ME 529 – Refrigeration Engineering

Lecture 5:
Compressors Analysis I
Ammar M. Bahman
Assistant Professor of Mechanical Engineering
Kuwait University
E-mail: [Link]@[Link]

Updated material and slides from

© Eckhard A. Groll © Davide Ziviani
Purdue University
Ray W. Herrick Laboratories
E-mail: groll@[Link], dziviani@[Link]
5.1
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 CONTENTS

● Review of Compressor Types

● Legacy Compressors

● Novel Compressors

● Summary

5.2
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 Review of Compressor Types:
General “viewpoints” about compressors

● “The compressor is the heart in a refrigeration system”!

» It is the only active main component, maintaining a flow of refrigerant

● “Compressors have a cooling capacity and a COP/EER”!

» Compressors by themselves do not have a cooling capacity or COP/EER
» However, compressors are often rated by cooling capacity and
COP/EER based on assumed system state points

● The task of the compressor in a refrigeration system is to provide a mass

flow rate of refrigerant from a low pressure level to a high pressure level

5.3
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 Review of Compressor Types:
Overview of Refrigerating Compressors
Compressor Types
(adapted from CRC
Dynamic Handbook, 2017)
Radial Flow Axial Flow Ejector

Positive Displacement

Rotary Reciprocating
Vane Trochoid Screw Scroll Liquid-Ring

Single Rotor Two Rotors Tri-Rotors Recip Swash Diaphragm Linear

S-RAM

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 Review of Compressor Types:
Range of Applications of Compressors

Cooling Capacity (kW)

0 100 101 5x101 102 5x102 103

Domestic
Refrigerators & Room AC Commercial AC & R Industrial AC & R
Freezers Large AC
Automotive
AC Unitary AC & HP
Fractional
Linear
Fractional 200 kW (50 tons)
Piston (Reciprocating)
Fractional Rotary 50 kW Spool 300 kW (85 tons)

5 kW (1.5 tons) Scroll 75 kW (20 tons)

150 kW (40 tons) Screw 1500 kW (400 tons)

Note: compressor technologies are 350 kW (100 tons) Centrifugal ..and up

constantly evolving 5.5
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 Review of Compressor Types:
Differences with respect to Motor Location

● Hermetic
» Welded steel shell houses both compressor and motor
» Usually smaller sizes; high manufacturing cost of larger sizes
● Semi-hermetic
» Common, but bolted, housing for compressor & motor
» Intermediate capacities
» Often multiple cylinders for increased capacity
● Open drive
» Motor external to shell
» Largest capacities
» Shaft seal necessary
» Automotive AC
5.6
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 Review of Compressor Types:
Compressor Types considered in this Lecture

● Positive Displacement Compressors:

» Reciprocating compressors
» Rotary Compressors:
̶ Rolling piston
̶ Rotary (Sliding) Vane
̶ Scroll
̶ Screw
̶ Etc.

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 Review of Compressor Types:
Reciprocating Compressors

Inlet pipe Discharge muffler

Shaft

Discharge
pipe

Discharge Suction
head head
Pistons 5.8
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 Review of Compressor Types:
Reciprocating Compressors

● Still most widely used compressor; simple to make, gives cost advantage
● Computer-aided design:
» Greatly increased performance and efficiency, with novel valve, port,
and flow passage design
» Can expect further improvements with study of internal heat transfer.
● Parallel compressors are low-cost way to obtain multiple capacities and improved
part load efficiency
● Common belief that other designs have inherently superior characteristics, e.g.,
reliability, volumetric efficiency, pressure oscillations, etc.
● Bottom line: Other types will continue to invade reciprocating market (e.g., rolling
piston compressors)

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 Review of Compressor Types:
Reciprocating Compressors

● Example of refrigeration compressor rack:

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 Review of Compressor Types:
Rotary Compressors

● (At least) Three types:

» Stationary (means non-rotating) vane, also called rolling piston compressor;
more popular for domestic refrigerators, window air conditioners, mini-split AC
units in Asia
» Rotating, sliding vane compressor; more popular some 20 years ago
» Swing vane; other novel designs e.g., Spool compressor

