Experimental Study of Spray Drying and Atomization with a Two-Fluid Nozzle to Produce Inhalable Particles

A series of 50 experiments was performed to investigate particle size and yield from three laboratory spray dryers with two-fluid nozzles, using an aqueous solution of egg albumin as the feed. First principles theory suggests that the main parameters affecting final particle size should be atomization gas flowrate and velocity, feed solution flowrate, solution concentration, and inlet and outlet gas temperature. The experiments demonstrated that atomization gas velocity at the nozzle correlated better than volumetric gas flowrate to the final particle size obtained. Increasing atomization gas flow gave a decrease in particle size, levelling off at high nozzle gas velocities approaching sonic values. Liquid flowrate had little effect, and hybrid ratios such as the ALM (atomization gas to liquid flow ratio) did not correlate well to measured final particle size for this system. This seems likely to apply to aqueous systems with temperature limitations, where liquid flowrates will be relatively low compared to gas flowrates (both atomization and main gas flow). Particle size generally increased with solution concentration, and in some cases scaled exactly, assuming a constant initial droplet size and final particle density. All experiments were performed below the boiling point and therefore temperature had little effect. Particles of 2–3 microns were obtained at high atomization gas flows, indicating initial droplet sizes of 4–7 microns at most, while lower flowrates gave substantially larger particles and a wider size distribution.