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DESIGN AND DEVELOPMENT OF THE VORTEX TUBE FOR IMPROVED

PERFORMANCE

Article · April 2019

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Journal of Basic and Applied Research International
25(2): 78-86, 2019
ISSN: 2395-3438 (P), ISSN: 2395-3446 (O)

DESIGN AND DEVELOPMENT OF THE VORTEX TUBE FOR

IMPROVED PERFORMANCE

MAYURI RAJENDRA CHAVAN1*, REENA PANT1

AND BHAVESHKUMAR N. PASI2
1
Department of Mechanical Engineering, Bharati Vidyapeeth College of Engineering, CBD Belapur - 400614,
Navi Mumbai, India.
2
Department of Mechanical Engineering, Vishwaniketan’s Institute of Management Enterpreneurship and
Engineering Technology, Khalapur - 410202, India.

AUTHORS’ CONTRIBUTIONS
This work was carried out in collaboration among all authors. Author MRC designed the study, performed the
experimental analysis, wrote the protocol and wrote the first draft of the manuscript. Authors RP and BNP
managed the literature searches. All authors read and approved the final manuscript.

Received: 10 January 2019

Accepted: 26 March 2019
Published: 08 April 2019 Original Research Article
__________________________________________________________________________________

ABSTRACT

The present study was to perform the design and development of the vortex tube for improved performance. The
material used in the mold manufacturing industry has limited efficiency and life. Geometrical and working
parameters affect on vortex tube efficiency and life. These parameters need to be emendated. The
experimentation is done for studying and modifying working and geometrical parameters of Bronze and
Aluminium. The improvement is observed in the performance of the vortex tube by changing the valve angle
and material. The economical material for vortex tube which gives better-required performance at different
pressure, velocity and flow parameters is proposed.

Keywords: Vortex tube; refrigeration; experimentation; valve angle; temperature.

1. INTRODUCTION
The vortex tube is a simple mechanical device without
any moving parts. It is used for the both heating and
refrigeration purpose. It is an ecofriendly device
which splits the hot air stream and cold air streams
from the inlet air stream. The vortex tube is one of the
non-conventional type refrigerating systems for the
production of refrigeration. The vortex tube is a
simple energy separating device which is compact and
simple to produce and to operate [1]. The Vortex
Tube was invented by French physicist Georges J.
Ranque in 1933. Fig. 1 shows the air flow process in a
vortex tube. Normally, a vortex tube is assembled by
nozzle, swirl chamber, cold end tube and hot end tube.
At the inlet of the tube, it then enters the swirl
chamber with a high tangential velocity. The effect of
vortex generator parameters (Cold orifice angle, Cold
orifice diameter and Nozzle area) on vortex tube
performance is investigated experimentally [2]. The
air then travels towards the hot end of the vortex tube
and separates into two parts, hot air swirls at the
outside part and cold air in the middle part of the
vortex tube. Once reached the conical valve, the cold
air travels backwards and flows out through the cold
outlet and the hot air flows out through the hot outlet.
The ratio of the cold air to the order to have the best
performance of the vortex tube.

_____________________________________________________________________________________________________

*Corresponding author: Email: mayurirchavan75@gmail.com;

 Chavan et al.; JOBARI, 25(2): 78-86, 2019

Fig. 1. Flow structure of Vortex tube

2. LITERATURE SURVEY is scope for analysis of vortex tube using the non-
metallic materials like Acrylic, Nylon, plasticized
2.1 Experimental Analysis of Different polyvinyl chloride (PVC), Chlorinated polyvinyl
Parameters of Vortex Tube chloride (CPVC) etc [5].

