PROJECT REPORT

Effect of Length and Shape of Vortex Tube on Cooling Effect

Abstract
A vortex tube, also known as a Ranque–Hilsch vortex tube (RHVT), is a
mechanical device that separates compressed air into hot and cold streams
without any moving parts. The phenomenon occurs due to the complex fluid
dynamics inside the tube where high-pressure air enters tangentially, creating a
strong vortex flow. As the air spins at very high speed, energy separation occurs
and the air divides into two streams: a hot outer stream and a cold inner stream.
The cold air exits from one end of the tube while the hot air leaves through the
opposite end.

Vortex tubes are widely used in industrial cooling applications because of their
simple design, low maintenance requirements, and ability to produce cooling
without refrigerants or mechanical compressors. Typical applications include
machining process cooling, electronic component cooling, spot cooling of tools
and workpieces, and environmental control of small enclosures.

The performance of a vortex tube depends on several design and operating

parameters such as inlet pressure, diameter of the tube, nozzle configuration,
hot–end throttling, cold fraction, length of the tube, and the shape of the internal
components. Among these parameters, the length and shape of the vortex tube
play an especially important role in determining the temperature separation and
cooling efficiency because they directly influence the residence time, flow
structure and viscous dissipation within the tube.

This report focuses on analyzing how the length and shape of a vortex tube
influence the cooling effect. Different tube geometries and lengths are
considered in order to study their impact on temperature drop and overall
cooling performance. The report also discusses the operating principles of
vortex tubes, the factors affecting their performance, the mathematical modeling
of temperature separation, and the experimental methodology used to evaluate
their efficiency. The objective of this study is to understand the relationship
between vortex tube geometry and cooling effectiveness so that the design of
vortex tubes can be optimized for improved performance in industrial cooling
applications.

Table of Contents
1. Introduction
2. Background of Vortex Tube Technology
 3. Importance of Vortex Tube Cooling
4. Literature Review
5. Components of a Vortex Tube
6. Design of Vortex Tube System
7. Mathematical Modeling of Cooling Effect
8. Experimental Methodology
9. Performance Analysis Parameters
10. Results and Discussion
11. Conclusion
12. References

1. Introduction
A vortex tube is a compact device that produces both hot and cold air streams
from compressed air without requiring any moving mechanical components. The
vortex tube was first discovered by French physicist Georges J. Ranque in 1933
and later investigated and improved by German physicist Rudolf Hilsch in 1947.
Because of their contributions, the device is commonly referred to as the
Ranque–Hilsch vortex tube (RHVT).

The working principle of a vortex tube is based on the phenomenon of energy

separation within a rotating compressible airflow. When compressed air enters
the tube tangentially through one or more nozzles, it begins to rotate at very
high velocity, creating a strong swirling motion. As the air moves downstream in
a spiral path, part of the flow is forced toward the outer periphery of the tube
while another part returns along the central region. Due to conservation of
angular momentum, interaction between viscous shear layers, and compressible
effects, the air near the outer region of the tube becomes hotter while the air
near the center becomes colder.

The hot outer stream is typically discharged from the hot end of the tube
through a control valve, while the cold inner stream is extracted from the
opposite end through a cold orifice. The temperature difference between the
inlet air and the cold outlet air represents the cooling effect of the vortex tube,
whereas the temperature rise at the hot outlet represents the heating effect. The
ratio of the cold mass flow rate to the total inlet mass flow rate is called the cold
fraction and is an important parameter in vortex tube operation.

Vortex tubes are attractive for industrial applications because they are simple,
reliable and require minimal maintenance. Unlike conventional refrigeration
systems, vortex tubes do not use refrigerants, compressors, condensers, or
expansion valves. They operate solely using compressed air, which is already
available in many manufacturing plants. The absence of moving parts eliminates
issues related to wear, lubrication, and vibrations. Additionally, the device is
compact, lightweight and can be easily installed in confined spaces where
mechanical refrigeration is impractical.
One of the most important factors affecting vortex tube performance is the
geometry of the tube itself. The length of the tube controls the distance over
which the swirling flow can develop and the time for which the air remains
inside the vortex region. This directly affects the degree of energy separation
that occurs. If the tube is too short, the flow may not have sufficient
development length to achieve significant temperature separation. Conversely, if
the tube is excessively long, frictional losses and pressure drop may dominate
and reduce the cooling performance.

