Atomizer for improved ultra-fine powder production

A discrete gas jet nozzle for atomizing a melt, comprising a melt supply tube having a melt discharge orifice, a first annular array of a plurality of first discrete gas orifices arranged about the periphery of the melt supply tube to discharge gas jets toward the melt discharge orifice, a first gas supply manifold for supplying pressurized gas to the first discrete gas jet orifices, a second annular array of a plurality of second discrete gas jet orifices arranged outwardly of the first annular array, and a second gas supply manifold isolated from the first gas supply manifold for supplying pressurized gas to the second annular array, wherein the first gas supply manifold and the second gas supply manifold supply atomizing gas to the first annular array and the second annular array in a manner to control an atomizing gas flow structure to have a gas recirculation zone immediately below the melt discharge orifice.