Simulations of a full sonoreactor accounting for cavitation

A new strategy for modelling sonochemical reactors: Coupling of the non-linear Louisnard model with mass and heat transport equations with applications to cavitating viscous fluids

In this work, novel numerical models were developed and validated to offer new strategies in modelling sonochemical reactors. More specifically, in our original approach the non-linear Louisnard model was coupled with heat and mass transport equations to predict gradients in temperature and species concentration in a sonicated reactor. Additionally, a new operating window was investigated by modelling mixtures of increasing viscosity on both micro- and macroscale sonochemical effects. On the microscale, the effects of increasing viscosity on bubble dynamics were determined by solving the Keller-Miksis equation. Various cavitation threshold definitions were evaluated. The bubble collapse temperature was determined for all investigated mixtures and the energy dissipation of a single bubble was calculated. On the macroscale, different acoustic attenuation models were compared accounting for either linear or non-linear equations. Specifically, viscous losses were implemented in the non-linear Louisnard model, and model predictions were validated against experimental data. The model was able to predict multiple zones of cavitation in the reactor, as observed experimentally, and to estimate the dissipated energy for the different mixtures. Moreover, it was demonstrated that the cavitation-based attenuation dominates the other dissipation phenomena even for the most viscous solutions. The Louisnard model was coupled with heat transport equations, and using this extended version of the model, the temperature profiles were predicted for mixtures of increasing viscosity during sonication. Using a regression formula available in literature, radical production was related to the acoustic pressure field. By including reactions and mass transport in the acoustic model, for the first time in modelling ultrasonic reactors, the full distribution of light in the reactor during sonochemiluminescence (SCL) experiments for water was quantified.

Observation of cavitation dynamics in viscous deep eutectic solvents during power ultrasound sonication

Deep eutectic solvents (DESs) are a class of ionic liquid with emerging applications in ionometallurgy. The characteristic high viscosity of DESs, however, limit mass transport and result in slow dissolution kinetics. Through targeted application of high-power ultrasound, ionometallurgical processing time can be significantly accelerated. This acceleration is primarily mediated by the cavitation generated in the liquid surrounding the ultrasound source. In this work, we characterise the development of cavitation structure in three DESs of increasing viscosity, and water, via high-speed imaging and parallel acoustic detection. The intensity of the cavitation is characterised in each liquid as a function of input power of a commercially available ultrasonic horn across more than twenty input powers, by monitoring the bubble collapse shockwaves generated by intense, inertially collapsing bubbles. Through analysis of the acoustic emissions and bubble structure dynamics in each liquid, optimal driving powers are identified where cavitation is most effective. In each of the DESs, driving the ultrasonic horn at lower input powers (25%) was associated with greater cavitation performance than at double the driving power (50%).

Review on the impacts of external pressure on sonochemistry

The impact of hydrostatic pressure, commonly known as ambient or external pressure, on the phenomenon of sonochemistry and/or sonoluminescence has been extensively investigated through a multitude of experimental and computational studies, all of which have emphasized the crucial role played by this particular parameter. Numerous previous studies have successfully demonstrated the existence of an optimal static pressure for the occurrence of sonoluminescence and multi-bubble or single-bubble sonochemistry. However, despite these findings, a universally accepted value for this critical pressure has not yet been established. In addition, it has been found that the cavitation effect is completely inhibited when the static pressure is either too high or too low. This comprehensive review aims to delve into the primary experimental results and elucidate their significance in relation to hydrostatic pressure. We will then conduct an analysis of numerical calculations, focusing specifically on the influence of external pressure on single bubble sonochemistry. By delving into these calculations, we will be able to gain a deeper understanding of the experimental results and effectively interpret their implications.

Coffee brewing sonoreactor for reducing the time of cold brew from several hours to minutes while maintaining sensory attributes