Similarly, the shape of the tube can strongly influence the internal flow pattern
and pressure distribution. Straight cylindrical tubes are simple to manufacture,
but conical or diverging geometries can modify the expansion and
recompression processes and can potentially enhance energy separation.
Understanding how these design parameters affect cooling performance is
essential for optimizing vortex tube design for specific applications.

This report investigates the effect of tube length and tube shape on the cooling
performance of a vortex tube system. Using experimental data and simplified
mathematical models, the relationship between vortex tube geometry and
temperature separation is studied, and guidelines for optimized design are
proposed.

2. Background of Vortex Tube

Technology
The vortex tube is an unconventional device used for spot cooling and heating in
many industrial environments. Its operation is purely pneumatic and is based on
compressed air expansion rather than on a traditional vapor compression
refrigeration cycle. Because it does not require electricity at the point of use and
has no moving parts, the vortex tube can be applied in harsh or hazardous
environments where conventional refrigeration equipment cannot easily operate.

2.1 Historical Development

Georges Ranque first observed the vortex tube effect while experimenting with
cyclone separators and gas streams in the early 1930s. He noticed that gas
exiting a cyclone unexpectedly separated into distinct hot and cold regions. In
1933 he patented a device that utilized this effect. Several years later, Rudolf
Hilsch performed detailed experimental investigations and offered an
explanation based on thermodynamic and fluid dynamic analysis. Since then, the
device has been known as the Ranque–Hilsch vortex tube.

Initially, the vortex tube was considered an academic curiosity due to its
relatively low energy efficiency compared with conventional refrigeration
systems. However, its special advantages—such as compactness, simplicity, and
the absence of moving parts—led to increasing interest for niche applications
such as cooling of cutting tools, welding operations, and electronics. In the last
few decades, research has focused on improving the performance of vortex
tubes through optimization of their geometry and operating conditions.
2.2 Basic Operating Principle
The basic structure of a conventional counter-flow vortex tube consists of:

 A compressed air inlet connected to a nozzle or nozzle set

 A nozzle chamber where high-pressure air expands and accelerates
 A cylindrical vortex tube body
 A hot end equipped with a control valve
 A cold end with a calibrated orifice or nozzle
When compressed air enters the nozzle chamber, it is forced tangentially into
the tube, generating a high-speed swirling motion. The flow forms a free vortex
with high angular momentum, where the outer region experiences higher
pressure and temperature, while the inner core region experiences lower
pressure and temperature.

The hot stream moves toward the hot end of the tube and exits through the
control valve. By adjusting this valve, the proportion of hot and cold mass flow
rates can be changed. Part of the flow is forced back toward the cold end
through a central reverse vortex and exits as cold air. The resulting temperature
separation can be significant, with cold end temperatures sometimes reaching
tens of degrees Celsius below the inlet temperature, depending on the design
and operating conditions.

2.3 Application Areas

Vortex tubes are used in various applications, including:

 Spot cooling of cutting tools in machining operations

 Cooling of electronic components and control panels
 Cooling of sensors and instrumentation in hazardous or explosive
environments
 Environmental conditioning of small enclosures and operator
workstations
 Anti-fogging and de-icing of optical equipment and windows
In many of these applications, the ability to generate cold air instantly from
compressed air without bulky refrigeration equipment is a key advantage.

3. Importance of Vortex Tube

Cooling
Vortex tube cooling has gained importance in modern manufacturing and
process industries due to its unique combination of simplicity, reliability, and
environmental friendliness. Some of the main advantages are:
3.1 Advantages of Vortex Tubes
 No moving parts: The absence of rotating machinery or reciprocating
components leads to high reliability and very low mechanical
maintenance.
 Low maintenance requirements: Only periodic cleaning of filters and
orifices is usually required, with no need for lubricants or refrigerant
handling.
 Compact design: Vortex tubes are small and lightweight, which makes
them easy to install in congested areas or directly on machine tools.
 Instant cooling capability: Cooling or heating is available immediately
when compressed air is supplied, without the start-up delay associated
with conventional refrigeration systems.
 No refrigerants required: Since the working fluid is compressed air,
issues related to ozone-depleting or greenhouse refrigerants are
completely avoided.
 Ability to function in harsh environments: Vortex tubes can be used
in dirty, wet, or explosive atmospheres where conventional electrical
equipment would require special protection.