It has been investigated the performance of vortex

Till date, lots of researches and developments are
done related to vortex tube. It has been observed that
the performance of the vortex tube depends upon the
working parameters, geometrical parameters and
material selection. Therefore, the focus of this project
is to find out economically suitable material for a
vortex tube for better-required performance. Several
papers have been published on vortex tube on various
applications [3].
The effect of geometrical parameters on the vortex
tube by developing an experimental set up is studied.
In this work, a vortex tube was made of two types of
homogeneous woods. To check the performance of
the vortex tube, compressed air was used as a working
fluid. The aim of the experiment was to study the
variation of temperature at hot end and cold end with
respect to pressure variation and valve position
variation. Researchers have found that the
performance of the vortex tube is always directly
proportional to inlet compressed air. Also, the surface
finish of the nozzle and the hot tube plays a great role
in the performance of the vortex tube [4]. It has been
investigated that the thermal effect of nozzle materials
and working fluids on the thermal performance of the
vortex tube. This study revealed that steel as a nozzle
material has the highest value of temperature gradient
for air as a working fluid. It has been found that there
tube made of unplasticised polyvinyl chloride
(UPVC) material. The effect of the working
parameters include inlet pressure of compressed air,
cold mass fraction, ambient air temperature while the
geometrical parameters include diameters of the
nozzle, hot side and cold side, lengths of hot side and
cold side, conical angle of the valve are discussed [6].
It has been found that selection of vortex tube
material is very important for studying the effect of
various working parameters [7].
2.1.1 Vortex tube analysis with different materials
a) Stainless Steel
Length of the hot pipe = 840 mm Cold end = 80mm
Dia. of the hot pipe = 18 mm L/D ratio = 46.7
As the inlet pressure increases, the temperature at hot
end side increases. The augmentation in cold end side
temperature can be seen with the increase in pressure
The hot end side temperature is slightly higher than
the ambient temperature and the cold end side
temperature is almost equal to the ambient
temperature. After a particular value of the pressure,
here 10 kg/cm² the cold end side temperature remains
constant.

Table 1. Temperature difference of stainless steel vortex tube

Sr. Dia. of Dia. of Pressure Cold temp. Hot temp. Temp. the
no. nozzle (mm) diaphragm (mm) (kg/cm²) (°C) (°C) difference (°C)
1 8 10 2 30 32 2
2 8 10 4 29 32 3
3 8 10 6 27 31 4
4 8 10 8 30 32 2
5 8 10 10 28 31 3
6 8 10 12 28 32 4

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 Chavan et al.; JOBARI, 25(2): 78-86, 2019

Fig. 2. Temperature difference graph of Stainless steel vortex tube

b) Aluminum Alloy 2.2 Problem Statement

Length of the Hot pipe = 840 mm Cold end pipe = 340 mm,
Dia. of the hot pipe = 15 mm L/D ratio = 840/15 = 56
As compared to Stainless Steel case here more
temperature difference is observed but less
temperature drop at the cold end side. In this case the
temperature readings at both sides are more
fluctuating compared to Stainless Steel case.
During a literature survey it is found that the working
and geometrical parameters are based upon the
application for which vortex tube is used. The slight
change in these parameters can change vortex tube
performance significantly. The mould industry is
having the challenge to reduce long set up and
changeover times because of frequent failure of
vortex tubes.

The temperature difference is increasing for higher
temperature values. The cold end side temperature is
almost greater than ambient temperature, which is not
recommended. In case of reading No. 4, at a pressure
value of 8 kg/cm², the cold end side temperature is
higher than hot end side temperature.
2.2.1 Old vortex tube data
The current vortex tube in the industry is set at valve
angle 60° at hot end side of the vortex tube. The
temperature readings at different pressure values are
in Table 3.

Table 2. Temperature difference of aluminum alloy vortex tube

Sr. Diameter of Diameter of Pressure Cold Temp. Hot Temp. Temp.

no. nozzle (mm) diaphragm (mm) (Kg/cm2) (°C) (°C) difference (°C)
1 8 8 2 30 32 2
2 8 8 4 30 34 4
3 8 6 6 30 33 3
4 8 6 8 34 30 4
5 8 6 10 29 34 5
6 8 6 12 28 36 8

Fig. 3. Temperature difference graph of Aluminum alloy vortex tube

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 Chavan et al.; JOBARI, 25(2): 78-86, 2019

Table 3. Temperature difference of Bronze vortex tube

Sr. no. Properties Readings

I II III IV V
1 Pressure (kg/cm^2) 4.4 3.4 3 2.1 1
2 Cold end Temperature (°C) 22.3 25.6 24.3 23.2 26
3 Hot end Temperature (°C) 39.1 51.2 51.9 53.6 50