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 Review of Compressor Types:
Rotary Compressors

● (At least) Three types:

» Stationary (means non-rotating) vane, also called rolling piston compressor; more
popular for domestic refrigerators, window air conditioners, mini-split AC units in Asia
» Rotating, sliding vane compressor; more popular some 20 years ago
» Swing vane; other novel designs e.g., Spool Compressor
● Advantages over reciprocating compressors:
» Smaller size for given capacity
» No suction valve means better reliability
» Better operation over larger speed range
● Limiting factors:
» Wear and leakages have significant effect on performance
» Not reliable for field installations (needs clean environment)

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 Review of Compressor Types:
Rolling Piston Compressors

● Household air-conditioning and refrigeration systems requires increasing energy efficiency

standards:
» Variable-speed equipment
» Capacity modulation of compressors (Lee et al. 2015)

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Review of Compressor Types:
Rolling Piston Compressors

5.14
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Review of Compressor Types:
Rolling Piston Compressors

5.15
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 Review of Compressor Types:
Rolling Piston Compressors

● Typical mechanical structures of single-cylinder and twin-cylinder rotary compressors

(Zhang et al., 2014)

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 Review of Compressor Types:
Rolling Piston Compressors

● Two-stage rotary compressors can lead to potential energy savings through intercooling
and economizing
● Example capacity modulation developed by Lee et al. (2015):

5.17
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 Review of Compressor Types:
Scroll Compressors

● There are three different mechanical scroll mechanisms available

» Oldham-ring (most commonly used)
» Idler-shaft
» Co-rotating (or spinning) scroll

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 Review of Compressor Types:
Scroll Compressors

● Relatively complicated orbiting mechanism required with fairly complex geometry of the
mating scroll wraps, but with many advantages
● No valves, better reliability
» Check valves on the discharge plenum can be present at times to avoid back-flow
● No clearance volume effect, so volumetric efficiency is almost independent of pressure
ratio
● Ideal for variable speed and capacity
● Better dynamic balance, more uniform shaft torque, less pressure oscillations, less noise
and vibration

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 Review of Compressor Types:
Scroll Compressors

● Hermetic scroll compressor structure

5.20
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 Review of Compressor Types:
Scroll Compressors

● Hermetic scroll compressor structure

Orbiting and fixed scrolls
Discharge tube
& plenum
Oldham coupling

Suction tube
Thrust bearing

Upper bearing

Motor

Lower bearing
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 Review of Compressor Types:
Scroll Compressors

● Hermetic scroll compressor working principle:

𝜃=0 𝜃 = 𝜋/2 𝜃=𝜋 𝜃 = 3𝜋/2 5.22

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 Review of Compressor Types:
Scroll Compressors

● The geometry model is based on the description of a pair of

involute unwrapping from a base circle with a radius 𝑟! :

Involute angles on fixed scroll 5.23

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 Review of Compressor Types:
Scroll Compressors

● The wall thickness of the scroll wrap is usually constant, but variable wall geometries can also be
manufactured (Shaffer and Groll, 2013)
● The tip geometries are optimized to achieve proper volume ratio

5.24
Different base scroll forms Different tip geometries © A. Bahman
 Review of Compressor Types:
Scroll Compressors

● There are two major leakage flow paths in a scroll compressor:

» Radial leakage
» Flank leakage

Chen et al., (2002) Bell, (2011)

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 Review of Compressor Types:
Scroll Compressors

● Heat losses in an hermetic scroll compressor and discharge plenum (Diniz et al. 2015)

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 Review of Compressor Types:
Scroll Compressors

● Less space required for given capacity

● Suitable for higher pressure ratios such as needed for heat pump
applications
● Compliant mechanisms makes ingesting liquid and dirt easy
● Digital machining made production possible
● Costs will drop with increased speed of production
● Current research to improve efficiency, oil management, and extend
capacities and variable speed

