable by soundproofing the compressors or by not mounting them in the same room with the user.
More vibrations:
Oil free reciprocating air compressor produces vibration because of the oscillation of pistons and the compressive forces acting on it. The surrounding environment, structures and machineries may also feel those vibrations which can either damage the structures or hinder the effective functioning of delicate machineries. In such cases – proper installation (with vibration isolators and flexible connections) would be helpful to overcome their impact.
Maintenance Requirements:
Maintenance of axial air compressor is less than reciprocating air compressors for example rotary air compressors. Because their design includes valves, pistons, and other moving elements periodic maintenance, replacement of valves and lubrication in most cases is done. If these services are not performed, there is a decrease in efficiency, too much wear and ultimately breakdown.
With respect to different fields and industries, reciprocating air compressors are adaptable machines. Whether it’s heavy industrial usage or specialized commercial use, these compressors have an important role in the provision of compressed air in different processes. Now let us delve into the primary uses of reciprocating compressors.
Manufacturing:
Industries like food and beverage, textiles and electronics make extensive use of Reciprocating air compressors. Such compressors provide compressed air that is used for the operation of pneumatic tools, control systems and automation machinery among other things. They also provide air for cleaning, drying and packaging processes as well.
Automotive:
In the automotive sector, reciprocating compressors are used for many purposes, such as providing pneumatic tools for assembly and maintenance work, paint spraying systems and air driven tools. Moreover, these compressors are also used for inflating tires and for testing the emissions of vehicles.
Energy:
The energy sector, particularly oil and gas exploration and production, incorporates the use of reciprocating compressors. Process includes gas turbines for gas compression, gas lifting and gas reinjection. These types of compressors are also used in compressed natural gas (CNG) refueling stations and biogas compression.
Gas Stations:
Reciprocating air compressors are usually placed in gas stations for the purpose of inflating tires or providing air for the maintenance of vehicles by means of air tools. Thus these volumetric compressors are one of the best options in these cases to provide compressed air.
Dry Cleaning:
While most people are familiar with dustless cleaning through the use of various solvents, in fact, reciprocating compressors are utilized within the dry cleaning business in order to supply power to cleaning machines as well as compressed air to facilitate drying. These compromises.
Dental:
Dental handpieces, syringes, and other pneumatic dental apparatuses all require an air supply, which is often provided by a reciprocating air compressor in a dental office. Such appliances also make it possible to provide clean compressed air without using oil lubricants which is so important for the sterilization of dental procedures.
Blow Molding of PET Bottles:
Few industries rely on Reciprocating compressors in everyday production activities as in the case of polyethylene liquor bottles. These compressors are employed to generate high pressure air, which is subsequently used in the blow molding process where preforms are expanded to form the final shape of the bottle.
Breathing Air:
Reciprocating compressors are used to compress air for breathing purposes in different situations including scuba divers, firefighters, and industrial breathing apparatus. These for high quality, clean and high air supply, these compressors must conform to safety and air quality regulations.
Compressed Natural Gas (CNG):
CNG refueling stations are fitted with Reciprocating compressors for compressing natural gas to high pressure for the purpose of refueling vehicles. Specialized compressors are manufactured to the demands of CNG operation specifically for safe and effective performance.
Choosing the proper reciprocating air compressor is very important to optimize performance, efficiency, and reliability of a compressed air system. When selecting a reciprocating compressor, factors such as pressure ratings, volumetric capacity, electric power input, as well as noise output should be examined.
Pressure Requirements:
Outline the pressure range expected in your application. Reciprocating compressors can produce pressure as high as 6000 psi, however, majority of industrial processes entail a pressure range of 100 to 200 psi. Pay attention to the highest and the lowest pressures which your equipment and processes will need.
Capacity:
Outline the air flow CFM air flow rate for the application in this case telescoping boom and considerably higher levels of air flow. Remember the total air usage of the tools, apparatuses and materials used at the same time. It is crucial to choose a reciprocating air compressor with enough rated capacity to cover the peak air demand.
