Using Computation Fluid Dynamics to Determine Oil Droplet Breakup Parameters during Emulsion Atomization with Pressure Swirl Nozzles

A wide range of commercial powdered products are manufactured by spray drying emulsions. Some product properties are dependent on the oil droplet size, which can be affected by fluid mechanics inside the spray nozzle. However, most of the key flow parameters inside the nozzles are difficult to measure experimentally, and theoretical estimations present deviations at high shear rates and viscosities. Therefore, the purpose of this study was to develop a computational model that could represent the multiphase flow in pressure swirl nozzles and could determine the deformation stresses and residence times that oil droplets experience. The multiphase flow was modelled using the Volume-of-Fluid method under a laminar regime. The model was validated with experimental data using the operating conditions and the spray angle. The numerically calculated shear stresses were found to provide a better prediction of the final oil droplet size than previous theoretical estimations. A two-step breakup mechanism inside of the nozzle was also proposed. Additionally, some of the assumptions used in the theoretical estimations could not be confirmed for the nozzles investigated: No complete air core developed inside of the nozzle during atomization, and the shear stress at the nozzle outlet is not the only stress that can affect oil droplet size. Elongation stresses cannot be neglected in all cases.