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 Review of Compressor Types:
Screw Compressors

● The first over operational twin-screw compressor was built by Ljungström Steam Turbine
Co. (LST) in Sweden in 1937, where an engineer A. L. Lysholm designed the first screw
profile.
● LST renamed itself as “Svenska Rotor Maskiner” or SRM
● Twin-screw compressors are characterized by compactness (in relation to ton range),
lightweight, high reliability, high volumetric and isentropic efficiencies
● The performance is directly linked with the progresses in manufacturing the rotors
● Works well with both speed control and capacity modulation valves
● Relatively low-cost semi-hermetic machines in the 30-300 RT
● Challenges exist in scaling down twin-screw compressors

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 Review of Compressor Types:
Twin-Screw Compressors

Jack Sauls, 2014

5.29
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 Review of Compressor Types:
Twin-Screw Compressors

● The basic compression elements in a twin-screw compressor are the pair of helical
lobed rotors that mesh with each other
● A casing encloses the rotors with a tight clearance gap to allow the rotation.
Suction and discharge ports are part of the casing

Stosic, Smith, Kovacevic, (2005)

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 Review of Compressor Types:
Twin-Screw Compressors

5.31
Courtesy of Dr. Sham Rane, University of Oxford, UK
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 Review of Compressor Types:
Twin-Screw Compressors

● History of screw-compressor profiles:

● Lysholm profile
● Symmetric profile
● Asymmetric profile
● Modern profile (N-rack)

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 Review of Compressor Types:
Twin-Screw Compressors

● Rotor profiles and rotor geometry features:

» Wrap angle
» Rotor length-diameter ratio
» Gearing ratio

5.33
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 Review of Compressor Types:
Twin-Screw Compressors

● Typical construction of an oil-injected screw compressor with mechanical seal (open-drive

type):

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 Review of Compressor Types:
Twin-Screw Compressors

● Industrial-scale applications:

5.35
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 Review of Compressor Types:
Twin-Screw Compressors

● Capacity control mechanism:

5.36
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 Review of Compressor Types:
Single-Screw Compressors

● Twin-screw compressors operate with a pair of parallel screw rotors with spiraled convex-
and concave-shaped lobes
● A single-screw compressor comprises one grooved screw rotor and two gate rotors that
mesh perpendicularly with the screw rotor

● The single-screw mechanism was first invented by Zimmern (France) and patented
around 1960
5.37
» More than 20 years after twin-screw compressor were first put to use in late 1930s © A. Bahman
 Review of Compressor Types:
Single-Screw Compressors

● Similar to twin-screw compressors, single-screw compressors were first used for air compression.
Open-drive and semi-hermetic refrigeration compressors appeared to market late 1970s.
● Single-screw compressors can be theoretically classified into four-types, but only CP-type is used
commercially due to the complexity of manufacturing the other types
● Profile generation is based on double-envelope gearing theory

Leonardo da Vinci Worm Gear Type-B

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 Review of Compressor Types:
Single-Screw Compressors

● Single-screw compressors present balanced loading on the central rotor due to the simultaneous
compression process occurring on both sides of the rotor
» Extended bearing life
● The shape of the land between two consecutive grooves minimizes cascading effect of leakage
flows
● The accuracy in manufacturing of the rotors is essential to control the wear of tooth meshing profile

5.39
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 Review of Compressor Types:
Single-Screw Compressors

● Operating principle:

5.40
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 Review of Compressor Types:
Single-Screw Compressors

● Examples of semi-hermetic and open-drive single-screw compressors

5.41
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 Review of Compressor Types:
Single-Screw Compressors

● Similar to twin-screw compressors, also single-screw compressors have slide-valves to control

capacity and/or volume ratio
» Capacity control only

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 Review of Compressor Types:
Single-Screw Compressors

● Similar to twin-screw compressors, also single-screw compressors have slide-valves to control

capacity and/or volume ratio
» Volume ratio control only

5.43
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 Review of Compressor Types:
Single-Screw Compressors

