Studies on Hard Chrome Plating in Reciprocating Air Compressors

Abstract

This present work is to investigate the effects of chrome plating in reciprocating air compressors that result in reduction of power consumption. Reciprocating air compressors are the most commonly used compressors for domestic and industrial purposes to give required air output in terms of free air delivery, delivery temperature and maximum working pressure. This study also develops a better understanding on the effect of honing in the cylinder which reduces the surface roughness in the cylinder liner and results in greater air output. Cylinders are made of graded cast iron. The cylinder liner was honed to a thickness of about 0.26 mm and hard chrome plated to the same thickness. The honing improves the volumetric efficiency and hard chrome plating reduces the power consumption. The adequacy of this model can be verified using thermal image analysis, which includes the various temperature distribution plots around the compressor components. Further delivery temperature, actual displacement and free air delivery pressure are the parameters that conclude the deviation in actual and experimental values. Power consumption and efficiency owe for the major expenditures and maintenance for Reciprocating air compressors. This paper suggests the need of hard chrome plating to a compressor cylinder that resulted in annual power savings of about 25%. The increase in volumetric efficiency was about 20 - 30% from the actual conditions.