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A compressor is a mechanical device that increases the
pressure Pressure (symbol: ''p'' or ''P'') is the force applied perpendicular to the surface of an object per unit area over which that force is distributed. Gauge pressure (also spelled ''gage'' pressure)The preferred spelling varies by country and e ...
of a
gas Gas is one of the four fundamental states of matter (the others being solid, liquid, and plasma). A pure gas may be made up of individual atoms (e.g. a noble gas like neon), elemental molecules made from one type of atom (e.g. oxygen), or ...
by reducing its
volume Volume is a measure of occupied three-dimensional space. It is often quantified numerically using SI derived units (such as the cubic metre and litre) or by various imperial or US customary units (such as the gallon, quart, cubic inch). Th ...
. An
air compressor An air compressor is a pneumatic device that converts power (using an electric motor, diesel or gasoline engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of several methods, an air compressor forces m ...
is a specific type of gas compressor. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a
pipe Pipe(s), PIPE(S) or piping may refer to: Objects * Pipe (fluid conveyance), a hollow cylinder following certain dimension rules ** Piping, the use of pipes in industry * Smoking pipe ** Tobacco pipe * Half-pipe and quarter pipe, semi-circular ...
. The main distinction is that the focus of a compressor is to change the density or volume of the fluid, which is mostly only achievable on gases. Gases are compressible, while liquids are relatively incompressible, so compressors are rarely used for liquids. The main action of a pump is to pressurize and transport liquids. Many compressors can be staged, that is, the fluid is compressed several times in steps or stages, to increase discharge pressure. Often, the second stage is physically smaller than the primary stage, to accommodate the already compressed gas without reducing its pressure. Each stage further compresses the gas and increases its pressure and also temperature (if inter cooling between stages is not used).


Types

The main and important types of gas compressors are illustrated and discussed below:


Positive displacement

A positive displacement compressor is a system that compresses the air by the displacement of a mechanical linkage reducing the volume (since the reduction in volume due to a piston in thermodynamics is considered as positive displacement of the piston). Put another way, a positive displacement compressor is one that operates by drawing in a discrete volume of gas from its inlet then forcing that gas to exit via the compressor's outlet. The increase in the pressure of the gas is due, at least in part, to the compressor pumping it at a mass flow rate which cannot pass through the outlet at the lower pressure and density of the inlet.


Reciprocating compressors

Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or portable, can be single or multi-staged, and can be driven by electric motors or internal combustion engines. Small reciprocating compressors from 5 to 30 
horsepower Horsepower (hp) is a unit of measurement of power, or the rate at which work is done, usually in reference to the output of engines or motors. There are many different standards and types of horsepower. Two common definitions used today are t ...
(hp) are commonly seen in automotive applications and are typically for intermittent duty. Larger reciprocating compressors well over are commonly found in large industrial and petroleum applications. Discharge pressures can range from low pressure to very high pressure (>18000 psi or 124 MPa). In certain applications, such as air compression, multi-stage double-acting compressors are said to be the most efficient compressors available, and are typically larger, and more costly than comparable rotary units. Another type of reciprocating compressor, usually employed in automotive cabin
air conditioning Air conditioning, often abbreviated as A/C or AC, is the process of removing heat from an enclosed space to achieve a more comfortable interior environment (sometimes referred to as 'comfort cooling') and in some cases also strictly controlling ...
systems, is the swash plate or wobble plate compressor, which uses pistons moved by a swash plate mounted on a shaft (see '' axial piston pump''). Household, home workshop, and smaller job site compressors are typically reciprocating compressors 1½ hp or less with an attached receiver tank. A
linear compressor A linear compressor is a gas compressor where the piston moves along a linear track to minimize friction and reduce energy loss during conversion of motion. This technology has been successfully used in cryogenic applications which must be oilless ...
is a reciprocating compressor with the piston being the rotor of a linear motor. This type of compressor can compress a wide range of gases, including refrigerant, hydrogen, and natural gas. Because of this, it finds use in a wide range of applications in many different industries and can be designed to a wide range of capacities, by varying size, number of cylinders, and cylinder unloading. However, it suffers from higher losses due to clearance volumes, resistance due to discharge and suction valves, weighs more, is difficult to maintain due to having a large number of moving parts, and it has inherent vibration.


Ionic liquid piston compressor

An
ionic liquid piston compressor An ionic liquid piston compressor, ionic compressor or ionic liquid piston pump is a hydrogen compressor based on an ionic liquid piston instead of a metal piston as in a piston-metal diaphragm compressor. Principle An ionic liquid compressor tak ...
, ''ionic compressor'' or ''ionic liquid piston pump'' is a
hydrogen compressor A hydrogen compressor is a device that increases the pressure of hydrogen by reducing its volume resulting in compressed hydrogen or liquid hydrogen. Traditionally, applications for hydrogen compressors included Chlorine electrolyser and many che ...
based on an
ionic liquid An ionic liquid (IL) is a salt in the liquid state. In some contexts, the term has been restricted to salts whose melting point is below a specific temperature, such as . While ordinary liquids such as water and gasoline are predominantly made of ...
piston instead of a metal piston as in a piston-metal
diaphragm compressor {{Short description, Variant of the reciprocating compressor A diaphragm compressor is a variant of the classic reciprocating compressor with backup and piston rings and rod seal. The compression of gas occurs by means of a flexible membrane, inste ...
.


Rotary screw compressors

Rotary screw compressors use two meshed rotating positive-displacement helical screws to force the gas into a smaller space. These are usually used for continuous operation in commercial and industrial applications and may be either stationary or portable. Their application can be from to over and from low pressure to moderately high pressure (>). The classifications of rotary screw compressors vary based on stages, cooling methods, and drive types among others. Rotary screw compressors are commercially produced in Oil Flooded, Water Flooded and Dry type. The efficiency of rotary compressors depends on the air drier, and the selection of air drier is always 1.5 times volumetric delivery of the compressor. Designs with a single screw or three screws instead of two exist. Screw compressors have fewer moving components, larger capacity, less vibration and surging, can operate at variable speeds, and typically have higher efficiency. Small sizes or low rotor speeds are not practical due to inherent leaks caused by clearance between the compression cavities or screws and compressor housing. They depend on fine machining tolerances to avoid high leakage losses and are prone to damage if operated incorrectly or poorly serviced.