● Similar to twin-screw compressors, also single-screw compressors have slide-valves to control

capacity and/or volume ratio
» Independent dual slide-valves

5.44
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 Review of Compressor Types:
Single-Screw Compressors

● Single-screw compressors are widely used for both air-compression and refrigeration for industrial
and commercial applications
● The complex manufacturing of the rotor limits their widely adoption with respect to twin-screw
compressors
● However, single-screw machines are suitable also low power range < 20 kW, a territory where
twin-screw machines struggle
● Current research concerns primarily novel profile design of the meshing pair by using non-
conventional manufacturing techniques (e.g., Ziviani et al. 2018)

5.45
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Review of Compressor Types:
Internally Geared Screw Compressors

Dmitrov, 2015

Dmitrov, 2017

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 Review of Compressor Types:
Internally Geared Screw Compressors

● The motivation is to improve the scalability of twin-screw compressors and take advantage
of advanced in rotor manufacturing techniques
● Small and fractional capacities. Usually, twin-screw machines are not effective in the low
power range <50 kW
● Absence of blowhole
● Potential reduction in over- and under-compression losses due to internal compression
instead of external compression
● Low friction materials to limit losses
● Axial discharge enables possible control over discharge pulsations. In twin-screw
compressors, discharge ports are tangential to the screw axis
● Higher rotational speeds

5.47
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 Review of Compressor Types:
Internally Geared Screw Compressors

● Rotor profiles and porting can be highly optimized in terms of shapes:

Conventional Gerotor type
internally geared pump Internal rotor profiles and loci of contact points as
function of 𝝀 (Beard, 1985)

Internal screw machine model

(Read, 2018)

5.48
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 Review of Compressor Types:
Internally Geared Screw Compressors

● Challenges in manufacturing rotors of this type with the requisite of high accuracy using efficient
and economical methods
● Advanced manufacturing techniques, e.g. additive material techniques, could expand the possible
profiles
● Only simple configuration using constant pitch and profile rotors with stationary porting has been
proven (Read et al., 2018)
● Only one commercial products by Vert Rotors

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 Review of Novel Compressor Types:
Linear Compressor

● History of linear compressor (Zhang et al., 2018)

5.50
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 Review of Novel Compressor Types:
Spool Compressor

● Achieve competitive compressor performance at significant reduced manufacturing costs:

» Introduced by Kemp et al. (2008,2010)
» Performance data presented by Orosz et al. (2012)
» Detailed models and analyses presented by Bradshaw et al. (2013, 2016, 2018)

5.51
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 Review of Novel Compressor Types:
Spool Compressor

● Four major components with simple

geometry for reduced manufacturing
costs

● Spool face motion nearly eliminates

frictional and leakage losses between
vane and face

● Active sealing elements allow for creative

solutions to minimize leakage and friction
5.52
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 Review of Novel Compressor Types:
Spool Compressor

● Evolution of the working chambers

Bradshaw et al. (2013). A comprehensive model of a novel rotating 5.53

spool compressor. Int. J. Refrigeration 36, 1974-1981 © A. Bahman
 Review of Novel Compressor Types:
Spool Compressor

● Experimental results of volumetric and overall isentropic efficiencies for 6th gen. spool
compressors:

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 Review of Novel Compressor Types:
Spool Compressor

● Experimental indicated diagram of 7th gen. spool compressor:

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 Review of Novel Compressor Types:
Spool Compressor

● Experimental indicated diagram of 7th gen. spool compressor:

Bradshaw et al. (2016). Development of a Loss Pareto for a 5.56

Rotating Spool Compressor…App. Thm. Engr. 99, 392-401 © A. Bahman
 Review of Novel Compressor Types:
Spool Compressor - Summary

● Latest prototype achieves very competitive

volumetric and energy efficiencies
● Manufacturing cost much lower than scroll
compressors
● Size range comparable to reciprocating
compressors
● Commercialization interaction with multiple
compressor manufacturers
● Concept shows good performance as an
expander in ORC applications ASHRAE/AHR Expo 2019

