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DOE OSTI2026

Filament extension atomizers: A study of integration potential into spray dryers for high-viscosity and non-Newtonian fluids

Filament extension atomizers (FEAs) are an emerging class of spray nozzles designed to atomize high-viscosity and non-Newtonian fluids that are challenging for conventional pressure or two-fluid nozzles. In this study, we investigate the influence of roller geometry, surface velocity, roller material, and fluid rheology on the atomization performance of FEA systems using concentrated whey protein suspensions (50–70 wt. %). Extensional and shear rheology experiments, along with high-speed imaging and particle image velocimetry, reveal that filament breakup dynamics are governed by competition between inertial, capillary, and viscoelastic stresses. High roller rotational velocity leads to narrower spray cones, contradicting rheology experiments and suggests a significant inertial contribution to filament breakup. Smaller rollers operating at the same rotational velocity led to broader spray cones consistent with expectations. An FEA nozzle was integrated into a conventional dryer producing particles in the 100 μm range. Results suggest that FEA technology enables atomization of highly viscous fluids at industrially relevant spray cone angles similar to those generated by pressure nozzles, offering a pathway to improve energy efficiency in spray drying by enabling higher solids loading feedstocks. Furthermore, these insights provide critical guidance for optimizing FEA nozzle designs and process parameters across a range of applications.

Energy efficiency↗

DOE OSTI2026

Filament Extension Atomization for High Solids Loading in Energy Efficient Spray Drying Systems

We demonstrate that we could scale FEA to reach outputs needed by industrial production, while increasing solids loading of the sprayed product by at least 30% and maintaining equal or better spray powder. After testing a wide range of products, in collaboration with industry partners we decided on our primary spray products of dry whey and WPC-80, two common materials processed and sold by US manufacturers with different parameters. We sprayed these with FEA at solids loadings of 70% for dry whey and 45% for WPC-80 with a spray output with particle sizes similar to industrial particles sizes and reduced variation in particle size. We simultaneously scaled up FEA first with a multi-nip with 6 nips surrounding a central roller with parallel axis of rotation and eventually with a tapered design that solved problems we encountered with our initial design. We were able to achieve output from a single array from our first design of up to 4.7 liters per minute (L/min) and from an array of our second multi-nip of 8 L/min exceeding expectations. This demonstrates that FEA technology can indeed be scaled up to meet the needs of industrial production. More arrays can be added as necessary to meet a wide range of spray dryer designs. We also tested FEA to create dried powders from a small scale (10 L/hour of water removal) spray dryer. Though we were not able to produce large quantities of powder from FEA due to challenges in integration, the powder we produced was higher quality and produced from higher solids loading materials. From our technoeconomic analysis we for a typically sized spray dryer, we estimate a 27% cost reduction and 41% energy and carbon reduction for WPC-80 and a 39-57% cost reduction and 52-76% energy reduction for sweet dry whey (depending on the exact product).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2026

H I Depletion Begins Well Beyond the Virial Radius: A FAST Stacking Study of 36 Galaxy Clusters to 5 × R 200

Abstract We present a stacking study of the neutral atomic hydrogen (H i ) content in and around 36 local galaxy clusters at z < 0.07, using a combination of the FAST All Sky H i survey (FASHI) and the extensive spectroscopic catalog mainly from the Dark Energy Spectroscopic Instrument (DESI). We employ spectral stacking techniques to probe the average H i mass and HI-to-stellar mass ratio ( M HI / M * ) for member galaxies down to stellar masses of M * ∼ 10 9 M ⊙ , spanning a projected cluster-centric distance of up to 5 R 200 . Our analysis reveals a pronounced environmental effect; both M HI and M HI / M * decrease steadily toward the cluster center, dropping by ∼0.5 dex on average from the outskirts to the core. Crucially, we find that M HI / M * of galaxies remain lower than the field galaxies even at the 5 R 200 . This provides direct, statistical evidence for substantial gas stripping and preprocessing in the cluster outskirts, likely occurring in infalling groups and large-scale filaments. By further splitting the sample by g − r color, we show that the H i deficiency persists at fixed galaxy color; even the bluest cluster members exhibit ∼0.5 dex lower M HI / M * than field galaxies of similar color, reflecting environmental effects on the cold gas reservoir prior to full optical transformation. The total H i mass within clusters and their outskirts agrees broadly with predictions from cosmological simulations. Our results underscore the critical role of the extended cluster environment in quenching galaxies by depleting their cold gas reservoirs well before they enter the dense cluster core.

Cheng, Cheng [Chinese Academy of Sciences South Am↗