Combining COMSOL modeling with acoustic pressure maps to design sono-reactors

Scaled-up and economically viable sonochemical systems are critical for increased use of ultrasound in environmental and chemical processing applications. In this study, computational simulations and acoustic pressure maps were used to design a larger-scale sono-reactor containing a multi-stepped ultrasonic horn. Simulations in COMSOL Multiphysics showed ultrasonic waves emitted from the horn neck and tip, generating multiple regions of high acoustic pressure. The volume of these regions surrounding the horn neck were larger compared with those below the horn tip. The simulated acoustic field was verified by acoustic pressure contour maps generated from hydrophone measurements in a plexiglass box filled with water. These acoustic pressure contour maps revealed an asymmetric and discrete distribution of acoustic pressure due to acoustic cavitation, wave interaction, and water movement by ultrasonic irradiation. The acoustic pressure contour maps were consistent with simulation results in terms of the effective scale of cavitation zones (∼10 cm and <5 cm above and below horn tip, respectively). With the mapped acoustic field and identified cavitation location, a cylindrically-shaped sono-reactor with a conical bottom was designed to evaluate the treatment capacity (∼5 L) for the multi-stepped horn using COMSOL simulations. In this study, verification of simulation results with experiments demonstrates that coupling of COMSOL simulations with hydrophone measurements is a simple, effective and reliable scientific method to evaluate reactor designs of ultrasonic systems.     

Realization of cavitation fields based on the acoustic resonance modes in an immersion-type sonochemical reactor

Different modes of cavitation zones in an immersion-type sonochemical reactor have been realized based on the concept of acoustic resonance fields. The reactor contains three main components, namely a Langevin-type piezoelectric transducer (20 kHz), a metal horn, and a circular cylindrical sonicated cell filled with tap water. In order to diminish the generation of cavitation bubbles near the horn-tip, an enlarged cone-shaped horn is designed to reduce the ultrasonic intensity at the irradiating surface and to get better distribution of energy in the sonicated cell. It is demonstrated both numerically and experimentally that the cell geometry and the horn position have prominent effects on the pressure distribution of the ultrasound in the cell. With appropriate choices of these parameters, the whole reactor works at a resonant state. Several acoustic resonance modes observed in the simulation are realized experimentally to generate a large volume of cavitation zones using a very low ultrasonic power.     

Generation and control of acoustic cavitation structure

The generation and control of acoustic cavitation structure are a prerequisite for application of cavitation in the field of ultrasonic sonochemistry and ultrasonic cleaning. The generation and control of several typical acoustic cavitation structures (conical bubble structure, smoker, acoustic Lichtenberg figure, tailing bubble structure, jet-induced bubble structures) in a 20–50 kHz ultrasonic field are investigated. Cavitation bubbles tend to move along the direction of pressure drop in the region in front of radiating surface, which are the premise and the foundation of some strong acoustic cavitation structure formation. The nuclei source of above-mentioned acoustic cavitation structures is analyzed. The relationship and mutual transformation of these acoustic cavitation structures are discussed.     

Modeling cavitation in a rapidly changing pressure field – Application to a small ultrasonic horn

Ultrasonic horn transducers are frequently used in applications of acoustic cavitation in liquids. It has been observed that if the horn tip is sufficiently small and driven at high amplitude, cavitation is very strong, and the tip can be covered entirely by the gas/vapor phase for longer time intervals. A peculiar dynamics of the attached cavity can emerge with expansion and collapse at a self-generated frequency in the subharmonic range, i.e. below the acoustic driving frequency. The term “acoustic supercavitation” was proposed for this type of cavitation Žnidarčič et al. (2014) [1].We tested several established hydrodynamic cavitation models on this problem, but none of them was able to correctly predict the flow features. As a specific characteristic of such acoustic cavitation problems lies in the rapidly changing driving pressures, we present an improved approach to cavitation modeling, which does not neglect the second derivatives in the Rayleigh–Plesset equation. Comparison with measurements of acoustic supercavitation at an ultrasonic horn of 20 kHz frequency revealed a good agreement in terms of cavity dynamics, cavity volume and emitted pressure pulsations.The newly developed cavitation model is particularly suited for simulation of cavitating flow in highly fluctuating driving pressure fields.     

