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1. Atomization of High Viscosity Liquids Using a Two-Fluid Counterflow Nozzle: Experiments and Modeling

   https://doi.org/10.1115/GT2020-15691  

   Rangarajan, Roshan; Zhang, Hongyuan; Strykowski, Paul J.; Hoxie, Alison; Yang, Suo; Srinivasan, Vinod (September 2020, ASME Turbo Expo 2020: Turbomachinery Technical Conference and Exposition)

   null (Ed.)

   We study the enhanced atomization of viscous liquids by employing a novel two-fluid atomizer. The nozzle establishes a countercurrent flow configuration in which the gas and liquid are directed in opposite directions, establishing a two-phase mixing layer. Detailed measurements of droplet size distributions were carried out using laser shadowgraphy, along with high speed flow visualization. The measurements suggest that the liquid emerges as a spray with little further secondary atomization. The performance of this nozzle is compared to the ‘flow-blurring’ nozzle studied by other investigators for four test liquids of viscosity ranging from 1 to 133.5 mPa.s. The counterflow nozzle produces a spray whose characteristics are relatively insensitive to fluid viscosity over the range studied, for gas-liquid mass flow ratios between 0.25 and 1. To gain insight into the mixing process inside the nozzle, simulations are carried out using an Eulerian-Eulerian Volume of Fluid (VoF) approach for representative experimental conditions. The simulation reveals the detailed process of self-sustained flow oscillations and the physical mechanism that generate liquid filaments and final droplets. 

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2. High-fidelity simulation of a rotary bell atomizer with electrohydrodynamic effects

   Krisshna, Venkata; Owkes, Mark (August 2021, ICLASS 2021, 15th Triennial International Conference on Liquid Atomization and Spray Systems)

   Rotary Bell Atomizers (RBA) are extensively used as paint applicators in the automotive industry. Atomization of paint is achieved by a bell cup rotating at speeds of 40k-60k RPM in the presence of a background electric field. Automotive paint shops amount up to 70% of the total energy costs [Galitsky et. al., 2008], 50% of the electricity demand [Leven et. al., 2001] and up to 80% of the environmental concerns [Geffen et al., 2000] in an automobile manufacturing facility. The atomization process in an RBA affects droplet size and velocity distribution which subsequently control transfer efficiency and surface finish quality. Optimal spray parameters used in industry are often obtained from expensive trial-and-error methods. In this work, three-dimensional near-cup atomization (primary and secondary breakup) are simulated computationally using a high-fidelity volume-of-fluid transport scheme that includes an electrohydrodynamic effects. The influence of fluid properties (viscosity ratio, flow rate and charge density), nozzle rotation rate and bell potential on atomization are investigated by performing a parametric study. This cost-effective method of research aims to identify the ideal spray parameters to achieve maximum transfer efficiency. 

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3. Investigating atomization characteristics in an electrostatic rotary bell atomizer

   https://doi.org/10.1016/j.ijmultiphaseflow.2024.104814  

   Krisshna, Venkata; Owkes, Mark (May 2024, International Journal of Multiphase Flow)

   Electrostatic rotary bell atomizers are commonly used in several engineering applications, including the automobile industry. A high-speed rotating nozzle operating in a strong background electric field atomizes paint into charged droplets that range from a few micrometers to tens of micrometers in diameter. The atomization process directly determines the droplet size and droplet charge distributions which subsequently control the transfer efficiency and the surface finish quality. We have previously developed a tool to perform high fidelity simulations of near-bell atomization with electrohydrodynamic effects. In this work, we perform simulations employed with a droplet ancestry extraction tool to analyze previously inaccessible information and understand the physical processes driving atomization. We find that the electric field accelerates breakup processes and enhances secondary atomization. The total number of droplets, the ratio of secondary to primary droplets, and the ratio of coalescence to breakup activity are all much higher when operating in an electric field. We analyze the droplet velocity, local Weber number and charge density statistics to understand the complex physics in electrically assisted breakup. The results of the study have helped us gain insights into the physics of atomization in electrostatic rotary sprays. 

