Compressor Intercooling and Staging — online
How many stages does your compressor need, what does each intercooler have to remove, and how much power does intercooling save? Answer it in one workbook, with real-gas properties.
Yellow cells are inputs; orange cells are choices; blue cells choose the unit. Select or hover over an input to see its help in the box below the toolbar. The sheet is the same as the Excel tool (USD 49) — the Guide, method and references are in the Excel file.
What this compressor intercooling and staging calculator does
Stage a compressor: the number of stages from your discharge-temperature limit, equal-ratio stage table, intercooler duty and cooling water, UA, and the power intercooling saves, with real-gas properties for pure gases and mixtures.
- Number of stages. The smallest number of stages (1 to 6) that keeps every discharge temperature and pressure ratio inside your limits, or set it yourself.
- Stage-by-stage table. Suction and discharge pressure and temperature, margin to your limit, gas power, polytropic exponent and compressibility.
- Intercooler duty and UA. Gas outlet at cooling-water inlet plus approach, duty, cooling-water flow, log-mean temperature difference and the UA for your cooler designer.
- Power saved by intercooling. Against a single stage: shaft power, isothermal efficiency, and the yearly energy and money saved.
- Real-gas properties. Any pure chemical or a mixture of up to 12 components, with Peng-Robinson states, so compressibility is included, not assumed.
- Cooling-water what-if. Gas power and yearly cost for warmer or cooler water, with warnings for dew point, near-critical suction and temperature cross.
How it was checked
24 selector combinations, eight further gases and a custom mixture, and 46 edge cases against an independent Peng-Robinson Python model: largest difference 7E-14 relative; thermodynamics cross-checked with CoolProp for methane.
Related
- Compressor Intercooling and Staging Excel tool — USD 49, keep the workbook, its Guide and the report sheet.
- All online tools
Questions
Is the compressor intercooling and staging calculator free?
You can enter and check all your data free. The full results, findings and printable sheet are unlocked with a 3-run pack (USD 9), a monthly subscription to all online tools (USD 15) or a yearly one (USD 99).
Are the results the same as the Excel tool?
Yes. The online tool runs the formulas of the Compressor Intercooling and Staging Excel workbook and was checked cell by cell against the Excel file.