The industrial revolution not only transformed manufacturing but also revolutionized how gases are transported, stored, and utilized. The demand for pressurized gas in industries like energy, chemicals, and refrigeration led to the development of gas compressors, which have become essential tools in modern industrial applications.
The first gas compressors were simple mechanical devices requiring significant manual effort, but advancements in technology introduced piston-based and rotary compressors, drastically improving efficiency and capability. Today, gas compressors are used in a wide range of industries for applications such as gas pipelines, refrigeration, and chemical processing. If your business relies on gas compression, selecting the right gas compressor is critical for operational efficiency and long-term success.
This guide will help you understand the basics of gas compressors and guide you through the process of selecting the best option for your needs.
What is a Gas Compressor?
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. It plays a critical role in industrial operations, enabling the transportation, storage, and processing of gases for various applications. Gas compressors are used in industries like oil and gas, chemical processing, manufacturing, refrigeration, and power generation.
These machines work by trapping gas in a confined space and applying force to compress it, either through positive displacement (e.g., pistons or rotary screws) or dynamic processes (e.g., impellers or axial flow). The compressed gas is then used for tasks such as powering tools, moving gases through pipelines, enhancing chemical reactions, or maintaining optimal pressure in systems. Understanding the type of gas being compressed and its intended use is essential when choosing the right gas compressor, as each application requires specific pressure and flow rate capabilities.
The Purpose of Gas Compressors
Gas compressors play a vital role in numerous industries, supporting a wide range of processes and applications. Before investing in a gas compressor, it’s important to clearly define its purpose for your operations. Consider the industry your business operates in, the type of gas being handled, the required pressure and flow rate, and whether the process demands continuous or intermittent use.
For businesses currently outsourcing gas compression needs, an in-house compressor provides improved control over operations, enhances production efficiency, and reduces costs associated with third-party services. Additionally, gas compressors help maintain system integrity by ensuring consistent pressure and flow, which minimizes downtime and optimizes performance.
Whether your operations involve transporting gases through pipelines, pressurizing storage tanks, or facilitating chemical reactions, a gas compressor is an indispensable tool that ensures precision, reliability, and efficiency in your processes.
History of Gas Compressors
- Early Development: Air pumps in the 17th century laid the groundwork for gas compression.
- Industrial Revolution: Steam-driven air compressors powered tools and ventilated mines.
- 20th Century Innovations: Rotary screw compressors introduced continuous flow, whilecentrifugal designs enabled high-capacity operations.
- Modern Era: Today’s compressors incorporate energy-efficient materials, automation, and digital controls, meeting demands for cleaner energy and renewable applications.
Where Are Gas Compressors Used?
Gas compressors are essential across a wide range of industries, supporting critical processes that require pressurized gases. Their applications include:
- Oil and Gas: Gas compressors are vital for transporting natural gas through pipelines, enhancing extraction processes, and compressing gases for storage or distribution.
- Chemical Processing: They facilitate chemical reactions by maintaining consistent pressure and are used for gas blending, separation, and recovery in industrial plants.
- Refrigeration and HVAC: Gas compressors are key components in refrigeration and air conditioning systems, compressing refrigerants to regulate temperature.
- Power Generation: Compressors are used to pressurize air or gas for turbines in power plants, ensuring efficient energy production.
- Manufacturing: Compressors provide pressurized air or gas to power tools, support pneumatic systems, and supply gases for welding or cutting applications.
- Medical and Pharmaceutical: Used for oxygen compression, sterilization systems, and medical gas storage.
- Food and Beverage: Compressors support packaging systems, carbonation of beverages, and controlled-atmosphere storage.
How Are Gas Compressors Used?
Gas compressors function by increasing the pressure of a gas while reducing its volume, enabling efficient transport, storage, and utilization. Here’s how they are typically used:
- Transporting Gases: Gas compressors move natural gas or other industrial gases through pipelines by pressurizing them to overcome resistance and maintain flow over long distances.