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4. Visualization of Internal Flow Dynamics in Counterflow Atomizers Using X-Ray Diagnostics and Laser Shadowgraphy

   Hoxie, A.; Srinivasan, V.; Johnson, E.; Kastengren, A. (May 2022, ILASS-Americas 32nd Annual Conference on Liquid Atomization and Spray Systems)

   Experiments were carried out to observe the flow inside counterflow atomizers over a range of operating conditions and fluid properties. Liquids used were water and propylene glycol, while the gas was either air or helium. Liquid flow rates ranged from 10 ml/min to 40 ml/min, with gas liquid ratio (GLR) ranging from 0.1 to 0.6. The primary experiments used the 7-BM line of the Advanced Photon Source in Argonne National Laboratories with a 2.6 mm atomizer produced from (Poly)Ethyl-Ether-Ketone (PEEK). The X-Ray beam was operated in phase contrast mode, leading to interference patterns near the gas-liquid interface and enabling a qualitative understanding of the flow structure. Complementary optical work applied laser shadowgraphy to a 1 mm orifice atomizer constructed with quartz capillary tubing. A diffuse pulsed Nd:YAG laser backlight captured instantaneous gas-liquid interface positions in the internal flow. With both techniques, two distinct flow behaviors are observed corresponding to low and high GLR values. At low GLR, the inertia of the injected gas is insufficient to penetrate the liquid downflow. The gas stream entering the mixing chamber in the upstream direction is immediately deflected by the denser liquid and enters the discharge tube around a central liquid jet, which is sheared and accelerated by the surrounding gas, leading to breakup. A distinct frequency of jet breakup is observed inside the discharge tube, with the liquid jet oscillating and fragmenting against the walls. The situation at high GLR is quite different, however, as the incoming gas stream asymmetrically penetrates upstream into the mixing chamber, taking the form of a high-speed jet confined along one wall, and displaying a flapping instability as it encounters the liquid flowing downstream. This flapping causes violent mixing, resulting in a highly disturbed interface, along with the generation of liquid ligaments and gas bubbles. This two-phase mixture enters the discharge tube with no liquid jet formation evident for this case. The transition between these two regimes is explored by changing the liquid viscosity and gas molar mass, and weak sensitivity to fluid properties is observed. Further, quantitative image analysis techniques applied to the low and high GLR cases allow extraction of the frequencies of the liquid jet in the discharge tube at low GLR, as well as the flapping mode at high GLR. 

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5. Impact of inlet gas turbulence on the formation, development and breakup of interfacial waves in a two-phase mixing layer

   https://doi.org/10.1017/jfm.2021.481  

   Jiang, D.; Ling, Y. (August 2021, Journal of Fluid Mechanics)

   Understanding the development and breakup of interfacial waves in a two-phase mixing layer between the gas and liquid streams is paramount to atomization. Due to the velocity difference between the two streams, the shear on the interface triggers a longitudinal instability, which develops to interfacial waves that propagate downstream. As the interfacial waves grow spatially, transverse modulations arise, turning the interfacial waves from quasi-two-dimensional to fully three-dimensional. The inlet gas turbulence intensity has a strong impact on the interfacial instability. Therefore, parametric direct numerical simulations are performed in the present study to systematically investigate the effect of the inlet gas turbulence on the formation, development and breakup of the interfacial waves. The open-source multiphase flow solver, PARIS, is used for the simulations and the mass–momentum consistent volume-of-fluid method is used to capture the sharp gas–liquid interfaces. Two computational domain widths are considered and the wide domain will allow a detailed study of the transverse development of the interfacial waves. The dominant frequency and spatial growth rate of the longitudinal instability are found to increase with the inlet gas turbulence intensity. The dominant transverse wavenumber, determined by the Rayleigh–Taylor instability, scales with the longitudinal frequency, so it also increases with the inlet gas turbulence intensity. The holes formed in the liquid sheet are important to the disintegration of the interfacial waves. The hole formation is influenced by the inlet gas turbulence. As a result, the sheet breakup dynamics and the statistics of the droplets formed also change accordingly. 

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