Dependence of cavitation,chemical effect,and mechanical effect thresholds on ultrasonic frequency

Cavitation, chemical effect, and mechanical effect thresholds were investigated in wide frequency ranges from 22 to 4880 kHz. Each threshold was measured in terms of sound pressure at fundamental frequency. Broadband noise emitted from acoustic cavitation bubbles was detected by a hydrophone to determine the cavitation threshold. Potassium iodide oxidation caused by acoustic cavitation was used to quantify the chemical effect threshold. The ultrasonic erosion of aluminum foil was conducted to estimate the mechanical effect threshold. The cavitation, chemical effect, and mechanical effect thresholds increased with increasing frequency. The chemical effect threshold was close to the cavitation threshold for all frequencies. At low frequency below 98 kHz, the mechanical effect threshold was nearly equal to the cavitation threshold. However, the mechanical effect threshold was greatly higher than the cavitation threshold at high frequency. In addition, the thresholds of the second harmonic and the first ultraharmonic signals were measured to detect bubble occurrence. The threshold of the second harmonic approximated to the cavitation threshold below 1000 kHz. On the other hand, the threshold of the first ultraharmonic was higher than the cavitation threshold below 98 kHz and near to the cavitation threshold at high frequency.     

Influence of dissolved gases on sonochemistry and sonoluminescence in a flow reactor

In the present work, the influence of gas addition is investigated on both sonoluminescence (SL) and radical formation at 47 and 248 kHz. The frequencies chosen in this study generate two distinct bubble types, allowing to generalize the conclusions for other ultrasonic reactors. In this case, 47 kHz provides transient bubbles, while stable ones dominate at 248 kHz. For both bubble types, the hydroxyl radical and SL yield under gas addition followed the sequence: Ar > Air > N₂ >> CO₂. A comprehensive interpretation is given for these results, based on a combination of thermal gas properties, chemical reactions occurring within the cavitation bubble, and the amount of bubbles. Furthermore, in the cases where argon, air and nitrogen were bubbled, a reasonable correlation existed between the OH-radical yield and the SL signal, being most pronounced under stable cavitation at 248 kHz. Presuming that SL and OH originate from different bubble populations, the results indicate that both populations respond similarly to a change in acoustic power and dissolved gas. Consequently, in the presence of non-volatile pollutants that do not quench SL, sonoluminescence can be used as an online tool to qualitatively monitor radical formation.     

Degradation of 4-chloro 2-aminophenol using combined strategies based on ultrasound,photolysis and ozone

The present work investigates the degradation of 4-chloro 2-aminophenol (4C2AP), a highly toxic organic compound, using ultrasonic reactors and combination of ultrasound with photolysis and ozonation for the first time. Two types of ultrasonic reactors viz. ultrasonic horn and ultrasonic bath operating at frequency of 20 kHz and 36 kHz respectively have been used in the work. The effect of initial pH, temperature and power dissipation of the ultrasonic horn on the degradation rate has been investigated. The established optimum parameters of initial pH as 6 (natural pH of the aqueous solution) and temperature as 30 ± 2 °C were then used in the degradation studies using the combined approaches. Kinetic study revealed that degradation of 4C2AP followed first order kinetics for all the treatment approaches investigated in the present work. It has been established that US + UV + O₃ combined process was the most promising method giving maximum degradation of 4C2AP in both ultrasonic horn (complete removal) and bath (89.9%) with synergistic index as 1.98 and 1.29 respectively. The cavitational yield of ultrasonic bath was found to be eighteen times higher as compared to ultrasonic horn implying that configurations with higher overall areas of transducers would be better selection for large scale treatment. Overall, the work has clearly demonstrated that combined approaches could synergistically remove the toxic pollutant (4C2AP).     