- Storing Gases: Compressors pressurize gases into tanks or cylinders, reducing their volume for compact and safe storage, commonly used in industrial and medical applications.
- Powering Equipment: Compressed gas powers pneumatic tools, engines, and equipment in manufacturing and construction.
- Refrigeration and Cooling: Compressors are integral to HVAC and refrigeration systems, compressing refrigerants to regulate temperature through heat exchange cycles.
- Chemical Processing: Gas compressors maintain specific pressures needed for chemical reactions, separation, or gas blending in industrial processes.
- Energy Production: They pressurize air or gases for turbines in power plants, enabling efficient energy generation.
Choosing a Gas Compressor Type
The variety of gas compressors available today is vast, and no single model is suitable for every application. This diversity arises from the differences in gas types, required pressure levels, flow rates, and the specific demands of various industries. To select the right gas compressor, it’s essential to understand the properties of the gas being compressed and the operational requirements of your system. The ideal gas compressor will meet your pressure and flow rate needs efficiently and reliably. Below are the main types of gas compressors to consider:
Gas Screw Compressors
Gas Screw compressors use intermeshing helical rotors to compress gas, providing steady and reliable flow. Known for their efficiency and durability, they are ideal for medium-to-high flow applications at moderate pressure levels, commonly used in industries like oil and gas, manufacturing, and refrigeration. Available in oil-lubricated and oil-free designs, they meet various cleanliness requirements. While less suited for variable speed control or ultra-high pressures, their low maintenance and consistent performance make them a top choice for demanding industrial operations.
Reciprocating Gas Compressors
Reciprocating gas compressors, among the oldest types, use pistons to compress gas by reducing its volume and increasing pressure. Ideal for high-pressure, low-flow applications, they are commonly used in oil and gas, chemical processing, and power generation. Available in single-acting and double-acting designs, they handle pressures exceeding 1,000 PSI. While slower and requiring more maintenance, their precision and reliability make them essential for demanding high-pressure applications.
Bare Screw Compressors
Bare screw compressors, a core type of rotary screw compressor, consist of only the compression unit—two intermeshing helical screws—allowing for customization and integration into existing systems. They provide continuous gas flow, making them ideal for medium-to-high flow applications in industries like oil and gas, manufacturing, and chemical processing. While requiring careful pairing with external components and less suited for high-pressure or variable-speed needs, they offer cost-effective, flexible, and efficient solutions for tailored industrial operations.
Scroll Compressors
Scroll compressors are efficient and compact, using interleaved spiral scrolls to compress gas with minimal noise and maintenance. Ideal for low-to-medium flow rates and moderate pressures, they are widely used in HVAC, refrigeration, and clean industrial processes. Though unsuited for high-pressure or variable-flow applications, their energy efficiency, reliability, and space-saving design make them a popular choice.
Rotary Vane Compressors
Rotary vane compressors use a spinning rotor with sliding vanes to trap and compress gas, delivering steady and continuous flow. Ideal for moderate pressure and flow rate applications, they are commonly used in industrial processes, HVAC systems, and gas transportation. Known for low noise, durability, and ease of maintenance, they excel in consistent operations but are less suitable for high-pressure or variable-speed requirements. Their efficiency and reliability make them a trusted choice for moderate-pressure gas compression.
Semi-Hermetic Compressors
Semi-hermetic compressors, widely used in refrigeration and HVAC systems, house both the motor and compressor in a sealed casing to reduce refrigerant leakage while allowing for maintenance. They are ideal for medium-to-large applications like commercial freezers and cold storage, offering reliable performance and efficient cooling. Though less compact than hermetic models and not as easily accessible as open compressors, their durability, efficiency, and serviceability make them a cost-effective choice for industrial and commercial refrigeration needs.
