Multi Stage Reciprocating Air Compressor: Understanding The Mechanism
A Reciprocating compressor also called a piston compressor, is a positive-displacement air compressor system that comes with one or more cylinders, pistons, and a crankshaft.
While this air compressor system works well in certain industries for certain applications, it often fails to impress some industries which require high volumes of pressurized air to perform heavy-duty industrial applications.
That’s where multi-stage compressors come in.
In today’s blog, we will discuss the application and mechanism of a multi-stage reciprocating (piston) compressor. We will also address most FAQs about multi-stage reciprocating (piston) compressors.
The Working Mechanism of Multi-Stage Air Compressors
Multi-stage compressors consist of two or more different-sized piston cylinders.
The atmospheric air goes through the compression stage twice. Before going through the second cylinder, the air is cooled using the heat exchanger, which puts less strain on the chambers in the second and third compression stages.
Applications of A Multi-stage Reciprocating Air Compressor
When deciding on reciprocating compressors and its parts, consider the following four factors to determine whether or not a single-stage, two-stage, or three-stage, also called a multi-stage piston compressor, is the perfect fit for your application.
Pressure:
First and foremost, you need to identify the amount of pressure required to carry out the application. Single-stage compressors work well for low-pressure applications requiring 135 PSI. For a larger application, an industrial two-stage compressor is an ideal choice as it produces 90 PSI in the first compression stage and then 175 PSI in the second.
Multi-stage reciprocating compressors are used for super-heavy-duty applications that require a pressure of up to 6000 PSI. These compressors are suitable to handle air as well as other non-corrosive gases.
Need for Temperature Control:
Multi-stage compressors can control air temperature better than any other air compressor. The atmospheric air is cooled before entering each chamber, resulting in a lower temperature air output.
So, multi-stage compressors are your best fit if you need to maintain a certain temperature at the end-use consumption.
Need for Oil-free Applications:
Most Oil-free multi-stage compressors use an intercooler, which reduces the interstage temperature and reduces moisture (does condensate management). The quality of discharge air delivered is 100% Oil-free Class 0. These units are available in air and water-cooled options with discharge pressures of up to 40 bar.
Cost:
A single-stage compressor is a great choice if you only consider the initial cost. However, you shouldn’t confine your decision to buy and install an air compressor system only around the initial cost. You must also consider the operational and lifetime cost and then make an informed decision.
Electricity consumption contributes the most to an overall ownership cost of an air compressor. In this scenario, two-stage and three-stage compressors are a suitable choice as they cool air before every compression stage, which results in less work and more energy efficiency.
It makes sense to prioritize the correct equipment for your application based on energy efficiency and maintenance, the lifetime cost should be considered.
Most FAQs About Multistage Reciprocating Compressors
What Is a 2-Stage Air Compressor?
A two-stage air compressor refers to an air compressor that uses two cylinders to perform heavy-duty industrial applications. Unlike a single-stage compressor, a two-stage compressor uses two pistons for higher discharge pressures with more efficient performance and reliability.
What Is a 3-Stage Air Compressor?
A 3-stage compressor comprises three separate chambers that compress air at a higher level with the help of additional heat exchanges and chambers. Compared to single-stage and two-stage, three-stage air compressors are reliable on higher discharge pressures with better interstage temperatures, lower piston speeds and overall efficiency with less mechanical wear and tear.
What is the difference between a single-stage and a multistage compressor?
A single stage with only one cylinder carries out the compression procedure. However, a multi-stage compressor consists of more than one cylinder connected to produce high discharge pressures.
Are multi-stage compressors only used for reciprocating (piston) compressors?
Multi-stage compressors aren’t confined to reciprocating (piston) compressors. Multi-stage centrifugal compressor systems are common in industries like refineries, pulp and paper manufacturing hubs, and chemical and other processing plants. Also Oil-free Screw compressors are referred to as multi-stage, as typically they have 2 stages of compression in both air or water cooled variants.
Atlas Copco - A Trusted Multi-Stage Reciprocating Compressor Brand
Atlas Copco is a premium air compressor manufacturer and supplier. Its comprehensive range of products comprises single-stage, two-stage and three-stage air compressor systems, which are smartly manufactured for decreased inter-stage temperatures and increased uptime.
The multi-stage reciprocating compressors come as complete units, horizontally balanced skid mounted, which makes installation, operation and maintenance simple and efficient. HX/HN-15 produces 100% oil-free compressed air for high-pressure applications – making them a perfect fit for food and Beverage, PET, Water Transmission (surge vessel applications), electronics, laboratories and power industries.
Learn more about high-pressure and customized reciprocating gas compressors here.
You can download this brochure to better understand our multi-stage reciprocating compressors or directly talk to our experts.