Atomization for spray drying of high viscous feed liquids is still a challenging task. For this reason, we investigated the potential of two internal mixing pneumatic atomizers, namely an effervescent atomizer (EA) and an Air-Core-Liquid-Ring (ACLR) atomizer. Both atomizers are characterized by a two-phase flow in the exit orifice. While this can be either a two-phase plug or annular flow in case of the EA geometry, the ACLR atomizer enforces annular flow conditions. In this study, spraying experiments were conducted at liquid viscosities between 0.12 and 0.69 Pa•s. The investigations were performed at a constant liquid flow rate of 20 L/h and gas pressures from 0.3 to 0.9 MPa. Besides the commonly used correlation between Gas-to-Liquid-Ratio (GLR) and time-averaged Sauter mean diameters (SMD), we analyzed in-depth the time dependent fluctuation of SMDs, as steady atomization is crucial for spray drying applications. We can conclude that due to strong fluctuations of the SMDs the EA is not suitable for the aimed application in spray drying of high viscous feed liquids. In contrast, the ACLR atomizer is a very promising nozzle for spray drying applications as it delivers much better performance and steadiness also at high liquid viscosities.

Air-core–liquid-ring (ACLR) atomization presents a specific type of internal mixing pneumatic atomization. It can be used for disintegration of high viscous feed liquids into small droplets at relatively low gas consumptions. However, the specific principle of ACLR atomization is still under research and no guidelines for process and atomizer design are available. Regarding literature on pre-filming atomizers, it can be hypothesized for ACLR atomization that the liquid film thickness inside the exit orifice of the atomizer, as well as the resulting spray droplet sizes decrease with increasing air-to-liquid ratio (ALR) and decreasing feed viscosity. In this study, the time dependent liquid film thickness inside the exit orifice of the atomizer was predicted by means of computational fluid dynamics (CFD) analysis. Results were compared to high speed video images and correlated to measured spray droplet sizes. In conclusion, the hypothesis could be validated by simulation and experimental data, however, at high viscosity and low ALR, periodic gas core breakups were detected in optical measurements. These breakups could not be predicted in CFD simulations, as the simplification of an incompressible gas phase was applied in order to reduce computational costs and time. Nevertheless, the presented methods show good potential for improvement of atomizer geometry and process design as well as for further investigation of the ACLR atomization principle.

Laser diffraction is among the most widely used methods for spray droplet size measurements. However, the so-called beam-steering effect must be considered when pneumatic atomizers are used for droplet generation. The beam-steering effect is a systematic measurement error, leading to the detection of apparent large spray droplets due to gradients in the refractive index of the gas phase. The established correction method is based on the reduction of the laser diffraction system’s measurement range by deactivation of detectors, relevant for the detection of large droplets. As this method is only applicable when size ranges of real and apparent droplet sizes are clearly different, an alternative method for beam-steering correction is introduced in the presented study. It is based on a multimodal log-normal fit of measured spray droplet sizes. The modality representing the largest droplets is correlated to the beam-steering effect and therefore excluded from the measured size distribution. The new method was successfully applied to previously published droplet size distribution measurements of an internal mixing Air-Core-Liquid-Ring (ACLR) atomizer. In measurements where the method of detector deactivation is applicable, excellent accordance of droplet size distributions, gained by both correction methods, was found. In measurements with overlapping real and apparent parts of the distribution, the new correction method led to a significant reduction of overestimated large droplets. As a consequence, we conclude that the new method presented here for beam-steering correction should be applied in laser diffraction measurements of spray droplet sizes, generated by pneumatic atomizers.

Air-core-liquid-ring (ACLR) atomizers present a specific type of internal mixing pneumatic atomizers, which can be used for efficient atomization of high viscous liquids. Generally, atomization efficiency is considered as a correlation between energy input and resulting droplet size. In pneumatic atomization, air-to-liquid ratio by mass (ALR) is commonly used as reference parameter of energy input. However, the pressure energy of the atomization gas is not considered in the calculation of ALR. In internal mixing ACLR atomizers, it can be assumed that this energy contributes to liquid disintegration by expansion of the gas core after exiting the atomizer. This leads to the hypothesis that droplet sizes decrease with increasing gas pressure at constant ALR. Therefore, the use of volumetric energy density (EV) as a reference parameter of energy input was investigated at different gas pressures between 0.4 and 0.8 MPa. Furthermore, scale up-related influences on the atomization efficiency of ACLR atomization were investigated by use of an atomizer with enlarged exit orifice diameter. We can conclude that EV can be applied as a reference parameter of ACLR atomization processes with different gas pressures. However, within the range investigated no clear influence of gas pressure on atomization efficiency was found. Up-scaling of ACLR atomizers allows production of similar droplet sizes, but atomization efficiency decreases with increasing exit orifice diameter.

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