Optimised Twin Fluid Atomiser Design for High-Viscosity, Shear-Thinning Fluids

This study explores the optimisation of nozzle design for external twin fluid, single-stage atomisation in handling high-viscosity, shear-thinning polydimethylsiloxane (PDMS). A single PDMS grade was employed and atomised using unheated sonic air and the viscosity was varied by the fluid temperature. A systematic experimental approach was used, varying nozzle geometry—specifically apex angle, gas nozzle diameter, and number of gas nozzles—to identify the optimal nozzle configuration (ONC). The spray qualities of the nozzle configurations were evaluated via high-speed imaging at 75,000 FPS. Shadowgraphy was employed for the optical characterisation of the spray, determining the optimal volumetric air-to-liquid ratio (ALR), a key parameter influencing energy efficiency and operational cost, and for assessing droplet size distributions under varying ALR and viscosity of PDMS. The ONC yielded a Sauter mean diameter d32 of 570 × 10−6m, at an ALR of 8532 and a zero-shear viscosity of 15.9 Pa s. The results are relevant for researchers and engineers developing twin fluid atomisation systems for challenging industrial fluids with similar physical properties, such as those in wastewater treatment and coal–water slurry atomisation (CWS). This study provides design guidelines for external twin fluid atomisers to enhance atomisation efficiency under such conditions.