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Liquid atomization processes generating sprays and aerosols of droplets areused in many delivery and coating systems involving pure solvents, solutions,and suspensions. In our recent experimental work, we introduced a novel liquidatomization process generating micro-sprays and aerosols of submicron-diameterdroplets for pure solvents, solutions, and suspensions: gas jets disintegratethin liquid films that are formed as bubbles approach a liquid surface. Here wedevelop a theoretical description of droplet sizes and flow rates, using thefirst principles of conservation of mass and energy, and accounting for theratios of specific energies and the ratios of specific energy rates provided bythe atomizing gas and dissipated by the atomized liquid. We introduceatomization diagrams as a graphical tool to determine possible, impossible, andexpected droplet diameters and specific flow rates in aerosols and spraysproduced under various conditions. We find a reasonable agreement between thetheory and experiments for five different liquids converted into aerosols ofsubmicron-diameter droplets by an atomization process where gas jetsdisintegrate thin liquid films that are formed as bubbles approach a liquidsurface, and also for five traditional pressure nozzles that produce sprays ofdroplets of hundreds of microns in diameter. Our study explored the overallrange of Ohnesorge number between 0.01-100, and the analysis and atomizationdiagrams contribute to understanding of liquid atomization and can serve as atheoretical framework for comparing different liquid atomization techniques.

Possible, Impossible, and Expected Diameters and Production Rates of Droplets in Aerosols and Sprays