Pretreatment of defatted wheat germ proteins (by-products of flour mill industry) using ultrasonic horn and bath reactors: Effect on structure and preparation of ACE-inhibitory peptides

The ultrasonic horn and bath reactors were compared based on production of angiotensin-converting-enzyme (ACE) inhibitory peptides from defatted wheat germ proteins (DWGP). The DWGP was sonicated before hydrolysis by Alcalase. Degree of hydrolysis, ACE-inhibitory activity, surface hydrophobicity, fluorescence intensity, free sulfhydryl (SH), and disulfide bond (SS) were determined. The highest ACE-inhibitory activity of DWGP hydrolysate was obtained at power intensity of 191.1 W/cm² for 10 min in the ultrasonic horn reactor. The fixed frequency of 33 kHz and the sweep frequency of 40 ± 2 kHz resulted in the maximum ACE-inhibitory activity. The combined irradiation of dual fixed frequency (24/68 kHz) produced significant increase in ACE-inhibitory activity compared with single frequency (33 kHz). The ultrasonic probe resulted in significant higher ACE-inhibitory activity compared with ultrasonic bath operating at single or dual fixed and sweep frequencies. The changes in conformation of the DWGP due to sonication were confirmed by the changes in fluorescence intensity, surface hydrophobicity, SH_f and SS contents and they were found in conformity with the ACE-inhibitory activity in case of the ultrasonic horn reactor but not in bath reactor.     

Ultrasound assisted intensified recovery of lactose from whey based on antisolvent crystallization

The current work deals with understanding the fundamental aspects of intensified recovery of lactose from paneer (cottage cheese) whey using the anti-solvent induced sonocrystallization. Ultrasonic horn (22 kHz) with varying power levels over the range of 40–120 W has been used for initial experiments at 100% duty cycle and two different levels of ultrasonic exposure time as 10 min and 20 min. Similar experiments were also performed using ultrasonic bath for the same time of exposure but with at two ultrasonic frequencies (22 kHz and 33 kHz). It was observed that the lactose recovery as well as purity increased with an increase in ultrasonic power at 100% duty cycle for the case of treatment time as 10 min whereas the lactose recovery and purity increased only till an optimum power for the 20 min treatment. In the case of ultrasonic bath, lactose purity increased with an increase in the ultrasonic frequency from 22 kHz to 33 kHz though the lactose recovery marginally decreased. Overall, it was observed that the maximum lactose recovery was ∼98% obtained using ultrasonic horn while the maximum lactose purity was ∼97%. It was also observed that maximum lactose recovery was ∼94% for the case of ultrasonic bath while the maximum lactose purity was ∼92%. The work has enabled to understand the optimized application of ultrasound so as to maximize both the lactose yield and purity during the recovery from whey.     

The effects of ultrasound on micromixing

The Villermaux–Dushman reaction is a widely used technique to study micromixing efficiencies with and without sonication. This paper shows that ultrasound can interfere with this reaction by sonolysis of potassium iodide, which is excessively available in the Villermaux–Dushman solution, into triiodide ions. Some corrective actions, to minimize this interference, are proposed. Furthermore, the effect of ultrasonic frequency, power dissipation, probe tip surface area and stirring speed on micromixing were investigated. The power and frequency seem to have a significant impact on micromixing in contrast to the stirring speed and probe tip surface area. Best micromixing was observed with a 24 kHz probe and high power intensities. Experiments with different frequencies but a constant power intensity, emitter surface, stirring speed, cavitation bubble type and reactor design showed best micromixing for the highest frequency of 1135 kHz. Finally, these results were used to test the power law model of Rahimi et al. This model was not able to predict micromixing accurately and the addition of the frequency, as an additional parameter, was needed to improve the simulations.     