Rotary vane compressors

Rotary vane compressors consist of a rotor with a number of blades inserted in radial slots in the rotor. The rotor is mounted offset in a larger housing that is either circular or a more complex shape. As the rotor turns, blades slide in and out of the slots keeping contact with the outer wall of the housing. Thus, a series of increasing and decreasing volumes is created by the rotating blades. Rotary vane compressors are, with piston compressors one of the oldest of compressor technologies. With suitable port connections, the devices may be either a compressor or a vacuum pump. They can be either stationary or portable, can be single or multi-staged, and can be driven by electric motors or internal combustion engines. Dry vane machines are used at relatively low pressures (e.g., ) for bulk material movement while oil-injected machines have the necessary volumetric efficiency to achieve pressures up to about in a single stage. A rotary vane compressor is well suited to electric motor drive and is significantly quieter in operation than the equivalent piston compressor. Rotary vane compressors can have mechanical efficiencies of about 90%.


Rolling piston

The Rolling piston in a rolling piston style compressor plays the part of a partition between the vane and the rotor. Rolling piston forces gas against a stationary vane. 2 of these compressors can be mounted on the same shaft to increase capacity and reduce vibration and noise. A design without a spring is known as a swing compressor. In refrigeration and air conditioning, this type of compressor is also known as a rotary compressor, with rotary screw compressors being also known simply as screw compressors. It offers higher efficiency than reciprocating compressors due to less losses from the clearance volume between the piston and the compressor casing, it's 40% to 50% smaller and lighter for a given capacity (which can impact material and shipping costs when used in a product), causes less vibration, has fewer components and is more reliable than a reciprocating compressor. But its structure does not allow capacities beyond 5 refrigeration tons, is less reliable than other compressor types, and is less efficient than other compressor types due to losses from the clearance volume.


Scroll compressors

A scroll compressor, also known as scroll pump and scroll vacuum pump, uses two interleaved spiral-like vanes to pump or compress fluids such as
liquids A liquid is a nearly incompressible fluid that conforms to the shape of its container but retains a (nearly) constant volume independent of pressure. As such, it is one of the four fundamental states of matter (the others being solid, gas, a ...
and
gas Gas is one of the four fundamental states of matter (the others being solid, liquid, and plasma). A pure gas may be made up of individual atoms (e.g. a noble gas like neon), elemental molecules made from one type of atom (e.g. oxygen), or ...
es. The vane geometry may be
involute In mathematics, an involute (also known as an evolvent) is a particular type of curve that is dependent on another shape or curve. An involute of a curve is the locus of a point on a piece of taut string as the string is either unwrapped from or ...
, archimedean spiral, or hybrid curves. They operate more smoothly, quietly, and reliably than other types of compressors in the lower volume range. Often, one of the scrolls is fixed, while the other orbits eccentrically without rotating, thereby trapping and pumping or compressing pockets of fluid between the scrolls. Due to minimum clearance volume between the fixed scroll and the orbiting scroll, these compressors have a very high
volumetric efficiency Volumetric efficiency (VE) in internal combustion engine engineering is defined as the ratio of the mass density of the air-fuel mixture drawn into the cylinder at atmospheric pressure (during the intake stroke) to the mass density of the same volu ...
. These compressors are extensively used in air conditioning and refrigeration because they are lighter, smaller and have fewer moving parts than reciprocating compressors and they are also more reliable. They are more expensive though, so peltier coolers or rotary and reciprocating compressors may be used in applications where cost is the most important or one of the most important factors to consider when designing a refrigeration or air conditioning system. This type of compressor was used as the supercharger on Volkswagen G60 and G40 engines in the early 1990s. When compared with reciprocating and rolling piston compressors, scroll compressors are more reliable since they have fewer components and have a simpler structure, are more efficient since they have no clearance volume nor valves, and possess the advantages both of surging less and not vibrating so much. But, when compared with screw and centrifugal compressors, scroll compressors have lower efficiencies and smaller capacities.


