Single stage vs. 2-stage air compressor - advantages at ...
Single stage vs. 2-stage air compressor - advantages at ...
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Heating the air in compression can actually help. If you start with room temperature air and compress it, the heating makes it expand so it has a larger volume and lowered viscosity, making it push out the exhaust valve faster. If the tank is large enough that the air in it is reasonably cool, that air temperature defines the back pressure, not the air going through the exhaust port. If the heat conduction between the intake and exhaust ports is high enough to significantly heat the incoming air, then the compression stroke starts with a smaller charge and resultant loss in output. Cool in, hot out improves the throughput.
The manufacturer only listing displacement (swept volume) is just dodging the issue. A good spec sheet gives the actual output at various pressures. These compressors never deliver the full swept volume. Running at slow speeds and against low back pressure, they may come close, but all drop off when they have to work hard. Configured as a two stage where the low pressure cylinder was only working against about 15 PSI in the manifold between the cylinders, at 62 CFM swept volume and 100 PSI it actually delivered 56 CFM. That is about the best you could expect. I sized the orifice in the bead gun to match and sent the air through the cooler and to it, only feeding the 200 gal. tank when not blasting. With the large storage, other people in the shop never noticed.
Another factor usually neglected is the force needed to open an atmospheric intake valve. Running my Gardner Denver ACR as a vacuum pump, it would rapidly go up to 25 in hg gauge and stop. The approximately 4-5 in difference between that and atmospheric pressure was the differential needed to actuate the valve. That difference is also subtracted from the fill pressure when it is used as a compressor, although that is mitigated a bit because once the valve snaps open, it will tend to stay.
The viscosity of the air can have a surprising effect. I once repaired some huge heaters for an aluminum annealing oven big enough to handle truck loads. The operator commented that even though he had the blower motors rewound for the maximum performance possible, he had to start with the blowers off and heat the air until it got thin enough to avoid overloading them.
All these factors get in the equation, which isn't simple.
Bill
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Heating the air in compression can actually help. If you start with room temperature air and compress it, the heating makes it expand so it has a larger volume and lowered viscosity, making it push out the exhaust valve faster. If the tank is large enough that the air in it is reasonably cool, that air temperature defines the back pressure, not the air going through the exhaust port. If the heat conduction between the intake and exhaust ports is high enough to significantly heat the incoming air, then the compression stroke starts with a smaller charge and resultant loss in output. Cool in, hot out improves the throughput.The manufacturer only listing displacement (swept volume) is just dodging the issue. A good spec sheet gives the actual output at various pressures. These compressors never deliver the full swept volume. Running at slow speeds and against low back pressure, they may come close, but all drop off when they have to work hard. Configured as a two stage where the low pressure cylinder was only working against about 15 PSI in the manifold between the cylinders, at 62 CFM swept volume and 100 PSI it actually delivered 56 CFM. That is about the best you could expect. I sized the orifice in the bead gun to match and sent the air through the cooler and to it, only feeding the 200 gal. tank when not blasting. With the large storage, other people in the shop never noticed.Another factor usually neglected is the force needed to open an atmospheric intake valve. Running my Gardner Denver ACR as a vacuum pump, it would rapidly go up to 25 in hg gauge and stop. The approximately 4-5 in difference between that and atmospheric pressure was the differential needed to actuate the valve. That difference is also subtracted from the fill pressure when it is used as a compressor, although that is mitigated a bit because once the valve snaps open, it will tend to stay.The viscosity of the air can have a surprising effect. I once repaired some huge heaters for an aluminum annealing oven big enough to handle truck loads. The operator commented that even though he had the blower motors rewound for the maximum performance possible, he had to start with the blowers off and heat the air until it got thin enough to avoid overloading them.All these factors get in the equation, which isn't simple.Bill
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