Design and atomization properties for an inside-out type effervescent atomizer

Atomization of aqueous polymer solutions is a key step in the formulation of several pharmaceutical products. Droplet size control is essential in order to produce pharmaceutical products with the desired properties. The purpose of this paper is to investigate design issues for an inside-out type of effervescent atomizer used to spray water and aqueous solutions of polyvinylpyrrolidone (Kollidon® K-30) and hydroxypropyl methylcellulose (Pharmacoat® 603). The atomizer was operated at air-to-liquid mass ratios of 0.1, 0.3, and 0.5 and a feed pressure of 1172 kPa. Fluid viscosities ranged from 1 to 47 mPa.s. The influence of several atomizer design features was considered, including exit orifice length-to-diameter ratio, exit orifice diameter, the total area of the air injection holes, the distance between the air injection point and the exit orifice, the diameter of the mixing chamber, and the orientation of both air and liquid flows. Droplet size distributions were shown to vary significantly with the atomizer's exit orifice diameter, air injector design, and air injector distance to the exit orifice. In all cases air-to-liquid mass ratio played a key role in the mean droplet size. The design of the atomizer was shown to have the most pronounced effect on the mean droplet size at the lowest air-to-liquid mass ratios. Optimization of the atomizer design is very important in order to obtain small droplet sizes in pharmaceutical processes where the amount of air/gas should be minimized, e.g., closed-cycle spray drying and agglomeration processes.