Diaphragm compressors

A diaphragm compressor (also known as a membrane compressor) is a variant of the conventional reciprocating compressor. The compression of gas occurs by the movement of a flexible membrane, instead of an intake element. The back-and-forth movement of the membrane is driven by a rod and a crankshaft mechanism. Only the membrane and the compressor box come in contact with the gas being compressed. The degree of flexing and the material constituting the diaphragm affects the maintenance life of the equipment. Generally stiff metal diaphragms may only displace a few cubic centimeters of volume because the metal cannot endure large degrees of flexing without cracking, but the stiffness of a metal diaphragm allows it to pump at high pressures. Rubber or silicone diaphragms are capable of enduring deep pumping strokes of very high flexion, but their low strength limits their use to low-pressure applications, and they need to be replaced as plastic embrittlement occurs. Diaphragm compressors are used for hydrogen and compressed natural gas (
CNG Compressed natural gas (CNG) is a fuel gas mainly composed of methane (CH4), compressed to less than 1% of the volume it occupies at standard atmospheric pressure. It is stored and distributed in hard containers at a pressure of , usually in cy ...
) as well as in a number of other applications. The photograph on the right depicts a three-stage diaphragm compressor used to compress hydrogen gas to for use in a prototype
compressed hydrogen Compressed hydrogen (CH2, CGH2 or CGH2) is the gaseous state of the element hydrogen kept under pressure. Compressed hydrogen in hydrogen tanks at 350 bar (5,000 psi) and 700 bar (10,000 psi) is used for mobile hydrogen storage in hydrogen vehic ...
and
compressed natural gas Compressed natural gas (CNG) is a fuel gas mainly composed of methane (CH4), compressed to less than 1% of the volume it occupies at standard atmospheric pressure. It is stored and distributed in hard containers at a pressure of , usually in cy ...
(CNG) fueling station built in downtown
Phoenix, Arizona Phoenix ( ; nv, Hoozdo; es, Fénix or , yuf-x-wal, Banyà:nyuwá) is the capital and most populous city of the U.S. state of Arizona, with 1,608,139 residents as of 2020. It is the fifth-most populous city in the United States, and the on ...
by the
Arizona Public Service Arizona Public Service (APS) is the largest electric utility in Arizona, United States. Since 1985, it has been the principal subsidiary of publicly traded S&P 500 member Pinnacle West Capital Corporation, known as AZP Group until 1987. Pinnacl ...
company (an electric utilities company).
Reciprocating compressor A reciprocating compressor or piston compressor is a positive-displacement compressor that uses pistons driven by a crankshaft to deliver gases at high pressure. Pressures of up to 5,000 PSIG are commonly produced by multistage reciprocating ...
s were used to compress the
natural gas Natural gas (also called fossil gas or simply gas) is a naturally occurring mixture of gaseous hydrocarbons consisting primarily of methane in addition to various smaller amounts of other higher alkanes. Low levels of trace gases like carbo ...
. The reciprocating natural gas compressor was developed by
Sertco In April 1979, Sertco Industries, Inc. was incorporated for the purpose of general manufacturing and assembly as well as sales of machined parts. Operations began using the latest CNC machinery available at the time. As of 2015, the company employs ...
. The prototype
alternative fuel Alternative fuel, known as non-conventional and advanced fuels, are any materials or substances that can be used as fuels, other than conventional fuels like; ''fossil fuels'' (petroleum (oil), coal, and natural gas), as well as nuclear materi ...
ing station was built in compliance with all of the prevailing safety, environmental and building codes in Phoenix to demonstrate that such fueling stations could be built in urban areas.


Dynamic


Air bubble compressor

Also known as a
trompe A trompe is a water-powered air compressor, commonly used before the advent of the electric-powered compressor. A trompe is somewhat like an airlift pump working in reverse. Trompes were used to provide compressed air for bloomery furnaces ...
. A mixture of air and water generated through turbulence is allowed to fall into a subterranean chamber where the air separates from the water. The weight of falling water compresses the air in the top of the chamber. A submerged outlet from the chamber allows water to flow to the surface at a lower height than the intake. An outlet in the roof of the chamber supplies the compressed air to the surface. A facility on this principle was built on the Montreal River at Ragged Shutes near Cobalt, Ontario in 1910 and supplied 5,000 horsepower to nearby mines.


Centrifugal compressors

Centrifugal compressors use a rotating disk or
impeller An impeller or impellor is a rotor used to increase the pressure and flow of a fluid. It is the opposite of a turbine, which extracts energy from, and reduces the pressure of, a flowing fluid. In pumps An impeller is a rotating componen ...
in a shaped housing to force the gas to the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section converts the velocity energy to pressure energy. They are primarily used for continuous, stationary service in industries such as
oil refineries An oil refinery or petroleum refinery is an industrial process plant where petroleum (crude oil) is transformed and refined into useful products such as gasoline (petrol), diesel fuel, asphalt base, fuel oils, heating oil, kerosene, lique ...
,
chemical A chemical substance is a form of matter having constant chemical composition and characteristic properties. Some references add that chemical substance cannot be separated into its constituent elements by physical separation methods, i.e., w ...
and
petrochemical Petrochemicals (sometimes abbreviated as petchems) are the chemical products obtained from petroleum by refining. Some chemical compounds made from petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewable so ...
plants and natural gas processing plants. Their application can be from to thousands of horsepower. With multiple staging, they can achieve high output pressures greater than . This type of compressor, along with screw compressors, are extensively used in large refrigeration and air conditioning systems. Magnetic bearing (magnetically levitated) and air bearing centrifugal compressors exist. Many large
snowmaking Snowmaking is the production of snow by forcing water and pressurized air through a "snow gun", also known as a "snow cannon". Snowmaking is mainly used at ski resorts to supplement natural snow. This allows ski resorts to improve the reliabilit ...
operations (like
ski resorts A ski resort is a resort developed for skiing, snowboarding, and other winter sports. In Europe, most ski resorts are towns or villages in or adjacent to a ski area – a mountainous area with pistes (ski trails) and a ski lift system. In ...
) use this type of compressor. They are also used in internal combustion engines as superchargers and
turbocharger In an internal combustion engine, a turbocharger (often called a turbo) is a forced induction device that is powered by the flow of exhaust gases. It uses this energy to compress the intake gas, forcing more air into the engine in order to pro ...
s. Centrifugal compressors are used in small
gas turbine A gas turbine, also called a combustion turbine, is a type of continuous flow internal combustion engine. The main parts common to all gas turbine engines form the power-producing part (known as the gas generator or core) and are, in the directio ...
engine An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy. Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power ...
s or as the final compression stage of medium-sized gas turbines. Centrifugal compressors are the largest available compressors, offer higher efficiencies under partial loads, may be oil-free when using air or magnetic bearings which increases the heat transfer coefficient in evaporators and condensers, weigh up to 90% less and occupy 50% less space than reciprocating compressors, are reliable and cost less to maintain since less components are exposed to wear, and only generate minimal vibration. But, their initial cost is higher, require highly precise
CNC Numerical control (also computer numerical control, and commonly called CNC) is the automated control of machining tools (such as drills, lathes, mills, grinders, routers and 3D printers) by means of a computer. A CNC machine processes a p ...
machining, the impeller needs to rotate at high speeds making small compressors impractical, and surging becomes more likely. Surging is gas flow reversal, meaning that the gas goes from the discharge to the suction side, which can cause serious damage, specially in the compressor bearings and its drive shaft. It is caused by a pressure on the discharge side that is higher than the output pressure of the compressor. This can cause gases to flow back and forth between the compressor and whatever is connected to its discharge line, causing oscillations.