5.57
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 Review of Novel Compressor Types:
Linear Compressor

● Linear compressor is characterized by the absence of a crank mechanism which enables oil-
free operation:
» Piston is driven by moving magnet oscillating tubular motor
» Stroke is not fixed by the crank mechanism, but enforced by design and operating conditions
● Easy to modulate compressor capacity with the use of inverter
● Operation of the linear compressor reduces noise and vibration, and increases reliability over
conventional reciprocating compressors
● The linear compressor is effectively a vibration system and is characterized by a resonance
frequency
● A set of springs usually keeps the piston aligned with the cylinder and allows proper
reciprocating motion:
» Spring design requirements limit the scalability of linear compressors

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 Review of Novel Compressor Types:
Linear Compressor: Working Principle

Transient

Periodic
steady-state

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 Review of Novel Compressor Types:
Linear Compressor: Modeling

● Modeling approach:

Sub-models
Governing Equations • Leakage model
• Chamber model • Tube model
• Piston model • Flow path model
• Motor model • In-cylinder heat transfer
• Valve model • Friction loss
• Overall energy balance
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 Review of Novel Compressor Types:
Linear Compressor: Experimental Data

● Example of hermetic linear compressor for domestic refrigerators

with R-134a:

Description Value Unit

Working Fluid R134a -
Suction Pressure 111.81 kPa
Suction Temperature 8.08 oC

Pressure Ratio 5.5 -

Compressor Frequency 60 Hz

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 Review of Novel Compressor Types:
Linear Compressor: Experimental Data

● Example of hermetic linear compressor for domestic refrigerators with R-134a:

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 Review of Novel Compressor Types:
Linear Compressor: Summary

● Linear compressors are the highest performing

compressors on the market

● Linear compressors offer several opportunities for

design and control optimization

● Only two commercial products available:

» Embraco and LG
» Both are for refrigerator-freezer applications
(cooling capacity ~200 W)

● Research interest focuses on scaling to larger

capacities as well explore advanced cycle
architectures 5.63
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 References: Books

● General book on refrigeration with excellent chapters on compressors

» Mitchell, J.W., Braun, J.E., Principles of Heating, Ventilation, and Air Conditioning in Buildings,
J. Wiley & Sons (2013)
» ASHRAE Handbooks (Fundamentals, Refrigeration, HVACR Applications)
● General compressor book
» Compressors for Air Conditioning and Refrigeration, JSRAE Technical Book Series (English
vers.), 2018
● Specialized compressor books
» Proceedings of International Compressor Engineering Conferences at Purdue University
(Purdue ePubs)
» Proceeding International Conference on Compressors and their Systems at City University of
London (IOP Conference Series)

