A recently developed digital image analysis technique potentially capable of sizing particles of arbitrary shape and size and with wide dynamic range is examined. Shadow images of droplets or particles are produced in this case by back-illumination using an infra-red diode laser. The measurement performance of the particle/ droplet image analysis (PDIA) system has been assessed initially in terms of individual object diameters and the aim of this experimental investigation was to assess the robustness and accuracy of the technique. The first part of this paper provides a description of the fundamental principles of the technique followed by a thorough description of the calibration procedure in which the image processing routine was verified with calibration data of known particle sizes. The lenscamera optical behavior has been characterized whilst the relative uncertainties of various parameters such as the depth-of-field dependence on particle diameter, threshold level sensitivity and image signal-to-noise issues have been quantified and their effects on measurement accuracy discussed. Calibration data revealed that the depth-of-field varied with object diameter approximately linearly in the measured range 18 to 145 mm. The calibration data is subsequently incorporated into the PDIA processing algorithm and for defocused droplets or particles, enables their true diameter to be estimated by analyzing the droplet image properties. Greater emphasis on the application of the PDIA technique is deferred to the second part of this two-part paper where droplet size data obtained from a hollow-cone spray is compared with similar data measured via phase Doppler anemometry (PDA).

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A series of experiments were conducted in order to assess the robustness and accuracy of a recently developed digital image analysis technique (PDIA). This paper investigates the application of the PDIA technique to the sizing of relatively small fuel droplets of diameters in the range 5 to 30 μm produced by a pressure‐swirl atomizer. The measurement performance of the PDIA system has been assessed in terms of individual object diameters and also number and volume probability density functions of diameter in comparison to phase Doppler anemometry (PDA) data obtained under identical conditions. PDIA measurements revealed good agreement with spray data obtained by PDA at a measurement location 36 diameters downstream from the nozzle orifice with differences in the arithmetic mean diameter, D10 and volume mean diameter, D30 of approximately 5 and 3% respectively. The PDIA technique was shown to detect the presence of very large, predominantly non‐spherical droplets whose diameters were in excess of 100 μm. These droplets, although few in number constitute a significant proportion of the total spray volume and would have otherwise been either erroneously measured or have passed through the probe volume undetected using PDA due to non‐sphericity. Smaller objects may also be measured correctly by both methods although sensitivity to signal‐to‐noise ratio, for both methods can generate spurious and contradictory errors.