Effect of Nozzle Structure on Energy Separation Performance in Vortex Tubes

Vortex tubes are used in specialized scenarios where conventional refrigeration systems are impractical, such as tool cooling in CNC machines. The internal flow within a vortex tube is highly complex, with numerous factors influencing its energy separation process, and the coefficient of performance for refrigeration is relatively low. To investigate the impact of nozzle type on energy separation performance, vortex tubes with straight-type, converging-type, and converging–diverging-type nozzles were designed. Numerical simulation was conducted to explore their velocity, pressure, and temperature distribution at an inlet pressure of 0.7 MPa and a cold mass fraction of 0.1~0.9. The cooling effect, temperature separation effect, cold outlet mass flow rate, and refrigeration capacity of vortex tubes were assessed. The converging–diverging nozzle increases the gas velocity at the nozzle outlet while it does not significantly enlarge the airflow velocity in the vortex chamber. As the cold mass fraction rises, the cooling performance and cooling capacity of three vortex tubes first increase and then decrease. The maximum cooling effect and cooling capacity of vortex tubes are achieved at cold mass fractions of 0.3 and 0.7, respectively. Under identical conditions, the vortex tube with a converging nozzle achieves the highest cooling effect with a temperature drop of 36.6 K, whereas the vortex tube with converging–diverging nozzles possesses the largest gas flow rate, and the cooling capacity reaches 542.4 W. The vortex tube with straight nozzles exhibits the worst refrigeration performance with a cooling effect of 33.6 K and a cooling capacity of 465.9 W. It is indicated that optimizing the nozzle structure of the vortex tube to reduce flow resistance contributes to enhancing both the gas velocity entering the swirl chamber and the resultant refrigeration performance.