Diagonal or mixed-flow compressors

Diagonal or mixed-flow compressors are similar to centrifugal compressors, but have a radial and axial velocity component at the exit from the rotor. The diffuser is often used to turn diagonal flow to an axial rather than radial direction. Comparative to the conventional centrifugal compressor (of the same stage pressure ratio), the value of the speed of the mixed flow compressor is 1.5 times larger.


Axial compressors

Axial compressors are dynamic rotating compressors that use arrays of fan-like airfoils to progressively compress a fluid. They are used where high flow rates or a compact design are required. The arrays of airfoils are set in rows, usually as pairs: one rotating and one stationary. The rotating airfoils, also known as blades or ''rotors'', accelerate the fluid. The stationary airfoils, also known as ''stators'' or vanes, decelerate and redirect the flow direction of the fluid, preparing it for the rotor blades of the next stage. Axial compressors are almost always multi-staged, with the cross-sectional area of the gas passage diminishing along the compressor to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1 design pressure ratio a compressor will not function unless fitted with features such as stationary vanes with variable angles (known as variable inlet guide vanes and variable stators), the ability to allow some air to escape part-way along the compressor (known as interstage bleed) and being split into more than one rotating assembly (known as twin spools, for example). Axial compressors can have high efficiencies; around 90%
polytropic A polytropic process is a thermodynamic process that obeys the relation: p V^ = C where ''p'' is the pressure, ''V'' is volume, ''n'' is the polytropic index, and ''C'' is a constant. The polytropic process equation describes expansion and com ...
at their design conditions. However, they are relatively expensive, requiring a large number of components, tight tolerances and high quality materials. Axial compressors are used in medium to large
gas turbine A gas turbine, also called a combustion turbine, is a type of continuous flow internal combustion engine. The main parts common to all gas turbine engines form the power-producing part (known as the gas generator or core) and are, in the directio ...
engines, natural gas pumping stations, and some chemical plants.


Hermetically sealed, open, or semi-hermetic

Compressors used in
refrigeration The term refrigeration refers to the process of removing heat from an enclosed space or substance for the purpose of lowering the temperature.International Dictionary of Refrigeration, http://dictionary.iifiir.org/search.phpASHRAE Terminology, ht ...
systems must exhibit near-zero leakage to avoid the loss of the refrigerant if they are to function for years without service. This necessitates the use of very effective seals, or even the elimination of all seals and openings to form a
hermetic Hermetic or related forms may refer to: * of or related to the ancient Greek Olympian god Hermes * of or related to Hermes Trismegistus, a legendary Hellenistic figure based on the Greek god Hermes and the Egyptian god Thoth ** , the ancient and m ...
system. These compressors are often described as being either hermetic, open, or semi-hermetic, to describe how the compressor is enclosed and how the
motor An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy. Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power g ...
drive is situated in relation to the gas or vapor being compressed. Some compressors outside of refrigeration service may also be hermetically sealed to some extent, typically when handling toxic, polluting, or expensive gasses, with most non-refrigeration applications being in the petrochemical industry. In hermetic and most semi-hermetic compressors, the compressor and motor driving the compressor are integrated, and operate within the pressurized gas envelope of the system. The motor is designed to operate in, and be cooled by, the refrigerant gas being compressed. Open compressors have an external motor driving a shaft that passes through the body of the compressor and rely on rotary seals around the shaft to retain the internal pressure. The difference between the hermetic and semi-hermetic, is that the hermetic uses a one-piece welded steel casing that cannot be opened for repair; if the hermetic fails it is simply replaced with an entire new unit. A semi-hermetic uses a large cast metal shell with gasketed covers with screws that can be opened to replace motor and compressor components. The primary advantage of a hermetic and semi-hermetic is that there is no route for the gas to leak out of the system. The main advantages of open compressors is that they can be driven by any motive power source, allowing the most appropriate motor to be selected for the application, or even non-electric power sources such as an
internal combustion engine An internal combustion engine (ICE or IC engine) is a heat engine in which the combustion of a fuel occurs with an oxidizer (usually air) in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal c ...
or steam
turbine A turbine ( or ) (from the Greek , ''tyrbē'', or Latin ''turbo'', meaning vortex) is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The work produced by a turbine can be used for generating ...
, and secondly the motor of an open compressor can be serviced without opening any part of the refrigerant system. An open pressurized system such as an automobile air conditioner can be more susceptible to leak its operating gases. Open systems rely on lubricant in the system to splash on pump components and seals. If it is not operated frequently enough, the lubricant on the seals slowly evaporates, and then the seals begin to leak until the system is no longer functional and must be recharged. By comparison, a hermetic or semi-hermetic system can sit unused for years, and can usually be started up again at any time without requiring maintenance or experiencing any loss of system pressure. Even well lubricated seals will leak a small amount of gas over time, particularly if the refrigeration gasses are soluble in the lubricating oil, but if the seals are well manufactured and maintained this loss is very low. The disadvantage of hermetic compressors is that the motor drive cannot be repaired or maintained, and the entire compressor must be replaced if a motor fails. A further disadvantage is that burnt-out windings can contaminate the whole systems, thereby requiring the system to be entirely pumped down and the gas replaced (This can also happen in semi hermetic compressors where the motor operates in the refrigerant). Typically, hermetic compressors are used in low-cost factory-assembled consumer goods where the cost of repair and labor is high compared to the value of the device, and it would be more economical to just purchase a new device or compressor. Semi-hermetic compressors are used in mid-sized to large refrigeration and air conditioning systems, where it is cheaper to repair and/or refurbish the compressor compared to the price of a new one. A hermetic compressor is simpler and cheaper to build than a semi-hermetic or open compressor.


