Journal article
Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids
Physics of fluids (1994), v 38(2), 023331
01 Feb 2026
Abstract
Filament extension atomizers (FEAs) are an emerging class of spray nozzles designed to atomize high-viscosity and non-Newtonian fluids that are challenging for conventional pressure or two-fluid nozzles. In this study, we investigate the influence of roller geometry, surface velocity, roller material, and fluid rheology on the atomization performance of FEA systems using concentrated whey protein suspensions (50-70 wt. %). Extensional and shear rheology experiments, along with high-speed imaging and particle image velocimetry, reveal that filament breakup dynamics are governed by competition between inertial, capillary, and viscoelastic stresses. High roller rotational velocity leads to narrower spray cones, contradicting rheology experiments and suggests a significant inertial contribution to filament breakup. Smaller rollers operating at the same rotational velocity led to broader spray cones consistent with expectations. An FEA nozzle was integrated into a conventional dryer producing particles in the 100 mu m range. Results suggest that FEA technology enables atomization of highly viscous fluids at industrially relevant spray cone angles similar to those generated by pressure nozzles, offering a pathway to improve energy efficiency in spray drying by enabling higher solids loading feedstocks. These insights provide critical guidance for optimizing FEA nozzle designs and process parameters across a range of applications.
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Details
- Title
- Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids
- Creators
- Ravi Neelakantan - Palo Alto Research CenterNicolas J. Alvarez - Drexel UniversityThamires A. Lima - Drexel UniversityAditya Sangli - Palo Alto Research CenterEric Weflen - Palo Alto Research CenterBenjamin Boggs - Palo Alto Research CenterGregory Anderson - Palo Alto Research CenterDavid M. Johnson - Palo Alto Research Center
- Publication Details
- Physics of fluids (1994), v 38(2), 023331
- Publisher
- AIP Publishing
- Number of pages
- 13
- Resource Type
- Journal article
- Language
- English
- Academic Unit
- Chemical and Biological Engineering
- Web of Science ID
- WOS:001695409200001
- Scopus ID
- 2-s2.0-105030856146
- Other Identifier
- 991022163920904721