Understanding the operating limitations of an internal-mixing Air-Core-Liquid-Ring (ACLR) nozzle for process intensification in spray drying

Spray drying is a widely used method for producing food powders in large quantities, but it also has a high energy demand. To address this, researchers have long aimed to increase the solid content of liquid feeds, which poses the challenge of atomizing high-viscosity liquids into fine droplets. The Air-Core-Liquid-Ring (ACLR) nozzle offers a potential solution by inducing an internal annular flow, though it faces its own limitations due to internal flow instabilities. This study investigates how the nozzle flow conditions impact spray performance under different process conditions and liquid viscosities. We found that internal lamella thickness and atomization uniformity vary with pressure, viscosity, and liquid volume flow. Nonetheless, pressure appears to be the real critical factor in that case. The Air-to-Liquid Ratio (ALR) might be more decisive for the droplet size distribution than liquid viscosity. Future research should explore higher viscosities and consider simulations to circumvent experimental limitations.