Applications for Compressed Air Operated Vortex Tubes. Compressed air-operated vortex tubes have been commercialized since 1960. These devices take compressed air at a given inlet temperature. And split the flow up into a hot (usually waste) and a very cold (usable) air stream used for cooling.
The significant temperature drop improves. When an application requires such low values, sub-zero temperatures can be produced. While the cost of compressed air is still a concern in their use, specific applications make them viable. Pay attention when these application advantages outweigh the energy costs.
Consider the following
Cooling CCTV cameras, sensors, small control boxes in inkjet printers, and other small devices with vortex tubes or packaged versions like Panel Coolers is more economical than using cooling water alone or compressed air alone. Some other alternatives can even be more costly or challenging.The cold air produced by the vortex tube means less compressed air is required to use only compressed air. Water causes scaling issues because of the high heat exposure and circulation through small water lines.
Fans to cool usually cannot work well because of the hot and often dirty environment. Using heat pipes requires a cool ambient to be effective and limits the ability to cool. A similar situation exists with thermoelectric cooling.
Cabinet Enclosure Cooling or Panel Cooling (Electrical and electronic air conditioners) is ideal for Panel Cooling under certain conditions over regular air conditioners, fans, and other alternatives like water and thermoelectric.Regular air conditioners generally use less energy, but you must address refrigerant replacement over time, change filters regularly, and deal with condensation. Vortex tube-operated coolers are dependent only on compressed air temperature for cooling effect.
As a general guide, the hotter and dirtier the environment, the greater the benefit of vortex tube technology. This is because the worse the environment, the higher the maintenance costs, especially filter replacement, which is not only a filter cost but can also be an ever-increasing disposal cost.
This can offset any increased energy costs.For obvious reasons, a dirty environment is not conducive to the use of fans. They will clog quickly and stop workingA hot environment aggravates the problem and works against using thermoelectric technology. Water cooling introduces potential scaling issues and other maintenance costs.
Vortex tube-operated panel coolers are essentially maintenance-free, produce no condensate to deal with, and keep the control panel under slight positive pressure to keep out any nasty factory environment.
This is very advantageous if maintenance is complex because of panel location, whether in a hard-to-reach factory location or in a geographical area that lacks the necessary maintenance personnel.
Manufacturers typically package vortex tubes with a magnet and flexible hose to direct cold air. Especially in dry machining applications involving ceramics, glass, plastic, and materials like titanium.This can decrease machine time and improve the quality of the machining.
There has been an attempt to move away from liquid cooling as much as possible for environmental and safety reasons, which continues today. However, there are challenges as liquid cooling helps remove debris, and tooling material requirements can also change.
Using vortex tubes to chill liquid used for mist cooing also provides some lubrication when needed, such as in deep-hole drilling, and reduces the lubricant needed by as much as 20%.
Vortex tubes are perfect for other spot cooling applications.. Such as cooling hot melt adhesives, welds, soldering points, and gas samples. Because of their compact design, small footprint, no maintenance, and low capital cost.
While the commonly available vortex tubes are similar in design. Which has not changed for decades, companies such as Nex Flow are developing new, more efficient versions. Providing the potential for greatly expanded use.
For assistance in using vortex tube technology, Nex Flow can help.