Physical and chemical characteristics of ultrasonically-prepared water-in-diesel fuel: Effects of ultrasonic horn position and water content

An ultrasonic technique was applied to preparation of two-phase water-in-oil (W/O) emulsified fuel of water/diesel oil/surfactant. In this study, an ultrasonic apparatus with a 28 kHz rod horn was used. The influence of the horn tip position during ultrasonic treatment, sonication time and water content (5 or 10 vol%) on the emulsion stability, viscosity, water droplet size and water surface area of emulsion fuels prepared by ultrasonication was investigated. The emulsion stability of ultrasonically-prepared fuel significantly depended on the horn tip position during ultrasonic irradiation. It was found that the change in the stability with the horn tip position was partly related to that in the ultrasonic power estimated by calorimetry. Emulsion stability, viscosity and sum of water droplets surface area increased and water droplet size decreased with an increase in sonication time, and they approached each limiting value in the longer time. The maximum values of the viscosity and water surface area increased with water content, while the limiting values of the emulsion stability and water droplet size were almost independent of water content. During ultrasonication of water/diesel oil mixture, the hydrogen and methane were identified and the cracking of hydrocarbon components in the diesel oil occurred. The combustion characteristics of ultrasonically-prepared emulsion fuel were studied and compared with those of diesel oil. The soot and NOx emissions during combustion of the emulsified fuel with higher water contents were significantly reduced compared with those during combustion of diesel oil.     

Interaction behaviors at the interface between liquid Al–Si and solid Ti–6Al–4V in ultrasonic-assisted brazing in air

Power ultrasonic vibration (20 kHz, 6 μm) was applied to assist the interaction between a liquid Al–Si alloy and solid Ti–6Al–4V substrate in air. The interaction behaviors, including breakage of the oxide film on the Ti–6Al–4V surface, chemical dissolution of solid Ti–6Al–4V, and interfacial chemical reactions, were investigated. Experimental results showed that numerous 2–20 μm diameter-sized pits formed on the Ti–6Al–4V surface. Propagation of ultrasonic waves in the liquid Al–Si alloy resulted in ultrasonic cavitation. When this cavitation occurred at or near the liquid/solid interface, many complex effects were generated at the small zones during the bubble implosion, including micro-jets, hot spots, and acoustic streaming. The breakage behavior of oxide films on the solid Ti–6Al–4V substrate, excessive chemical dissolution of solid Ti–6Al–4V into liquid Al–Si, abnormal interfacial chemical reactions at the interface, and phase transformation between the intermetallic compounds could be wholly ascribed to these ultrasonic effects. An effective bond between Al–Si and Ti–6Al–4V can be produced by ultrasonic-assisted brazing in air.     

Effects of ultrasound frequency and acoustic amplitude on the size of sonochemically active bubbles – Theoretical study

Numerical simulation of chemical reactions inside an isolated spherical bubble of oxygen has been performed for various ambient bubble radii at different frequencies and acoustic amplitudes to study the effects of these two parameters on the range of ambient radius for an active bubble in sonochemical reactions. The employed model combines the dynamic of bubble collapse with the chemical kinetics of single cavitation bubble. Results from this model were compared with some experimental results presented in the literature and good apparent trends between them were observed. The numerical calculations of this study showed that there always exists an optimal ambient bubble radius at which the production of oxidizing species at the end of the bubble collapse attained their upper limit. It was shown that the range of ambient radius for an active bubble increased with increasing acoustic amplitude and decreased with increasing ultrasound frequency. The optimal ambient radius decreased with increasing frequency. Analysis of curves showing optimal ambient radius versus acoustic amplitude for different ultrasonic frequencies indicated that for 200 and 300 kHz, the optimal ambient radius increased linearly with increasing acoustic amplitude up to 3 atm. However, slight minima of optimal radius were observed for the curves obtained at 500 and 1000 kHz.     