3.2 Typical Applications

Because of these benefits, vortex tubes are used in the following applications:

 Cooling electronic components: Printed circuit boards, control panels,

and small cabinets can be cooled using cold air from vortex tubes to
prevent overheating and improve reliability.
 Cooling cutting tools during machining: In operations such as
turning, milling, drilling, and grinding, cold air jets from vortex tubes can
extend tool life and improve surface finish.
 Environmental control in hazardous environments: Vortex tubes can
provide air conditioning in areas where electrical equipment is restricted.
 Cooling of control panels and instrumentation: Cold air can be
directed onto temperature-sensitive devices to maintain stable operating
conditions.
Due to these advantages, researchers continue to study methods to increase
vortex tube efficiency and to better understand the influence of design
parameters such as tube length and shape on performance.

4. Literature Review
Several studies have examined the performance of Ranque–Hilsch vortex tubes
under different operating conditions and geometrical configurations.
Researchers have investigated effects related to inlet pressure, nozzle geometry,
number of nozzles, tube length, tube diameter, hot-end valve opening and cold
fraction. A brief overview is given below.

4.1 Effect of Operating Parameters

Experimental investigations have shown that:

 Increasing inlet pressure generally increases the temperature difference

between the hot and cold outlets, because more compressible work and
higher kinetic energy are available for energy separation.
 The cold fraction strongly affects both cold and hot outlet temperatures.
An optimum cold fraction exists at which the maximum temperature drop
at the cold end is observed.
 The diameter of the tube and the nozzle configuration influence the swirl
intensity and the distribution of axial and tangential velocities, which in
turn affect energy separation.

4.2 Studies on Tube Length

Many experiments reported in the literature indicate that increasing the tube
length improves temperature separation up to a certain limit. For relatively
short tubes, the vortex does not have sufficient development length, and energy
separation remains small. As the length increases, the interaction between the
forward and reverse vortices allows more energy exchange between the
peripheral and central regions, thereby enhancing the temperature difference.

However, beyond an optimal length, further increases in tube length cause

significant frictional losses along the wall, leading to pressure drop and energy
dissipation. The result is a reduction in overall cooling performance. This
behavior suggests the existence of an optimal length-to-diameter ratio (L/D) that
maximizes cooling efficiency.

4.3 Studies on Tube Shape

Researchers have also studied the effect of different tube shapes, such as:

 Straight cylindrical tubes

 Conical (converging or diverging) tubes
 Tubes with gradual expansion or contraction along the axial direction
Conical tubes can modify the axial pressure gradient and influence the
expansion of the swirling flow. For example, a diverging tube provides gradual
expansion that may enhance cooling by promoting additional expansion of the
central core. Conversely, certain shapes can cause premature flow separation or
increase turbulence dissipation, reducing performance.

Reported results generally indicate that suitable non-cylindrical geometries,

especially conical or slightly diverging tubes, can achieve better cooling
performance compared with simple straight tubes when properly designed.
4.4 Summary of Literature Findings
The literature clearly shows that vortex tube performance is sensitive to both
tube length and shape. There exists an optimum range of L/D ratio and specific
geometrical profiles that yield maximum temperature separation for given
operating conditions. Nevertheless, most previous studies have focused on either
length or shape individually. Comprehensive experimental data combining both
parameters for a given set of operating conditions are still limited.

In this project, a systematic experimental investigation is carried out in which

both tube length and tube shape are varied, and the resulting cooling effect is
analyzed.

5. Components of a Vortex Tube

A vortex tube system typically consists of several key components, each of which
plays a specific role in producing the hot and cold air streams. The major
components are described below.

5.1 Compressed Air Inlet

The compressed air inlet is the connection point between the plant compressed
air system and the vortex tube. Compressed air is usually supplied at pressures
in the range of 3–8 bar. Proper filtration and, if necessary, drying are required to
remove dust, oil and moisture, which could otherwise cause clogging of the
small nozzles and affect performance.