Thermodynamics of gas compression


Isentropic compressor

A compressor can be idealized as internally reversible and adiabatic, thus an
isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
steady state device, meaning the change in
entropy Entropy is a scientific concept, as well as a measurable physical property, that is most commonly associated with a state of disorder, randomness, or uncertainty. The term and the concept are used in diverse fields, from classical thermodynam ...
is 0.Cengel, Yunus A., and Michaeul A. Boles. Thermodynamics: An Engineering Approach. 7th Edition ed. New York: Mcgraw-Hill, 2012. Print. The enthalpy change for a flow process can be calculated. dH = VdP +TdS Isentropic dS is zero. dH = VdP Non flow isentropic processes like some positive displacement compressors may use a different equation. dH = PdV By defining the compression cycle as
isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
, an ideal efficiency for the process can be attained, and the ideal compressor performance can be compared to the actual performance of the machine. Isotropic Compression as used in
ASME The American Society of Mechanical Engineers (ASME) is an American professional association that, in its own words, "promotes the art, science, and practice of multidisciplinary engineering and allied sciences around the globe" via "continuing ...
PTC 10 Code refers to a reversible, adiabatic compression process Isentropic efficiency of Compressors: : \eta _C = \frac=\frac \cong \frac : h_1 is the
enthalpy Enthalpy , a property of a thermodynamic system, is the sum of the system's internal energy and the product of its pressure and volume. It is a state function used in many measurements in chemical, biological, and physical systems at a constant ...
at the initial state : h_ is the
enthalpy Enthalpy , a property of a thermodynamic system, is the sum of the system's internal energy and the product of its pressure and volume. It is a state function used in many measurements in chemical, biological, and physical systems at a constant ...
at the final state for the actual process : h_ is the
enthalpy Enthalpy , a property of a thermodynamic system, is the sum of the system's internal energy and the product of its pressure and volume. It is a state function used in many measurements in chemical, biological, and physical systems at a constant ...
at the final state for the isentropic process


Minimizing work required by a compressor


Comparing reversible to irreversible compressors

Comparison of the differential form of the energy balance for each device. Let q be heat, w be work, ke be kinetic energy and pe be potential energy. Actual Compressor:
: \delta q_ - \delta w_ = dh + dke + dpe Reversible Compressor:
: \delta q_ - \delta w_ = dh + dke + dpe
The right hand side of each compressor type is equivalent, thus:
: \delta q_ - \delta w_ = \delta q_ - \delta w_ re-arranging:
: \delta w_ - \delta w_ = \delta q_ - \delta q_
By substituting the known equation \delta q_ =T ds into the last equation and dividing both terms by T:
: \frac =ds - \frac \geq 0
Furthermore, ds \geq \frac and T is bsolute temperature( T \geq 0 ) which produces:
\delta w_ \geq \delta w_ or
w_ \geq w_ Therefore, work-consuming devices such as pumps and compressors (work is negative) require less work when they operate reversibly.


Effect of cooling during the compression process

isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
process: involves no cooling,
polytropic A polytropic process is a thermodynamic process that obeys the relation: p V^ = C where ''p'' is the pressure, ''V'' is volume, ''n'' is the polytropic index, and ''C'' is a constant. The polytropic process equation describes expansion and com ...
process: involves some cooling
isothermal In thermodynamics, an isothermal process is a type of thermodynamic process in which the temperature ''T'' of a system remains constant: Δ''T'' = 0. This typically occurs when a system is in contact with an outside thermal reservoir, and ...
process: involves maximum cooling By making the following assumptions the required work for the compressor to compress a gas from P_1 to P_2 is the following for each process:
Assumptions:
: P_1 and P_2 : Flow processes VdP : All processes are internally reversible : The gas behaves like an
ideal gas An ideal gas is a theoretical gas composed of many randomly moving point particles that are not subject to interparticle interactions. The ideal gas concept is useful because it obeys the ideal gas law, a simplified equation of state, and is a ...
with constant
specific heats Heat capacity or thermal capacity is a physical property of matter, defined as the amount of heat to be supplied to an object to produce a unit change in its temperature. The SI unit of heat capacity is joule per kelvin (J/K). Heat capacity i ...
Isentropic ( Pv^k = constant , where k = C_p/C_v):
: W_= \frac=\frac \left \left ( \frac \right ) ^ -1 \right Polytropic ( Pv^n = constant ):
: W_= \frac=\frac \left \left ( \frac \right ) ^ -1 \right Isothermal (T = constant or Pv = constant):
: W_= RT ln \left ( \frac\right ) By comparing the three internally reversible processes compressing an ideal gas from P_1 to P_2, the results show that isentropic compression ( Pv^k = constant ) requires the most work in and the isothermal compression(T = constant or Pv = constant) requires the least amount of work in. For the polytropic process ( Pv^n = constant ) work in decreases as the exponent, n, decreases, by increasing the heat rejection during the compression process. One common way of cooling the gas during compression is to use cooling jackets around the casing of the compressor.


Compressors in ideal thermodynamic cycles

Ideal
Rankine Cycle The Rankine cycle is an idealized thermodynamic cycle describing the process by which certain heat engines, such as steam turbines or reciprocating steam engines, allow mechanical work to be extracted from a fluid as it moves between a heat sourc ...
1->2
Isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
compression in a pump
Ideal
Carnot Cycle A Carnot cycle is an ideal thermodynamic cycle proposed by French physicist Sadi Carnot in 1824 and expanded upon by others in the 1830s and 1840s. By Carnot's theorem, it provides an upper limit on the efficiency of any classical thermodynam ...
4->1
Isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
compression
Ideal
Otto Cycle An Otto cycle is an idealized thermodynamic cycle that describes the functioning of a typical spark ignition piston engine. It is the thermodynamic cycle most commonly found in automobile engines. The Otto cycle is a description of what hap ...
1->2
Isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
compression
Ideal
Diesel Cycle The Diesel cycle is a combustion process of a reciprocating internal combustion engine. In it, fuel is ignited by heat generated during the compression of air in the combustion chamber, into which fuel is then injected. This is in contrast to ign ...
1->2
Isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
compression
Ideal
Brayton Cycle The Brayton cycle is a thermodynamic cycle that describes the operation of certain heat engines that have air or some other gas as their working fluid. The original Brayton engines used a piston compressor and piston expander, but modern gas tu ...
1->2
Isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
compression in a compressor
Ideal Vapor-compression refrigeration Cycle 1->2
Isentropic In thermodynamics, an isentropic process is an idealized thermodynamic process that is both adiabatic and reversible. The work transfers of the system are frictionless, and there is no net transfer of heat or matter. Such an idealized process ...
compression in a compressor
NOTE: The isentropic assumptions are only applicable with ideal cycles. Real world cycles have inherent losses due to inefficient compressors and turbines. The real world system are not truly isentropic but are rather idealized as isentropic for calculation purposes.


