Mechanism of droplet-formation in a supersonic microfluidic spray device

Spray drying is an approach employed in automotive, food, and pharmaceutical industries as a robust and cost efficient liquid atomization technique offering direct control over droplet dimensions. The majority of commercially available spray nozzles are designed for large throughput spray drying applications or uniform surface coating, but microfluidic nebulizers have recently been developed as small scale alternatives. Here, we explore the physical parameters that define the droplet size and formation under supersonic flow conditions commonly found in microfluidic spray drying systems. We examined the spray nozzle operation using high speed imaging and laser scattering measurements, which allowed us to describe the spray regimes and droplet size distributions. It was determined that by using this spray nozzle device, droplets with diameters of 4–8 μm could be generated. Moreover, we show that the supersonic de Laval nozzle model can be used to predict the average droplet size. Our approach can be used as a platform for interfacing fluid microprocessing with gas phase detection and characterization.