A two-stage air compressor is designed to produce high flow while providing high pressure. It operates more like a gas engine than the standard design of single-stage air compressors that are designed for low flow and low pressure. A two-stage turbine has two compression stages in sequence with each stage having one or more lobes. This can provide up to a 10:1 pressure ratio.

Two-stage compressors cost more but they provide better cooling, higher efficiency, and longer life along with increased power density. A two-stage compressor is usually more expensive than a single-stage, however, its performance cannot be matched. Having two stages in a compressor allows for intercooling which means air can be cooled between the compression stages. This means your system gets colder air so you need less capacity to produce the same amount of compressed air or if running at 100% capacity, it will last longer before overheating the motor due to the cooler intake temperature. A two-stage compressor also provides better power density than a single-stage compressor. The higher the pressure, the more air can be compressed in a small amount of space. Two-stage compressors are typically used on job sites where electric power is not available or with large stationary systems that require high capacity and high pressure levels.

Best 5 Two-Stage Air Compressors Reviewed

2 Stage Air Compressor: A Buyers Guide

There are two types of compressors that comprise the category of two-stage compressors; piston and rotary screw.

Piston Compressors: The pistons in a piston compressor move up and down inside the cylinder and push air out through an outlet valve.

Rotary Screw Compressors: These consist of two or three lobes, each with its own set of vanes which is rotated by a drive shaft at its base. It crushes air against a stationary nozzle ring hence compressing the air.

A two-stage air compressor works by having the intake air pass through the first stage, which compresses it to a lower pressure. The second stage then compresses that same intake air even more pushing it into the tank or output pipe. A two-stage system could have one or both stages being rotary screw compressors. Each stage can incorporate intercooling in its design although there are designs that combine the two types of compression stages.

Piston Compressors: A single piston compresses intake air in one chamber with an outlet port for compressed air. For every stroke of the piston, about 80% of the power is transferred to driving compression and 20% is lost in friction between parts. Rotary Screw Compressors: Two or three lobes are rotated creating compression in each lobe. The pressurized air is forced out through an outlet port. About 70% of the power is transferred to driving compression and 30% is lost in friction between parts.

These two types of compressors have different advantages and disadvantages: Advantages of Two Stage Air Compressors: Lower noise output than single stage models More power density than single stage compressor Higher CFM for less money Disadvantages of Two Stage Air Compressors: Bigger and heavier than single stage models Costs more than a single stage model. Advantages of Single Stage Air Compressors: Compact design, easier to transport Quieter operation Disadvantages of Single Stage Air Compressors: Less power and CFM than a two-stage model Costs more than a two-stage compressor.

Two stage air compressors offer these key features: Two independent compression stages – One for low pressure and one for high Pressure reduction between stages – Each stage reduces pressure to compensate for the rise in pressure from the following stage Intercooling – Cool is achieved by pumping air through the compression stages for increased efficiency Cooler intake air – Compressor is able to breath in colder, more dense air which can allow for higher capacity or longer life.