Temperature

Compression of a gas increases its
temperature Temperature is a physical quantity that expresses quantitatively the perceptions of hotness and coldness. Temperature is measurement, measured with a thermometer. Thermometers are calibrated in various Conversion of units of temperature, temp ...
. For a polytropic transformation of a gas: : \begin pV^n=\text=p_1V_1^n=p_2V_2^n \Rightarrow \frac \ = \left( \frac \right) ^ n & \\ \frac=\text=\frac=\frac \Rightarrow \left( \frac \right) ^ \frac = \frac & \end The work done for polytropic compression (or expansion) of a gas into a closed cylinder. : W = \int_^ p dV = p_1 V_1^n \int_^ V^ dV = \frac (V_2^ - V_1^) = \frac V_1^ \left( \frac -1 \right) = \frac \left( \frac -1 \right) = : = \frac \left( \left( \frac \right)^ -1 \right) = \frac \left( \left( \frac \right)^ -1 \right) = \frac \left( \frac -1 \right) so : W = - \frac \left( \left( \frac \right)^ -1 \right) in which ''p'' is pressure, ''V'' is volume, ''n'' takes different values for different compression processes (see below), and 1 & 2 refer to initial and final states. * Adiabatic – This model assumes that no energy (heat) is transferred to or from the gas during the compression, and all supplied work is added to the internal energy of the gas, resulting in increases of temperature and pressure. Theoretical temperature rise is: : T_2 = T_1 \left(\frac \right)^ with ''T''1 and ''T''2 in degrees Rankine or
kelvin The kelvin, symbol K, is the primary unit of temperature in the International System of Units (SI), used alongside its prefixed forms and the degree Celsius. It is named after the Belfast-born and University of Glasgow-based engineer and phy ...
s, ''p''2 and ''p''1 being absolute pressures and \kappa = ratio of specific heats (approximately 1.4 for air). The rise in air and temperature ratio means compression does not follow a simple pressure to volume ratio. This is less efficient, but quick. Adiabatic compression or expansion more closely model real life when a compressor has good insulation, a large gas volume, or a short time scale (i.e., a high power level). In practice there will always be a certain amount of heat flow out of the compressed gas. Thus, making a perfect adiabatic compressor would require perfect heat insulation of all parts of the machine. For example, even a bicycle tire pump's metal tube becomes hot as you compress the air to fill a tire. The relation between temperature and compression ratio described above means that the value of n for an adiabatic process is \kappa (the ratio of specific heats). *
Isothermal In thermodynamics, an isothermal process is a type of thermodynamic process in which the temperature ''T'' of a system remains constant: Δ''T'' = 0. This typically occurs when a system is in contact with an outside thermal reservoir, and ...
– This model assumes that the compressed gas remains at a constant temperature throughout the compression or expansion process. In this cycle, internal energy is removed from the system as heat at the same rate that it is added by the mechanical work of compression. Isothermal compression or expansion more closely models real life when the compressor has a large heat exchanging surface, a small gas volume, or a long time scale (i.e., a small power level). Compressors that utilize inter-stage cooling between compression stages come closest to achieving perfect isothermal compression. However, with practical devices perfect isothermal compression is not attainable. For example, unless you have an infinite number of compression stages with corresponding intercoolers, you will never achieve perfect isothermal compression. For an isothermal process, n is 1, so the value of the work integral for an isothermal process is: : W = \int_^ p dV = p_1 V_1 \int_^ \frac dV = p_1 V_1 \ln \frac = - p_1 V_1 \ln \left( \frac \right) When evaluated, the isothermal work is found to be lower than the adiabatic work. *
Polytropic A polytropic process is a thermodynamic process that obeys the relation: p V^ = C where ''p'' is the pressure, ''V'' is volume, ''n'' is the polytropic index, and ''C'' is a constant. The polytropic process equation describes expansion and com ...
– This model takes into account both a rise in temperature in the gas as well as some loss of energy (heat) to the compressor's components. This assumes that heat may enter or leave the system, and that input shaft work can appear as both increased pressure (usually useful work) and increased temperature above adiabatic (usually losses due to cycle efficiency). Compression efficiency is then the ratio of temperature rise at theoretical 100 percent (adiabatic) vs. actual (polytropic). Polytropic compression will use a value of n between 0 (a constant-pressure process) and infinity (a constant volume process). For the typical case where an effort is made to cool the gas compressed by an approximately adiabatic process, the value of n will be between 1 and \kappa.


Staged compression

In the case of centrifugal compressors, commercial designs currently do not exceed a compression ratio of more than 3.5 to 1 in any one stage (for a typical gas). Since compression raises the temperature, the compressed gas is to be cooled between stages making the compression less adiabatic and more isothermal. The inter-stage coolers (intercoolers) typically result in some partial condensation that is removed in
vapor–liquid separator In chemical engineering, a vapor–liquid separator is a device used to separate a vapor–liquid mixture into its constituent phases. It can be a vertical or horizontal vessel, and can act as a 2-phase or 3-phase separator. A vapor–liquid ...
s. In the case of small reciprocating compressors, the compressor flywheel may drive a cooling fan that directs ambient air across the intercooler of a two or more stage compressor. Because rotary screw compressors can make use of cooling lubricant to reduce the temperature rise from compression, they very often exceed a 9 to 1 compression ratio. For instance, in a typical diving compressor the air is compressed in three stages. If each stage has a compression ratio of 7 to 1, the compressor can output 343 times atmospheric pressure (7 × 7 × 7 = 343 atmospheres). ()