5.2 Nozzle Chamber

The nozzle chamber houses one or more nozzles that convert the pressure
energy of the compressed air into high-velocity jets. These nozzles are aligned
tangentially to the internal surface of the tube. As compressed air expands
through the nozzle, its static pressure decreases and its velocity increases,
generating the initial swirling motion inside the tube. The number, size and
orientation of the nozzles significantly influence the strength of the vortex and
the resulting temperature separation.

5.3 Vortex Tube Body

The vortex tube body is the main cylindrical or conical chamber where the
vortex motion occurs. Its inner surface guides the swirling flow, and its length
and shape determine the development of the forward and reverse vortices. In
this study, different lengths and shapes of the tube body are considered in order
to evaluate their effects on cooling performance.

5.4 Hot End Control Valve

The hot end control valve is mounted at one end of the tube and regulates the
flow of hot air leaving the device. By adjusting the valve opening, the operator
can change the resistance at the hot end and thus control the mass flow split
between the hot outlet and the cold outlet. The valve setting directly affects the
cold fraction and the temperature separation. Generally, there is an optimal
valve opening at which the cold end temperature reaches a minimum.

5.5 Cold End Outlet

The cold end outlet is located at the opposite end of the tube and is equipped
with a cold orifice or nozzle. The cold inner core of the vortex passes through
this orifice and exits as a cold air stream. The size and geometry of the cold
orifice influence the mass flow of the cold stream and its temperature.

6. Design of Vortex Tube System

The design of a vortex tube significantly influences its performance. Key design
parameters include tube length, tube diameter, nozzle configuration, tube shape
and hot-end valve geometry. In this project, special attention is given to tube
length and tube shape.

6.1 Design Parameters

The principal design parameters considered are:

 Tube length L
 Tube inner diameter D
 Length-to-diameter ratio L/ D
 Tube shape: straight, conical, or diverging
 Nozzle arrangement and inlet pressure (maintained constant for
comparison)
 Cold orifice diameter and hot-end valve setting

6.2 Tube Length for Straight Cylindrical Tubes

For experimental analysis, several vortex tube lengths are tested while keeping
the tube diameter and nozzle configuration constant. Typical data are given in
Table 6.1.

Table 6.1: Effect of Tube Length on Cold Air Temperature (Straight

Tube)

Tube Length (mm) Cold Temperature (°C)

150 12
200 10
250 8
 300 7
350 9

The table indicates that the cooling effect improves as the length increases from
150 mm to 300 mm, with the cold air temperature decreasing from 12 °C to 7
°C. However, further increase in length to 350 mm results in a higher cold
temperature of 9 °C, indicating a reduction in cooling performance. This
behavior confirms the existence of an optimal tube length for given operating
conditions.

6.3 Tube Shape Configurations

In addition to length, different tube shapes are considered in the experiments,
such as:

 Straight cylindrical tube

 Conical tube (slightly converging or diverging)
 Diverging tube with small expansion angle
An example set of experimental data for combined shape and length effects is
shown in Table 6.2.

Table 6.2: Example Data for Different Tube Shapes and Lengths

Tube Shape Length (mm) Cold Temp (°C) Hot Temp (°C)
Straight 200 10 45
Straight 250 8 48
Conical 250 7 50
Diverging 250 9 46

The data show that for the same length of 250 mm, the conical tube provides the
lowest cold temperature of 7 °C, indicating better cooling performance than the
straight or diverging tube. The diverging tube, while still effective, gives a
slightly higher cold temperature.

7. Mathematical Modeling of
Cooling Effect
To better understand the performance of the vortex tube, basic mathematical
relationships describing the cooling effect and temperature separation are used.

7.1 Temperature Drop

The temperature drop at the cold end can be expressed as:

Δ T c =T inlet − T cold

where:

 T inlet = inlet air temperature

 T cold = cold outlet temperature
Similarly, the temperature rise at the hot end is:

Δ T h=T hot −T inlet

where T hot is the hot outlet temperature.