Sonoluminescence and dynamics of cavitation bubble populations in sulfuric acid

The detailed link of liquid phase sonochemical reactions and bubble dynamics is still not sufficiently known. To further clarify this issue, we image sonoluminescence and bubble oscillations, translations, and shapes in an acoustic cavitation setup at 23 kHz in sulfuric acid with dissolved sodium sulfate and xenon gas saturation. The colour of sonoluminescence varies in a way that emissions from excited non-volatile sodium atoms are prominently observed far from the acoustic horn emitter (“red region”), while such emissions are nearly absent close to the horn tip (“blue region”). High-speed images reveal the dynamics of distinct bubble populations that can partly be linked to the different emission regions. In particular, we see smaller strongly collapsing spherical bubbles within the blue region, while larger bubbles with a liquid jet during collapse dominate the red region. The jetting is induced by the fast bubble translation, which is a consequence of acoustic (Bjerknes) forces in the ultrasonic field. Numerical simulations with a spherical single bubble model reproduce quantitatively the volume oscillations and fast translation of the sodium emitting bubbles. Additionally, their intermittent stopping is explained by multistability in a hysteretic parameter range. The findings confirm the assumption that bubble deformations are responsible for pronounced sodium sonoluminescence. Notably the observed translation induced jetting appears to serve as efficient mixing mechanism of liquid into the heated gas phase of collapsing bubbles, thus potentially promoting liquid phase sonochemistry in general.     

Ultrasound assisted dispersal of a copper nanopowder for electroless copper activation

This paper describes the ultrasound assisted dispersal of a low wt./vol.% copper nanopowder mixture and determines the optimum conditions for de-agglomeration. A commercially available powder was added to propan-2-ol and dispersed using a magnetic stirrer, a high frequency 850 kHz ultrasonic cell, a standard 40 kHz bath and a 20 kHz ultrasonic probe. The particle size of the powder was characterized using dynamic light scattering (DLS). Z-Average diameters (mean cluster size based on the intensity of scattered light) and intensity, volume and number size distributions were monitored as a function of time and energy input. Low frequency ultrasound was found to be more effective than high frequency ultrasound at de-agglomerating the powder and dispersion with a 20 kHz ultrasonic probe was found to be very effective at breaking apart large agglomerates containing weakly bound clusters of nanoparticles. In general, the breakage of nanoclusters was found to be a factor of ultrasonic intensity, the higher the intensity the greater the de-agglomeration and typically micron sized clusters were reduced to sub 100 nm particles in less than 30 min using optimum conditions. However, there came a point at which the forces generated by ultrasonic cavitation were either insufficient to overcome the cohesive bonds between smaller aggregates or at very high intensities decoupling between the tip and solution occurred. Absorption spectroscopy indicated a copper core structure with a thin oxide shell and the catalytic performance of this dispersion was demonstrated by drop coating onto substrates and subsequent electroless copper metallization. This relatively inexpensive catalytic suspension has the potential to replace precious metal based colloids used in electronics manufacturing.     

Effects of argon sparging rate,ultrasonic power,and frequency on multibubble sonoluminescence spectra and bubble dynamics in NaCl aqueous solutions

The sonoluminescence spectra from acoustic cavitation in aqueous NaCl solutions are systematically studied in a large range of ultrasonic frequencies under variation of electrical power and argon sparging. At the same time, bubble dynamics are analysed by high-speed imaging. Sodium line and continuum emission are evaluated for acoustic driving at 34.5, 90, 150, 365, and 945 kHz in the same reactor vessel. The results show that the ratio of sodium line to continuum emission can be shifted by the experimental parameters: an increase in the argon flow increases the ratio, while an increase in power leads to a decrease. At 945 kHz, the sodium line is drastically reduced, while the continuum stays at elevated level. Bubble observations reveal a remarkable effect of argon in terms of bubble distribution and stability: larger bubbles of non-spherical shapes form and eject small daughter bubbles which in turn populate the whole liquid. As a consequence, the bubble interactions (splitting, merging) appear enhanced which supports a link between non-spherical bubble dynamics and sodium line emission.     