3. EXPERIMENTAL RESULTS vortex tube is 4 months old and requires a cooling

The testing is performed by supplying compressed air
which acts as a medium. The regulating valve is
placed at the hot end side of the vortex tube. The
readings of the vortex tube measured in terms of
pressure (kg/cm^2), hot end and cold end temperature
(°C).
During an operation when pressurized air is supplied
through the vortex tube, some part of it comes from
the hot end and remaining from the cold end. With a
period of time pressure inside of the tube goes on
decreasing. This directly effects on the hot and cold
end temperature, which increases and decreases
respectively.
3.1 Old Vortex Tube Hot End Valve Partially
Open (60°)
The old vortex tube of Bronze used by the industry is
set for hot end side valve angle position at 60°. This
time of 110 seconds for one product. It needs
maintenance after 6 months due to the failure of
vortex tube parts.
Different cases are considered during the test, are
explained below:
 Hot end valve fully closed (90°)
 Hot end valve partially closed (60°)
 Hot end valve at middle position (45°)
 Hot end valve partially open (25°)
 Hot end valve fully open (0°)
3.2 Hot End Valve Fully Closed (90°)
When hot end valve is fully closed then pressurized
air from the compressor through the air inlet of vortex
tube is directly passed through cold end. The flow
does not have any restriction inside the tube, it simply
passed through a tube and therefore temperature
reading at cold end side showing atmospheric
temperature.

Table 4. Old vortex tube hot end valve partially open (60°)

Properties Readings
I II III IV V
1 Pressure (kg/cm^2) 4 3 2.5 2 1
2 Cold end Temperature (°C) 20.1 19.3 17.4 16 15.4
3 Hot end Temperature (°C) 31.9 32.8 33.2 34.8 35.5

Fig. 4. Testing set up

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 Chavan et al.; JOBARI, 25(2): 78-86, 2019

Table 5. Hot end valve fully closed (90

(90°)

Sr. no. Properties Readings

I II III IV V
1 Pressure (kg/cm^2) 4 3 2.5 2 1
2 Cold end Temperature
rature (°C) 28.8 (Atm. temp.) 28.3 28.6 28.7 28.6
3 Hot end Temperature (°C) - - - - -

Fig. 5. Pressure versus cold end temperature at 90° valve angle

As shown in graph (Fig. 5) there all to ambient
temperature. The between readings is about 0.5°C that
energy separation doesn't place here when the valve
is fully closed. So though we change pressure at
inlet there is slight variation at cold end side
temperature.
3.3 Hot End Valve Partially Closed (60°)
Initially, when the valve is closed
losed by a huge margin,
fluctuations in temperatures of the hot end are bit
higher. Also, keeping the valve closed at 60°, the
temperature at the cold end side has reduced
drastically from the atmospheric temperature and
higher temperature readings at the hot end are
obtained.
The cold end side temperature is reducing as the
pressure is increased. In this case the energy
separation takes place in good amount. Though the
cold end side temperature is obtained in the range of
13° to 19°C which is quite good, but the temperature
readings were fluctuating continuously.
3.4 Hot End Valve at Middle Position (45
(45°)
At the opening angle, hot end temperatures are
seemingly steady when compared to other such
conditions of pressure and valve positions. The cold
end temperature
mperature also has further decreased and
remained stable at this valve angle position. Along
with the cold end temperature, there is a significant
drop in the hot end temperature.
As shown in graph (Fig. 7) the cold end side
temperature is obtained betweenn the range of 12° to
15°C which is less compared to other valve angle
positions. Also, stability is observed in temperature
readings. As the pressure is increased, the cold
fraction increases at cold end side.

Table 6.
6 Hot end valve partially closed (60°)

Sr. no. Properties Readings

I II III IV V
1 Pressure (kg/cm^2) 4.5 3.5 3 2 1
2 Cold end Temperature (°C) 13 15.4 16.2 17.5 18.6
3 Hot end Temperature (°C) 42 52.7 53.9 54.3 54.4

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 Chavan et al.; JOBARI, 25(2): 78-86, 2019

Fig. 6. Pressure versus cold end temperature at 60° valve angle

Table 7. Hot end valve at middle position (45

(45°)

Sr. no. Properties Readings

I II III IV V
1 Pressure (kg/cm^2) 4.1 3.5 3.2 2 1
2 Cold end Temperature (°C) 15 14 12.9 12.8 12.2
3 Hot end Temperature (°C) 32 31.6 33.4 34.6 35.2

Fig. 7. Pressuree versus cold end temperature at 45° valve angle

3.5 Partially Open Hot End Valve (25°)
Now in this case the temperature at the hot and cold
end has increased. The changes in the temperature
which are not steady at the start afterwards becomes
steady.
The graph (Fig. 8) shows that the cold end side
readings are varying between the range of 17° to
23°C. The temperature is directly proportional to the
pressure. The temperature is fluctuating at the start,
after increasing pressure it becomes stable.
3.6 Hot End Valve Fully Open (0°)
In this case, the angle is at 0° because the conical
valve is fully open. So there is no restriction to the
inlet air flowing through the vortex tube. The
temperature readings obtained at cold end side are
almost equal to thee ambient temperature.

