Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids

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 μm 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.