Spray Flash Evaporation has recently demonstrated promising results in various fields of application and has more recently shown potential in the elaboration of nanoenergetic materials. This technique offers advantages in terms of morphology, size, and reactivity of the produced materials. However, specific thermodynamic conditions are required to produce these materials using acetone as a solvent: high injection temperature (typically between 80 and 160 °C) and low pressure (generally between 10 and 100 mbar) in the chamber are needed, i.e., superheat level. The study on the formation of acetone droplets in the far-field and under such conditions is lacking. Consequently, we propose here to further understand the relationship between injection temperature and back pressure in the chamber with nucleation and droplets characteristics (velocity, average size, size distribution, and concentration) in order to find optimal conditions for generating theoretically smaller particles through droplet evaporation. The tests were conducted in an unusual range of injection temperatures and pressures for flash boiling but commonly used for the production of energetic particles, from 80 to 200 °C and from 12 to 300 mbar, respectively. By using such conditions, it has been found that increasing the injection temperature and decreasing the back pressure are beneficial for generating a large concentration (up to 27.0 x 106droplets.cm−3) of smaller droplets with a narrow size distribution (down to 2.13 ± 0.13 µm) and high velocity (up to 204.2 m·s−1). It was also shown that there is an injection temperature threshold above 160 °C, beyond which the size distribution widens again by 12 % at 200 °C, and the number of droplets decreases by 64 %. This phenomenon can be observed only if we use a very high superheat level. This study demonstrates that these conditions are likely to promote and ultimately lead to the production of particles that are as fine and uniform in size as possible. Nevertheless, operating at very high injection temperatures (>160 °C) could hinder the nucleation and the formation of uniform droplets due to the high competition between the superheat level (Rp > 1188) and the surface tension of the liquid approaching near-zero values. By introducing the use of criteria related to mechanic and thermodynamics, along with droplet size and velocity, it was also observed that the droplet size is primarily influenced by the nucleation rate, while droplet velocity is influenced by both driving forces (mechanical and thermodynamic). The temperature and pressure in the chamber must therefore be carefully chosen to improve droplet formation and potentially produce smaller, homogeneous particles in size as they evaporate.
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