Split Rack Compressor Systems
Split rack compressor systems are designed for large-scale refrigeration, offering precise temperature control across multiple zones. Featuring a centralized rack of compressors separated from refrigeration units, these systems allow flexible installation and simplified maintenance. Commonly used in food storage, supermarkets, and manufacturing, they provide scalable and efficient cooling by enabling operators to adjust compressor use based on demand, optimizing energy and enhancing reliability. Though they require a higher initial investment, their energy efficiency, redundancy, and scalability make them ideal for complex refrigeration needs in industrial and commercial environments.
Compressor Parts and Accessories
Compressor parts and accessories are essential for ensuring the reliability and efficiency of gas compressors in industrial applications. Components like control panels, pressure transducers, crankshafts, and piston rings help maintain performance and extend compressor lifespan. Industries such as manufacturing, refrigeration, and energy rely on these parts to minimize downtime and optimize operations. Accessories like pressure controllers and advanced sensors enable precise monitoring and adjustments, ensuring consistent performance. Selecting high-quality, compatible parts is critical for maintaining system reliability and efficiency over the long term.
Popular Manufacturers of Gas Compressors
Ariel
Ariel is a leading manufacturer of reciprocating gas compressors for the global energy industry. Since 1966, more than 70,000 Ariel compressors have been deployed worldwide. These compressors are used to extract, process, transport, store, and distribute industrial gases. Applications include Upstream, Midstream, Downstream, CNG, RNG, Hydrogen, and CO2. Ariel sets the standard in the industry with expert design, advanced research and development, and exceptional customer support.
Vilter
Vilter, a brand under Copeland, has been a leader in industrial compression technology for over 150 years. Specializing in high-quality compressors, Vilter serves demanding applications in refrigeration and the oil and gas industries. Their product line includes single-screw and reciprocating compressors, designed for durability and efficiency in cold storage, food processing, and energy sectors. Vilter’s commitment to innovation is evident in their development of the first CO₂ transcritical compressor tailored for industrial use, reflecting their dedication to sustainable solutions. With a rich history of supporting industries worldwide, Vilter continues to set industry standards through advanced engineering and reliable performance.
Frick
Frick has been a pioneer in the refrigeration and gas compression industries since its founding in 1853. With a reputation for innovation and quality, Frick specializes in high-performance rotary screw compressors, reciprocating compressors, and advanced compressor packages. These products are engineered for demanding applications, including food processing, cold storage, and energy sectors.
Known for durability and efficiency, Frick compressors have become a benchmark in industrial refrigeration. The company’s commitment to excellence and innovation ensures reliable solutions tailored to meet modern industrial needs. With a legacy spanning over a century, Frick continues to lead in refrigeration and gas compression technology.
FES Midwest
FES Midwest, established in 1984, is a trusted provider of industrial and commercial refrigeration solutions across the Midwest. Specializing in screw compressors, piston compressors, and packaged compressor systems, FES Midwest delivers reliable and efficient systems for applications such as food processing, pharmaceutical manufacturing, and cold storage. With strong partnerships with top-tier manufacturers and a team of dedicated experts, FES Midwest ensures high-quality solutions tailored to meet the unique needs of its clients. From design and installation to maintenance and service, the company provides comprehensive support to ensure efficiency and reliability in refrigeration systems. FES Midwest continues to set the standard for excellence in the refrigeration industry.
Mycom
Mycom (Mayekawa), founded in 1924 by Kisaku Maekawa in Tokyo, Japan, has been a pioneer in industrial refrigeration and compression technology for a century. The company specializes in reciprocating compressors, screw compressors, and centrifugal compressors, serving industries such as food processing, cold storage, and energy sectors. Mayekawa’s commitment to innovation is evident in its development of high-speed multi-cylinder compressors and ammonia liquid pump recirculation systems, reflecting a dedication to sustainable and efficient solutions. With a global presence and a rich history of technological advancements, Mayekawa continues to set industry standards through advanced engineering and reliable performance.