Effect of amplitude and frequency of ultrasonic irradiation on morphological characteristics control of calcium carbonate

We have previously reported on the morphological control of calcium carbonate by changing synthetic conditions such as temperature, pH and degree of supersaturation in liquid reaction. The present study reports the effect of amplitude and frequency of ultrasonic irradiation on the particle size of calcium carbonate using a horn type ultrasonic apparatus at two different frequencies. The calcium carbonate precipitated by mechanical stirring had a particle size of about 20 μm. By contrast, the particle size of vaterite formed under ultrasonic irradiation was about 2 μm, with a specific surface area of 25–30 m²/g. The major polymorph of calcium carbonate formed by ultrasonic irradiation was vaterite with some calcite present. For 40 kHz ultrasonic irradiation, the specific surface area of the calcium carbonate increased with increasing amplitude. The particle size of vaterite formed at this frequency was about 2 μm, and its distribution was sharper than that obtained at 20 kHz. The mode diameter of the synthesized vaterite was found to decrease with increasing amplitude at 40 kHz.     

Investigation of acoustic cavitation energy in a large-scale sonoreactor

Acoustic cavitation energy distributions were investigated for various frequencies such as 35, 72, 110 and 170 kHz in a large-scale sonoreactor. The energy analyses were conducted in three-dimensions and the highest and most stable cavitation energy distribution was obtained not in 35 kHz but in 72 kHz. However, the half-cavitation-energy distance was larger in the case of 35 kHz ultrasound than in the case of 72 kHz, demonstrating that cavitation energy for one cycle was higher for a lower frequency. This discrepancy was due to the large surface area of the cavitation-energy-meter probe. In addition, 110 and 170 kHz ultrasound showed a very low and poor cavitation energy distribution. Therefore larger input power was required to optimize the use of higher frequency ultrasound in the sonoreactor with long-irradiation distance. The relationship between cavitation energy and sonochemical efficiency using potassium iodide (KI) dosimetry was best fitted quadratically. From 7.77 × 10^?10 to 4.42 × 10^?9 mol/J of sonochemical efficiency was evaluated for the cavitation energy from 31.76 to 103. 67 W. In addition, the cavitation energy attenuation was estimated under the assumption that cavitation energy measured in this study would be equivalent to sound intensity, resulting in 0.10, 0.18 and 2.44 m^?1 of the attenuation coefficient (α) for 35, 72 and 110 kHz, respectively. Furthermore, α/(frequency)² was not constant, as some previous studies have suggested.     

Experimental investigation of conical bubble structure and acoustic flow structure in ultrasonic field

The objective of this paper is to investigate the transient conical bubble structure (CBS) and acoustic flow structure in ultrasonic field. In the experiment, the high-speed video and particle image velocimetry (PIV) techniques are used to measure the acoustic cavitation patterns, as well as the flow velocity and vorticity fields. Results are presented for a high power ultrasound with a frequency of 18 kHz, and the range of the input power is from 50 W to 250 W. The results of the experiment show the input power significantly affects the structures of CBS, with the increase of input power, the cavity region of CBS and the velocity of bubbles increase evidently. For the transient motion of bubbles on radiating surface, two different types could be classified, namely the formation, aggregation and coalescence of cavitation bubbles, and the aggregation, shrink, expansion and collapse of bubble cluster. Furthermore, the thickness of turbulent boundary layer near the sonotrode region is found to be much thicker, and the turbulent intensities are much higher for relatively higher input power. The vorticity distribution is prominently affected by the spatial position and input power.     

Visualization and optimization of cavitation activity at a solid surface in high frequency ultrasound fields

Despite the increasing use of high frequency ultrasound in heterogeneous reactions, knowledge about the spatial distribution of cavitation bubbles at the irradiated solid surface is still lacking. This gap hinders controllable surface sonoreactions. Here we present an optimization study of the cavitation bubble distribution at a solid sample using sonoluminescence and sonochemiluminescence imaging. The experiments were performed at three ultrasound frequencies, namely 580, 860 and 1142 kHz. We found that position and orientation of the sample to the transducer, as well as its material properties influence the distribution of active cavitation bubbles at the sample surface in the reactor. The reason is a significant modification of the acoustic field due to reflections and absorption of the ultrasonic wave by the solid. This is retraced by numerical simulations employing the Finite Element Method, yielding reasonable agreement of luminescent zones and high acoustic pressure amplitudes in 2D simulations. A homogeneous coverage of the test sample surface with cavitation is finally reached at nearly vertical inclination with respect to the incident wave.