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 Additional References
• Adams G.P. “Modelling and Computer Simulation of Rotor Chatter and Oscillating Bearing Forces in Twin-Screw Compressors”. PhD Thesis,
Purdue University, 1993.
• Bell I.H. “Theoretical and experimental analysis of liquid flooded compression in scroll compressors”. PhD Thesis, Purdue University, 2011.
• Bahman, A.M., Ziviani, D., Groll, E.A., “Development and Validation of a Mechanistic Vapor-Compression Cycle Model”, International Refrigeration
and Air Conditioning Conference at Purdue, 2018. paper 2444.
• Casari N., Suman A., Ziviani D., van den Broek M., De Paepe M., Pinelli M. “Computational Models for the Analysis of positive displacement
machines: real gas and dynamic mesh. Energy Procedia 129(2017), 411-418. ”
• Chen, Y. “Mathematical modeling of scroll compressors”. PhD Thesis Purdue University, 2000.
• CRC Handbook of Thermal Engineering, Second Edition 2017. Chapter 4.11 “Compressors” Bach C.K., Bell I.H., Bradshaw C.R., Groll E.A.,
Krishna A., Kurtulus O., Mathison M., Shaffer B., Yang B., Zhang X., Ziviani D.
• Haykin S., “Neural Networks and Leaning Machines”, Third Edition, Pearson, 2009.
• Goodfellow, I., Bengio Y., Courville, A., “Deep learning (Adaptive computation and machine learning series)”, MIT, 2016
• Gulli A., Pal S. “Deep learning with Keras: implement neural networks with Keras on Teano and TensorFlow”, Packt, 2017
• Koai, K.L. “Mathematical modeling of twin screw compressors with special attention to gas pulsations in three-dimensional gas paths”. PhD Thesis,
Purdue University, 1990.
• Ledesma S., Belman-Flores J.M., Barroso-Maldonato J.M., “Analysis and modeling of a variable speed reciprocating compressor using ANN”,
International Journal of Refrigeration, 59(2015), 190-197.
• Lee, S.J., Shim, J., Kim, K.C., 2015. “Development of capacity modulation compressor based on a two stage rotary compressor – part I: Modeling
and simulation of compressor performance”, International Journal of Refrigeration, 54, 22-37.
• Lumpkin D.R., Bahman, A., Groll, E.A., “Two-phase injected and vapor-injected compression: Experimental results and mapping correlation for a
R-407C scroll compressor”. International Journal of Refrigeration, 86(2018), 449-462.
• Mathison, M.M. “Modeling and evaluation of advanced compression techniques for vapor compression equipment”. PhD Thesis, Purdue University
2011.
• Mathison, M.M., Braun, J.E., Groll, E.A., 2008. “Modeling of a Two-Stage Rotary Compressor”. HVAC&R Research, 14(5), 719-748
• Mendoza-Miranda, J.M., Mota-Babiloni A., Ramirez-Minguela, J.J., Munoz-Carpio V.D., Carrera-Rodriguez M., Navarro-Esbri J., Salazar-
Hernandez C., “Comparative evaluation of R1234yf,R1234ze(E) and R450A as alternatives to R134a in a variable speed reciprocating compressor,
Energy 114(2006), 753-766.”
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 Additional References, continued
• Ooi, K.T., Wong, T.N., 1997. “A computer simulation of a rotary compressor for household refrigerators”. Appl.
Therm. Eng., 17(1), 65-78
• Shaffer B.R. “Performance analysis of non-metallic dry running scroll compressors”. PhD Thesis, Purdue University,
2012.
• Tello-Oquendo, F.M., Navarro-Peris, E., Gonzalvez-Macia, J., “New characterization methodology for vapor injection
scroll compressors”, International Journal of Refrigeration, 74(2017), 528-539.
• Zendehboudi A., Li X., Wang B., “Utilization of ANN and ANFIS models to predict variable speed scroll compressor
with vapor injection”, International Journal of Refrigeration, 74(2017), 475-487
• Ziviani D., Suman A., Lecompte S., De Paepe M., van den Broek M., Spina P.R., Pinelli M., Venturini M., Beyene A.,
“Comparison of a Single-Screw and a Scroll Expander under Part-Load Conditions for low-grade heat recovery ORC
systems“, Energy Procedia 61(2014), 117-120.
• Ziviani D., Suman A., Gabrielloni J., Pinelli M., De Paepe M., van den Broek M., “CFD Approaches Applied to a Single-
Screw Expander”, 23rd International Compressor Engineering Conference at Purdue, 2016. Paper 1488.
• Ziviani, D. “Theoretical and experimental characterization of single-screw expanders for ORC applications”. PhD
Thesis, Ghent University, 2017.
• Ziviani, D., James, N.A., Accorsi, F.A., Braun, J.E., Groll, E.A., “Experimental and numerical analyses of a 5 kWe oil-
free open-drive scroll expander for small-scale ORC applications”. Applied Energy, 230(2018), 1140-1156.
• Ziviani, D., Bahman, A., James, N., Lumpkin, D., Braun, J.E., Groll, E.A., “Machine Learning Applied to Positive
Displacement Compressors and Expanders Performance Mapping”. International Compressor Engineering Conference
at Purdue, 2018. Paper 1170. [Ziviani et al., 2018b]
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List of Nomenclature

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List of Nomenclature

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