Safety is important when it comes to gas furnaces; and with large ovens, equipment is used to protect workers and equipment. A copper company was using natural gas for smelting, and they had a UV scanner to monitor the flames. If the burners go out, the scanner will turn off the gas valves to stop a potential explosion. As with many instruments, it is important to keep the electronics cool for proper measurements. In this case, they were having issues with accuracy from the high heat. They contacted EXAIR for a solution.
With their UV scanner, it was designed for a “cooling” device already. This was basically compressed air that would blow around the instrument. Because of the location, the compressed air was heating up to 125oF (52oC). This heat would not cool the scanner properly, and it was causing unreliable readings and premature shutdowns. They gave me the design specifications, and the scanner required 3.2 SCFM (90 SLPM) of air at atmospheric pressure with a maximum of 77oF (25oC). I mentioned that we had the perfect solution to keep the UV scanner cool and operational; the EXAIR Vortex Tube. This product can take elevated temperatures of compressed air and reduce it to lower temperatures. It is a low cost, reliable, maintenance-free solution that uses compressed air to produce cold air as low as -50oF (-46oC). With a range of cooling capacities from 135 BTU/hr to 10,200 BTU/hr, I was sure that we could meet the requirements for proper cooling.
To determine the correct size, I had to look at the temperature drop and the flow requirement. The temperature had to decrease from the 125oF (52oC) incoming compressed air to at least 77oF (25oC). This would equate to a 48oF (27oC) temperature drop. The other requirement was the amount of air flow, 3.2 SCFM (90 SLPM). With the chart below, I see that we are able to get a 52oF (29oC) temperature drop at a 70% Cold Fraction and 40 PSIG (2.8 bar) inlet pressure. EXAIR Vortex Tubes are very adjustable to get different outlet temperatures by changing the inlet pressure and the Cold Fraction. The Cold Fraction (CF) is the amount of air that will be coming out the cold end. With a 70% CF, that means that the adjusting screw on the hot end of the Vortex Tube is turned to allow 70% of the incoming compressed air to go out the cold end. So, with that information, we can size to the correct model.
In comparing the above information to the catalog data at 100 PSIG (6.9 bar), we have to consider the difference in absolute pressures. With an atmospheric pressure of 14.5 PSIG (1 bar), the equation looks like this:
Qv = (Qc / CF) * (Pc + 14.5 PSIA) / (Ps + 14.5 PSIA)
Qv – Catalog Vortex Tube flow (SCFM)
Qc – Cold Air Flow (SCFM)
CF – Cold Fraction
Pc – Catalog Pressure – 100 PSIG
Ps – Supply Pressure – PSIG (Chart above)
From this equation, we can solve for the required Vortex Tube:
Qv = (3.2 SCFM / 0.7) * (100 + 14.5 PSIA) / (40 + 14.5 PSIA) = 9.6 SCFM.
In looking at the catalog data, I recommended our model HT3210 Vortex Tube which uses 10 SCFM of compressed air at 100 PSIG. The HT prefix is for our High Temperature models for use in temperatures in the range of 125oF to 200oF (52oC to 93oC). So, after installing, the Vortex Tube was able to supply 73oF (23oC) air at a flow of 3.3 SCFM (94 SLPM); keeping the UV scanner reading correctly and accurately.
Sometimes compressed air by itself is not enough to “cool” your instruments. The EXAIR Vortex Tubes can reduce the temperature of your compressed air to very cold temperatures. If you believe that your measuring equipment is being affected by elevated temperatures like the company above, you can contact an Application Engineer at EXAIR to find the correct solution for you.