7.2 Cooling Efficiency Based on Ideal

Isentropic Expansion
A simplified measure of cooling effectiveness compares the actual temperature
drop with the ideal temperature drop achieved by isentropic expansion of
compressed air from inlet pressure Pin to cold outlet pressure Pc . For an ideal
gas with specific heat ratio k , the ideal exit temperature after isentropic
expansion is:

( )
k −1
Pc k
T ideal=T inlet
P in

The ideal temperature drop is:

Δ T ideal =T inlet −T ideal

The non-dimensional cooling efficiency can then be defined as:

Δ Tc
η c=
Δ T ideal

Values of η c less than 1 indicate that the actual temperature drop is lower than
the ideal isentropic expansion case, which is expected due to irreversibilities and
mixing inside the tube.

7.3 Energy Balance

A control volume energy balance for the vortex tube, neglecting heat transfer to
the surroundings, can be written as:

ṁin hin = ṁc hc + ṁh hh

where:
  ṁin = inlet mass flow rate
 ṁc = cold mass flow rate
 ṁh = hot mass flow rate
 h in , hc , hh = specific enthalpies at inlet, cold outlet and hot outlet
Defining the cold fraction μ as:

ṁc
μ=
ṁin

and assuming constant specific heat c p, the energy balance can be expressed in
terms of temperatures:

T inlet =μT cold +(1− μ)T hot

For known inlet temperature, cold fraction and either cold or hot temperature,
the other temperature can be predicted.

8. Experimental Methodology
The experimental investigation aims to determine how vortex tube length and
shape affect the cooling effect under controlled conditions.

8.1 Experimental Setup

The experimental setup consists of:

 An air compressor capable of delivering compressed air at controlled

pressures
 A pressure regulator and filtered air supply line
 A set of interchangeable vortex tubes with different lengths and shapes
 A hot-end control valve with adjustable opening
 Temperature sensors (thermocouples or RTDs) at the inlet, hot outlet and
cold outlet
 Pressure gauges at the inlet and outlets
 A flow control valve and rotameter or mass flow meter to measure air flow
rate
The vortex tubes used in the experiments are designed to have the same inlet
nozzle configuration and inner diameter, while the tube length and shape are
varied.

8.2 Experimental Procedure

The general procedure adopted is as follows:
 1. Preparation

o The air compressor is started and allowed to reach the desired

operating pressure.
o The pressure regulator is adjusted to maintain a constant inlet
pressure for all tests.
o The appropriate vortex tube (with specified length and shape) is
installed in the test rig.
2. Setting Operating Conditions

o The hot-end control valve is adjusted to a predetermined opening

corresponding to a selected cold fraction.
o The air flow rate through the vortex tube is established and
monitored using the flow meter.
3. Measurement of Temperatures and Pressures

o Temperature sensors measure the inlet air temperature, cold outlet

temperature and hot outlet temperature.
o Pressure gauges record the inlet, hot outlet and cold outlet
pressures.
o Measurements are taken after the system reaches steady-state
conditions.
4. Variation of Tube Geometry

o For each tube length, several readings are taken to ensure

repeatability.
o The same procedure is repeated for different tube shapes (straight,
conical and diverging) at a chosen length.
5. Data Recording and Analysis

o The recorded data (temperatures, pressures, flow rate and

geometry details) are tabulated.
o Temperature drops, temperature separation and cooling efficiency
are calculated using the mathematical relations described earlier.
This methodology ensures that the influence of tube length and shape can be
compared under similar operating conditions.

9. Performance Analysis Parameters

Several parameters are used to evaluate vortex tube performance and to
compare different geometrical configurations.

9.1 Temperature Separation

Temperature separation is defined as the difference between hot outlet and cold
outlet temperatures:

Δ T sep=T hot −T cold

A larger value of Δ T sep indicates more effective energy separation between the
hot and cold streams.

9.2 Cold End Temperature Drop

The cold end temperature drop is:

Δ T c =T inlet − T cold

This parameter directly represents the cooling effect of the vortex tube. Lower
cold end temperatures correspond to higher cooling potential.

9.3 Cooling Capacity

If the cold air mass flow rate ṁ c and specific heat c p are known, the cooling
capacity Q̇ c can be calculated as:

Q̇c =ṁc c p (T inlet − T cold )

Cooling capacity allows comparison of the amount of useful cooling produced by

different vortex tube configurations.

9.4 Pressure Drop

The pressure drop across the vortex tube is another important parameter that
affects performance. It is usually expressed as the difference between inlet
pressure and cold outlet pressure, or inlet pressure and hot outlet pressure.
Excessive pressure drop indicates high frictional losses inside the tube, which
can reduce efficiency.

