Atomizer design for viscous-melt atomization

The development of a gas atomization unit is introduced, which utilizes characteristic flow effects for efficient fragmentation of viscous liquids and melts. The proposed device combines a classical rotary atomizer with an external mixing gas atomizer. Here, the liquid stream is first transformed into a thin liquid sheet before disintegration. Thereby the specific surface energy is increased without breakup. The movement of the free flowing liquid film is controlled by the local gas flow field in order to transport the film into the most effective atomization region. The fragmentation process itself is caused by a perpendicular impinging gas stream. Numerical flow simulations are used for the development of the hybrid atomizer construction. Experiments using viscous model liquids show that for constant air-to-liquid mass-flow ratio the particle size is reduced using the hybrid atomizer compared with a conventional gas atomizer. Results of model experiments as well as of experiments with a viscous mineral melt are discussed.