6 Types of Air Compressors and Their Uses

An air compressor is a machine that takes atmospheric air into a chamber and compresses it to discharge at high pressure. You may require an air compressor for pneumatic projects, food packaging, or powering tools. Depending upon the working mechanism and shaft, various types of air compressors are applied in both large and small-scale industries. 

Types of Air Compressors

Based on internal mechanisms, air compressors are broadly classified into dynamic or positive displacement compressors. Below are six types of air compressors commonly used across various industries, with their advantages and disadvantages.

1. Reciprocating Compressors

These compressors are also known as piston air compressors. It uses a piston to compress air inside a cylinder. They work on a positive displacement mechanism. They are available in single-stage or two-stage configurations and are best suited for small industries or workshops. 

Advantages

• Reciprocating air compressors give high-pressure output.
• They are less expensive than other air compressors.

Disadvantages

• Reciprocating air compressors require regular maintenance due to wear and tear of the parts.
• These air compressors generate significant noise and vibration.

Suitability 

• These air compressors are best suited for automotive workshops and small manufacturing plants.

2. Rotary Air Compressors

These compressors use rotary screws to trap the air between the rotor blades of the screw element. This decreases the volume of the chamber and increases the pressure. The compressed air is then discharged at high pressure. 

Advantages

• It is a highly efficient air compressor.
• It produces low noise and consumes less energy.

Disadvantages

• The initial cost is high compared to reciprocating compressors.
• It requires high maintenance for best performance.

Suitability 

• It is suitable for manufacturing, construction and the chemical industry.

3. Centrifugal Compressor

These compressors use flat rotating discs to trap the air. The air enters at a 90-degree angle and flows radially outward from the blades along the shaft. The air is trapped at a low pressure and is guided towards a discharge chamber. The centrifugal compressor works on a dynamic compression mechanism.

Advantages

• It is suitable for high-capacity operations.
• It requires low maintenance.

Disadvantages

• Centrifugal compressors have a lower flow rate compared to axial compressors.
• It has a high initial cost and complex installation.

Suitability 

• It is suitable for large-scale industrial applications, chemical plants and HVAC systems.

4. Axial Compressor

This is a high-speed air compressor. Air flows axially through rows of airflow cascades to compress it and discharge it at high pressure. The axial compressor is suited for applications where continuous air flow is needed.

Advantages

• It is highly efficient and suitable for large-scale applications.
• It provides a continuous flow of air.

Disadvantages

• It is an expensive air compressor.
• It is difficult to operate and maintain.
• It is not suitable for small-scale applications.

Suitability 

• It is suitable for aerospace, turbo-machinery, and high-power generation applications.

5. Rotary Vane Compressors

This air compressor uses a rotary vane inside a cavity to compress the air and discharge it at high pressure. A rotary vane compressor delivers continuous air at constant pressure.

Advantages

• It operates quietly and has minimum maintenance needs.
• It comes in a compact and durable design.

Disadvantages

• It is suited only for small-scale applications.
• It is expensive compared to other compressors.

Suitability 

• It is suitable for pharmaceutical, printing and food packaging industries.

6. Rotary Screw Compressor

This compressor uses two rotors that twin and rotate in opposite directions to compress air in between. Rotary screw compressors come in oil-lubricated and oil-free types also. It is a displacement-type air compressor that delivers continuous air.

Advantages

• It does not require much maintenance.
• It is designed for continuous use.

Disadvantages

• The initial cost is high compared to reciprocating compressors.
• Dry air is required to prevent moisture issues.

Suitability 

• It is suitable for large-scale industrial applications such as manufacturing and construction. 

Conclusion

• Compressors such as reciprocating and axial compressors are highly efficient for large-scale applications, whereas rotary, rotary vane or screw compressors are suitable for applications that require continuous use.
• The various applications of air compressors include food packaging, power generation, HVAC systems, spray painting, pressure washing, and agricultural processes. 
• With reference to the above article, you can evaluate each factor to make the right decision for your business needs. Before purchasing an air compressor, you should consider the compressor’s mechanism, energy efficiency, noise levels, and maintenance needs.

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