10. Results and Discussion

The experimental results show that both tube length and tube shape significantly
influence the cooling performance of the vortex tube.

10.1 Influence of Tube Length

From Table 6.1, as the tube length increases from 150 mm to 300 mm, the cold
outlet temperature decreases from 12 °C to 7 °C. This implies an increase in the
cold end temperature drop and improved cooling performance. Physically, the
longer tube length allows more development of the swirling flow and provides
more distance for energy exchange between the outer hot region and the inner
cold core.
However, when the length is further increased to 350 mm, the cold outlet
temperature rises to 9 °C, indicating a reduction in cooling performance. This
trend demonstrates that beyond a certain optimal length, frictional losses along
the tube wall and increased residence time cause additional entropy generation
and energy dissipation, offsetting the benefits of longer flow development.

Therefore, for a given tube diameter and operating pressure, there exists an
optimal length–to–diameter ratio that maximizes temperature separation. In
practical design, this optimal length must be determined based on experimental
data or detailed numerical simulations.

10.2 Influence of Tube Shape

The results in Table 6.2 show that tube shape also plays a crucial role in
determining vortex tube performance. For a length of 250 mm:

 The straight tube yields a cold temperature of 8 °C.

 The conical tube yields a lower cold temperature of 7 °C and a slightly
higher hot temperature of 50 °C, indicating enhanced energy separation.
 The diverging tube yields a cold temperature of 9 °C, which is higher than
that of the straight tube and conical tube, suggesting comparatively lower
cooling performance.
The superior performance of the conical tube can be attributed to its ability to
provide gradual variation in cross-sectional area, which influences the expansion
of the tangential and axial velocity components. This geometry may help
maintain a strong central reverse flow while controlling viscous dissipation,
thereby enhancing the energy separation mechanism.

In contrast, an improperly designed diverging tube may cause flow separation

and increased turbulence, which can dissipate useful energy and reduce the
effective temperature difference.

10.3 Combined Effect of Length and Shape

When both length and shape are considered together, it becomes clear that
optimal performance is achieved only when both parameters are carefully
selected. A conical tube of insufficient length may not allow full development of
the vortex, while an excessively long conical tube may still suffer from frictional
losses. Similarly, a straight tube can perform reasonably well if its length is near
the optimal value, even if its shape is not tailored for maximum energy
separation.

Therefore, the design of vortex tubes must be based on a combined optimization

of length, shape, and other parameters such as nozzle configuration and cold
fraction. Experimental data, like those presented in this report, provide essential
guidance for such optimization.

11. Conclusion
The Ranque–Hilsch vortex tube is a simple and effective device for spot cooling
and heating that operates without moving parts. The cooling effect is produced
through the separation of compressed air into hot and cold streams inside a
swirling flow field. In this project, the influence of vortex tube length and tube
shape on the cooling effect was systematically investigated.

The analysis shows that both tube length and tube shape play critical roles in
determining temperature separation and cooling efficiency:

 Increasing tube length improves cooling performance up to an optimal

value, as it provides sufficient development length for the internal vortex
and enhances energy exchange between the hot peripheral region and the
cold core.
 Beyond the optimal length, friction and pressure losses become
significant and reduce the cooling effect.
 Tube shape modifies the internal flow structure. Conical tubes, when
properly designed, can yield better cooling performance than straight
tubes by promoting favorable expansion and energy separation. Diverging
tubes may either improve or degrade performance depending on the
expansion angle and surface finish.
Optimizing these design parameters can significantly improve vortex tube
performance for specific industrial applications. For instance, selecting an
appropriate combination of length, shape and operating conditions can enable
efficient cooling of cutting tools, electronics, and small enclosures using only
compressed air.

12. References
1. Ranque, G. J. (1933). Experiments on expansion in a vortex tube.
2. Hilsch, R. (1947). The use of expansion of gases in a centrifugal field.
3. Behera, U., et al. Experimental investigation of vortex tube performance.
4. Eiamsa-ard, S., & Promvonge, P. Review of Ranque–Hilsch vortex tube
research.
5. Saidi, M. H., & Valipour, M. Experimental study of vortex tube cooling
performance.