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Compressors are classified into positive displacement (pressurizing by reducing gas volume) and dynamic (converting kinetic energy to pressure energy). Below is a detailed breakdown:
1. Positive Displacement Compressors
Principle: Periodically reducing a sealed space to increase pressure.
Applications: Medium-to-high pressure scenarios (1–300 bar).
| Reciprocating/Piston | Single-stage (<15 bar), Multi-stage (>300 bar) | ✅ High-pressure capability, simple structure ❌ High vibration & noise | Refrigerators, gas cylinders, industrial gas filling |
| Rotary Screw | Oil-injected (<13 bar), Oil-free (clean air for food/pharma) | ✅ Continuous operation, 70-90% efficiency ❌ High upfront cost | Factory tools, natural gas pipelines |
| Scroll | Displacement: 0.5–15 m³/min | ✅ Silent, pulsation-free airflow ❌ Complex repairs | Home AC, EVs, medical equipment |
| Vane | Flow rate <10 m³/min | ✅ Compact, stable output ❌ Rapid vane wear | Small compressors, vacuum pumps |
2. Dynamic Compressors
Principle: High-speed impellers convert kinetic energy to pressure.
Applications: High-flow, low-to-medium pressure scenarios (<50 bar).
| Centrifugal | Flow rate >2000 m³/h, RPM 10,000–100,000 | ✅ Massive flow, oil-free ❌ Low efficiency at partial loads | Oil refineries, aircraft APUs, gas pipelines |
| Axial | Pressure ratio 5–15, Flow rate >500,000 m³/h | ✅ Extreme flow capacity ❌ Ultra-high cost | Jet engines, power plants, petrochemicals |
3. Specialized Compressors
| Diaphragm | Metal diaphragm isolates lubricants | ISO Class 0 air purity | Semiconductors, hydrogen fuel cells |
| Linear | Electromagnetic piston drive (no crankshaft) | 30% higher energy efficiency | Cryogenics, premium refrigeration |
| Hypercompressors | Pressure >5000 bar | Polyethylene production, deep-sea research | Material science, extreme environments |
4. Emerging Technologies
Magnetic Bearing Centrifugals: Oil-free, frictionless operation for data center cooling (40%+ energy savings).
Hydrogen Compressors: 900-bar pressure tolerance with anti-embrittlement design for green hydrogen.
AI-Driven Optimization: Real-time load prediction with adaptive speed control (20-40% energy reduction).
Selection Guidelines
Pressure Requirements:
<10 bar → Screw/Piston
10–300 bar → Multi-stage piston/Diaphragm
300 bar → Hypercompressors
Flow Requirements:
<50 m³/min → Scroll/Piston
2000 m³/h → Centrifugal/Axial
Air Purity:
Food/Pharma → Oil-free screw/Diaphragm
General industry → Oil-injected screw/Centrifugal
Case Studies:
Tesla Gigafactory: Uses oil-free screw compressors for ISO 8573-1 Class 0 air in battery production.
Space Exploration: NASA employs linear compressors for -150°C cooling in deep-space probes.