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 Chavan et al.; JOBARI, 25(2): 78-86, 2019

As shown in graph (Fig. 9) we can see that the highest flow takes place. There is no separation between the
temperature is obtained at cold end side for this valve inlet air as it goes out immediately through open end
angle position. The temperature range for cold end at hot and cold side.
side obtained between 25° to 29°C is fully open, so

Table 88. Partially open hot end valve (25°)

Sr. no. Properties Readings

I II III IV V
1 Pressure (kg/cm^2) 4.5 3 2.5 2 1
2 Cold end Temperature
perature (°C) 17 20.4 20.7 21.8 23.2
3 Hot end Temperature (°C) 47 52.7 54.3 54 54.4

Fig. 8. Pressure versus cold end temperature at 25° valve angle

Table 9. Hot end valve fully open (0°)

Sr. no. Properties Readings

I II III IV V
1 Pressure (kg/cm^2) 3.5 3 2.5 2 1
2 Cold end Temperature (°C) 28.6 28.4 27 28.8 25.5
3 Hot end Temperature (°C) 38.7 41.1 46.3 46.8 48.1

Fig. 9. Pressure versus cold end temperature at 0° valve angle

84

Table 10. The difference between current vortex tube and aluminium alloy vortex tube
Comparison old vs new Average cold end
temperature
Old vortex tube of Bronze 17.64°C
New vortex tube of Aluminium 13.38°C
Performance comparison between old and new
40 vortex tube
Cold end temperature (°C)
20
0
4 3.5
Pressure (kg/cm^2)
New tube cold end temperature (°C)
Fig. 10. New vs old vortex tube performance comparison
Fig. 9 readings are taken at different valve position
angle. From the above cases reading, it is seen that, by
varying or changing the valve position at a different
angle, it directly cold end temperature as well as hot
end temperature. Hence, always the performance of
vortex tube is directly proportional to inlet
compressed air and also on the nozzle valve position
at the hot end side.
3.7 Brief Explanation for the above
Temperature Variations with Valve Angle
As the inlet air flows in the hot end side pipe of the
vortex tube towards the control valve, the flow can be
restricted using this control valve. When the hot end
side pressure in the tube is higher compared to the
ambient pressure, then some part of inlet air stream is
reversed through central part of the tube. There is
energy interaction between two air streams flowing in
the opposite direction within the vortex tube. The
outer air stream near vortex tube wall in the forward
direction has higher temperature than the inlet air. The
other air stream of central part in the reverse direction
has lower temperature than the inlet air. The part of
this inlet air stream which gets back towards the
diaphragm and when it passes through the diaphragm
hole the air gets cooled and comes out from the cold
side pipe, while the other part of this air stream is
passed through the opening of the valve. Different
control valve opening positions gives various values
of temperature difference at cold end and hot end. The
valve angle position at 45° gives good result in the
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Chavan et al.; JOBARI, 25(2): 78-86, 2019
Maintenance Cost
6 months after installation 4280 Rs
8 months after installation 3910 Rs.
3 2
Old tube cold end temperature (°C)
experiment hence it is selected here for better
performance of vortex tube.
4. RESULTS
The old and new vortex tubes are compared for cold
end temperature, maintenance cost and manufacturing
cost as shown below (Table 10). Aluminium tube
shows better results for good performance with less
cost.
5. CONCLUSION
The temperature difference of 4.26°C is observed
between the new vortex tube Aluminium and the old
vortex tube of Bronze. The new vortex tube is giving
more effective cooling temperature compared to the
old vortex tube. As seen in the table, the new vortex
tube is having more life without maintenance due to
less wear and tear of Aluminium material compared to
Bronze. In case of economic comparison, the new
vortex tube is having a low cost for manufacturing. In
addition to this due to frequent maintenance the old
vortex tube will be having high maintenance cost
compared to the new vortex tube. Hence new vortex
tube proposed to have good performance with reduced
cost.
COMPETING INTERESTS
Authors have declared that no competing interests
exist.
 Chavan et al.; JOBARI, 25(2): 78-86, 2019

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