Drive motors

There are many options for the motor that powers the compressor: * Gas
turbine A turbine ( or ) (from the Greek , ''tyrbē'', or Latin ''turbo'', meaning vortex) is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The work produced by a turbine can be used for generating ...
s power the axial and centrifugal flow compressors that are part of jet engines. * Steam turbines or
water turbine A water turbine is a rotary machine that converts kinetic energy and potential energy of water into mechanical work. Water turbines were developed in the 19th century and were widely used for industrial power prior to electrical grids. Now, ...
s are possible for large compressors. *
Electric motor An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate for ...
s are cheap and quiet for static compressors. Small motors suitable for domestic electrical supplies use
single-phase In electrical engineering, single-phase electric power (abbreviated 1φ) is the distribution of alternating current electric power using a system in which all the voltages of the supply vary in unison. Single-phase distribution is used when load ...
alternating current Alternating current (AC) is an electric current which periodically reverses direction and changes its magnitude continuously with time in contrast to direct current (DC) which flows only in one direction. Alternating current is the form in whic ...
. Larger motors can only be used where an industrial electrical
three phase Three-phase electric power (abbreviated 3φ) is a common type of alternating current used in electricity generation, transmission, and distribution. It is a type of polyphase system employing three wires (or four including an optional neutral ...
alternating current supply is available. *
Diesel engine The diesel engine, named after Rudolf Diesel, is an internal combustion engine in which ignition of the fuel is caused by the elevated temperature of the air in the cylinder due to mechanical compression; thus, the diesel engine is a so-ca ...
s or
petrol engine A petrol engine (gasoline engine in American English) is an internal combustion engine designed to run on petrol (gasoline). Petrol engines can often be adapted to also run on fuels such as liquefied petroleum gas and ethanol blends (such as ' ...
s are suitable for portable compressors and support compressors. * In automobiles and other types of vehicles (including piston-powered airplanes, boats, trucks, etc.), diesel or gasoline engine's power output can be increased by compressing the intake air, so that more fuel can be burned per cycle. These engines can power compressors using their own crankshaft power (this setup known as a supercharger), or, use their exhaust gas to drive a turbine connected to the compressor (this setup known as a
turbocharger In an internal combustion engine, a turbocharger (often called a turbo) is a forced induction device that is powered by the flow of exhaust gases. It uses this energy to compress the intake gas, forcing more air into the engine in order to pro ...
).


Lubrication

Compressors that are driven by an electric motor can be controlled using a
VFD VFD may refer to: * Factory Workers' Union of Germany, (german: Verband der Fabrikarbeiter Deutschlands, link=no), a former trade union in Germany * Vacuum fluorescent display, a display device on consumer electronics equipment * Variable-freque ...
or
power inverter A power inverter, inverter or invertor is a power electronic device or circuitry that changes direct current (DC) to alternating current (AC). The resulting AC frequency obtained depends on the particular device employed. Inverters do the opp ...
, however many hermetic and semi-hermetic compressors can only work in a range of or at fixed speeds, since they may include built-in oil pumps. The built-in oil pump is connected to the same shaft that drives the compressor, and forces oil into the compressor and motor bearings. At low speeds, insufficient quantities of oil reach the bearings, eventually leading to bearing failure, while at high speeds, excessive amounts of oil may be lost from the bearings and compressor and potentially into the discharge line due to splashing. Eventually the oil runs out and the bearings are left unlubricated, leading to failure, and the oil may contaminate the refrigerant, air or other working gas.