Power Consumption:
Discuss power consideration such as compressor motor power rating and the use of electric supply for operation of the reciprocating pump. Be sure that the electrical system of your establishment is capable of accommodating the power requirements of the unit. Also, it would be beneficial to employ a power efficient compressor to cut back on the running costs.
Noise Levels:
Give some consideration to noise levels associated with the reciprocating compressor, more so if this will be located in the workspace or close to noise sensitive areas. Thus, a low-noise compressor should be sought or employing noise-dampening enclosures would be appropriate.
Duty Cycle:
Find out the anticipated duty cycle of the reciprocating compressor, this is the proportion of running time that the compressor will be operated. When the duty cycle is higher, a more powerful, durable pump is required for constant work. Take into account the daily or weekly working hours and modify the compressor selection when necessary.
In order to choose the right size and specifications of reciprocating air compressor, do the following steps.
Find out the overall air consumption by adding up the air consumed by all the tools, equipment and processes needed at the same time.
Allow a cushion of 10-20% on the overall air demand to cater for such issues as leakages, future increase in work load and maximum demand period.
Establish the range of pressure required, regarded as the minimum and maximum pressure required by your equipment and processes.
Choose a reciprocating compressor whose capacity (CFM) and pressure capability meets or exceeds the air demand and pressure calculations made by you.
Employ Considerations on power ratings, noise levels and duty cycle of the compressor to avoid mismatch with your facility and application.
Seek the services of an air compressor expert or the manufacturer to aid in the sizing and selection process of oil free air compressors reciprocating for your needs.
After settling on the appropriate reciprocating air compressor to use, it is imperative to evaluate the air treatment expectations at the same time in order to guarantee the quality and the cleanliness of the compressed air achieved. Air treatment components include:
Dryers:
These are devices designed to minimize the moisture content within compressed air, so as to avoid its condensation and corrosion within the compressed air system. There are several different types of dryers for instance, refrigerated dryers, desiccant dryers, membrane dryers differentiating in their effectiveness and suitable levels of humidity.
Filters:
These types of filters are designed to eliminate dust, oil particles and other airborne pollutants from the compressed air stream. Filters come in different classes and varieties, like particulate filters, coalescing filters, activated carbon and many more based on the type of contaminants to be separated.
Lubricators:
Lubricators inject a set amount of oil to the compressed air network to grease pneumatic devices and equipment. This is beneficial since it reduces friction and wear and tear to the tools, minimizing damage and enhancing operation capabilities.
Reciprocating air compressors are employed in a number of industries that require the use of compressed air because they use the up and down motion of pistons in the cylinders to compress air. In selecting the best reciprocating piston compressors, there are a number of factors to be considered such as the pressure ratings, volume of air, power requirement and noise levels. In an optimization stand point, the proper selection of a reciprocating air compressor into a compressed air system is very important in enhancing the performance, efficiency and reliability of the entire system. For professional help regarding the usage of reciprocating compressors, you can call the team of experts from Aivyter to help you out.
A reciprocating air compressor is a positive displacement mechanism in which air is compressed using pistons worked by a crankshaft. It functions by compressing air in a secured section of an apparatus, that is adjusting the volume of air inside the chamber hence increasing it pressure.
When sizing a reciprocating compressor, additional factors like air pressure, volume requirements, and duty cycle should also be considered. Consider consulting with an expert or check out some websites with a compressor-sizing section to find out which should be the specs of the compressor that you will need.
Reciprocating compressors are applied in a variety of economic activities, such as the production, automotive, agricultural and construction industries. They are employed for the purposes of operating air powered tools, machinery or systems and for compressed air supply for various applications.
Some of the routine checks and maintenance for reciprocating compressors include air filter replacement, lubrication of moving components, belt tension adjustment, and a valve examination. You should also adhere to the recommendations of the manufacturer, and ensure provisions are made for regular preventative maintenance.
Reciprocating compressors are very high pressure, economical, and available in numerous sizes and power ratings without the loss of efficiency. They are also more robust, dependable, and cheaper for commencement than different compressor design types of containers.