Applications

Gas compressors are used in various applications where either higher pressures or lower volumes of gas are needed: * In
pipeline transport Pipeline transport is the long-distance transportation of a liquid or gas through a system of pipes—a pipeline—typically to a market area for consumption. The latest data from 2014 gives a total of slightly less than of pipeline in 120 count ...
of purified natural gas from the production site to the consumer, a compressor is driven by a motor fueled by gas bled from the pipeline. Thus, no external power source is necessary. * In maritime cargo transport and cargo operations by
gas carrier A gas carrier, gas tanker, LPG carrier, or LPG tanker is a ship designed to transport Liquefied petroleum gas, LPG, LNG, CNG, or liquefied chemical gases in Bulk liquids, bulk. Types Fully pressurized gas carrier The seaborne transport of li ...
s. * Petroleum refineries, natural gas processing plants, petrochemical and chemical plants, and similar large industrial plants require compressing for intermediate and end-product gases. *
Refrigeration The term refrigeration refers to the process of removing heat from an enclosed space or substance for the purpose of lowering the temperature.International Dictionary of Refrigeration, http://dictionary.iifiir.org/search.phpASHRAE Terminology, ht ...
and air conditioner equipment use compressors to move
heat In thermodynamics, heat is defined as the form of energy crossing the boundary of a thermodynamic system by virtue of a temperature difference across the boundary. A thermodynamic system does not ''contain'' heat. Nevertheless, the term is ...
in refrigerant cycles (see ''
vapor-compression refrigeration Vapour-compression refrigeration or vapor-compression refrigeration system (VCRS), in which the refrigerant undergoes phase changes, is one of the many refrigeration cycles and is the most widely used method for air conditioning of buildings ...
''). * Gas turbine systems compress the intake
combustion Combustion, or burning, is a high-temperature exothermic redox chemical reaction between a fuel (the reductant) and an oxidant, usually atmospheric oxygen, that produces oxidized, often gaseous products, in a mixture termed as smoke. Combus ...
air. * Small-volume purified or manufactured gases require compression to fill high pressure cylinders for
medical Medicine is the science and practice of caring for a patient, managing the diagnosis, prognosis, prevention, treatment, palliation of their injury or disease, and promoting their health. Medicine encompasses a variety of health care practic ...
,
welding Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature techniques such as bra ...
, and other uses. * Various industrial, manufacturing, and building processes require compressed air to power
pneumatic tools A pneumatic tool, air tool, air-powered tool or pneumatic-powered tool is a type of power tool, driven by compressed air supplied by an air compressor. Pneumatic tools can also be driven by compressed carbon dioxide () stored in small cylinders a ...
. * In the manufacturing and blow moulding of PET
plastic bottles A plastic bottle is a bottle constructed from high-density or low density plastic. Plastic bottles are typically used to store liquids such as water, soft drinks, motor oil, cooking oil, medicine, shampoo, milk, and ink. The size ranges from v ...
and containers. * Some aircraft require compressors to maintain
cabin pressurization Cabin pressurization is a process in which conditioned air is pumped into the cabin of an aircraft or spacecraft in order to create a safe and comfortable environment for passengers and crew flying at high altitudes. For aircraft, this air is u ...
at altitude. * Some types of jet engines—such as
turbojet The turbojet is an airbreathing jet engine which is typically used in aircraft. It consists of a gas turbine with a propelling nozzle. The gas turbine has an air inlet which includes inlet guide vanes, a compressor, a combustion chamber, an ...
s and
turbofan The turbofan or fanjet is a type of airbreathing jet engine that is widely used in aircraft propulsion. The word "turbofan" is a portmanteau of "turbine" and "fan": the ''turbo'' portion refers to a gas turbine engine which achieves mechanic ...
s—compress the air required for fuel combustion. The jet engine's
turbine A turbine ( or ) (from the Greek , ''tyrbē'', or Latin ''turbo'', meaning vortex) is a rotary mechanical device that extracts energy from a fluid flow and converts it into useful work. The work produced by a turbine can be used for generating ...
s power the combustion air compressor. * In
underwater diving Underwater diving, as a human activity, is the practice of descending below the water's surface to interact with the environment. It is also often referred to as diving, an ambiguous term with several possible meanings, depending on contex ...
,
self-contained breathing apparatus A self-contained breathing apparatus (SCBA), sometimes referred to as a compressed air breathing apparatus (CABA) or simply breathing apparatus (BA), is a device worn to provide breathable air in an atmosphere that is immediately dangerous to ...
,
hyperbaric oxygen therapy Hyperbaric medicine is medical treatment in which an ambient pressure greater than sea level atmospheric pressure is a necessary component. The treatment comprises hyperbaric oxygen therapy (HBOT), the medical use of oxygen at an ambient pressure ...
, and other life support equipment, compressors provide pressurised
breathing gas A breathing gas is a mixture of gaseous chemical elements and compounds used for respiration. Air is the most common and only natural breathing gas, but other mixtures of gases, or pure oxygen, are also used in breathing equipment and enclosed ...
either directly or via high pressure gas storage containers, such as
diving cylinder A diving cylinder or diving gas cylinder is a gas cylinder used to store and transport high pressure gas used in diving operations. This may be breathing gas used with a scuba set, in which case the cylinder may also be referred to as a sc ...
s. In surface supplied diving, an air compressor is generally used to supply low pressure air (10 to 20 bar) for breathing. * Submarines use compressors to store air for later use in displacing water from buoyancy chambers to adjust buoyancy. *
Turbocharger In an internal combustion engine, a turbocharger (often called a turbo) is a forced induction device that is powered by the flow of exhaust gases. It uses this energy to compress the intake gas, forcing more air into the engine in order to pro ...
s and superchargers are compressors that increase
internal combustion engine An internal combustion engine (ICE or IC engine) is a heat engine in which the combustion of a fuel occurs with an oxidizer (usually air) in a combustion chamber that is an integral part of the working fluid flow circuit. In an internal c ...
performance by increasing the mass flow of air inside the cylinder, so the engine can burn more fuel and hence produce more power. *
Rail Rail or rails may refer to: Rail transport *Rail transport and related matters *Rail (rail transport) or railway lines, the running surface of a railway Arts and media Film * ''Rails'' (film), a 1929 Italian film by Mario Camerini * ''Rail'' ( ...
and heavy road transport vehicles use compressed air to operate
rail vehicle The term rolling stock in the rail transport industry refers to railway vehicles, including both powered and unpowered vehicles: for example, locomotives, freight and passenger cars (or coaches), and non-revenue cars. Passenger vehicles can be ...
or
road vehicle A vehicle (from la, vehiculum) is a machine that transports people or cargo. Vehicles include wagons, bicycles, motor vehicles (motorcycles, cars, trucks, buses, mobility scooters for disabled people), railed vehicles (trains, trams), wa ...
brakes—and various other systems ( doors,
windscreen wiper A windscreen wiper, windshield wiper, wiper blade (American English), or simply wiper, is a device used to remove rain, snow, ice, washer fluid, water, or debris from a vehicle's front window. Almost all motor vehicles, including cars, truc ...
s,
engine An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy. Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power ...
,
gearbox Propulsion transmission is the mode of transmitting and controlling propulsion power of a machine. The term ''transmission'' properly refers to the whole drivetrain, including clutch, gearbox, prop shaft (for rear-wheel drive vehicles), differe ...
control, etc.). * Service stations and auto repair shops use compressed air to fill pneumatic
tire A tire (American English) or tyre (British English) is a ring-shaped component that surrounds a wheel's rim to transfer a vehicle's load from the axle through the wheel to the ground and to provide traction on the surface over which t ...
s and power pneumatic tools. *
Fire piston A fire piston, sometimes called a fire syringe or a slam rod fire starter, is a device of ancient Southeast Asian origin which is used to kindle fire. It uses the principle of the heating of a gas (in this case air) by rapid and adiabatic compress ...
s and
heat pump A heat pump is a device that can heat a building (or part of a building) by transferring thermal energy from the outside using a refrigeration cycle. Many heat pumps can also operate in the opposite direction, cooling the building by removing ...
s exist to heat air or other gasses, and compressing the gas is only a means to that end. * Rotary lobe compressors are often used to provide air in pneumatic conveying lines for powder or solids. Pressure reached can range from 0.5 to 2 bar g. File:Diving air compressor P8046745.JPG, Diving air compressor in noise reduction cabinet


See also

* * * * * * * * * * * * * * * * * * * (piston compressor) * (a lobe-type compressor) * * * *


References

{{DEFAULTSORT:Gas Compressor Heating, ventilation, and air conditioning Diving support equipment Gas technologies Industrial gases