This research designed and developed an ultrasonic reactor for a fast and on demand production of cold brew coffee, remarkably reducing the brewing time from 24 h to less than 3 min. The technology was engineered by utilizing resonance to induce ultrasonic waves around the walls of the brewing basket of an espresso machine. The sound transmission system comprised a transducer, a horn and a brewing basket. This arrangement transformed the coffee basket into an effective sonoreactor that injected sound waves at multiple points through its walls, thereby generating multiple regions for acoustic cavitation within the reactor. Furthermore, acoustic streaming induced greater mixing and enhanced mass transfer during brewing. The design was accomplished by modeling the transmission of sound, and acoustic cavitation. Brew characterization and chemical composition analysis was performed, considering factors such as pH, acidity, color, and the composition of caffeine, fatty acids, and volatiles. The efficiency of the extraction increased by decreasing the basket loading percentage (BLP). For instance, sonicating at 100 W doubled the extraction yield and caffeine concentration, from 15.05 % to 33.44 % at BLP = 33 %, and from 0.91 mg/mL to 1.84 mg/mL at BLP = 67 %, respectively. The total fatty acids increased from 1.16 mg/mL to 9.20 mg/mL, representing an eightfold increase, at BLP = 33 %. Finally, a sensory analysis was conducted to evaluate appearance, aroma, texture, flavor, and aftertaste, which demonstrated that coffee brewed for 1 and 3 min in the sonoreactor exhibited almost undistinguishable properties compared to a standard 24 h brewing without ultrasound.

A mechanistic study identifying improved technology critical metal delamination from printed circuit boards at lower power sonications in a deep eutectic solvent

Deep eutectic solvents (DESs) are an emerging class of ionic liquids that offer a solution to reclaiming technology critical metals (TCMs) from electronic waste, with potential for improved life cycle analysis. The high viscosities typical of DESs, however, impose mass transport limitations such that passive TCM removal generally requires immersion over extended durations, in some cases in the order of hours. It is postulated that, through the targeted application of power ultrasound, delamination of key structures in electronic components immersed in DESs can be significantly accelerated, thereby enabling rapid recovery of TCMs. In this paper, we fully characterise cavitation in a Choline Chloride-Ethylene Glycol DES as a function of sonotrode input power, by the acoustic detection of the bubble collapse shockwave content generated during sonications at more than 20 input powers over the available range. This justifies the selection of two powers for a detailed study of ultrasonically enhanced TCM-delamination from printed circuit boards (PCBs). Dual-perspective high-speed imaging is employed, which facilitates simultaneous observation of TCM removal, and the cavitation evolution and interaction with the PCB surface. Bubble jetting is identified as a key contributor to initial pitting of the TCM layers, exposing the larger underlying copper layer, with the contributions of additional inertial cavitation-mediated phenomena such as bubble-collapse shockwaves also demonstrated as important for delamination. Optimal cavitation activity throughout the sonication then promotes etching of the copper base layer of the PCB structure targeted by the DES, liberating the overlaying TCMs in sections as large as 0.79 mm2. We report a thirtyfold improvement in processing time compared to passive delamination, with sonications at the lower power outperforming those at the higher power. The results demonstrate the potential for industrially scalable recovery of TCMs from the growing quantities of global e-waste, using combined power ultrasonics and DESs.

Sound attenuation in high mach number oscillating bubble media

We study theoretically and numerically sound attenuation in bubble-containing media when the bubbles are freely oscillating at high Mach numbers. This paper expands one of the main forms of bubble-related acoustic damping factors by extending the previous theories to higher Mach numbers, further improves the theories of nonlinear sound propagation in bubble-containing media. A nonlinear sound propagation model incorporating second-order liquid compression terms is developed, expressing the sound velocity and density in the medium as a function of the driving pressure, and taking into account the higher-order liquid compression effects on sound propagation. The correctness of the proposed model is verified by comparing with a linear model and a nonlinear model containing only low-order Mach number terms. When the bubble oscillates at a high Mach number, radiation damping, which is directly related to Mach number, becomes the main damping component affecting sound attenuation. The higher the driving amplitude, the stronger the nonlinear effect, and the greater the impact of high-order liquid compression effects on the sound attenuation, the more necessary it is to use the proposed model to calculate the sound attenuation. For high Mach numbers, varying the bubble radius and bubble number density, respectively, the difference between the proposed model and the model containing only low-order Mach number terms in capturing the pressure-dependent attenuation is calculated. Due to stronger radiation damping in smaller bubbles, the effect of compressibility becomes more important. The smaller the bubble radius, the greater the half-quality factor of the curve related to the difference in attenuation calculated by the two models, the more necessary it is to calculate the pressure-dependent attenuation using the proposed model. Here, the half-quality factor is defined as the corresponding frequency bandwidth when the curve falls from the maximum value to 22 times. Without considering the coupling effect between bubbles, the half-quality factor of the curve is not affected by the bubble number density.

Extensive investigation of geometric effects in sonoreactors: Analysis by luminol mapping and comparison with numerical predictions

This investigation focuses on the influence of geometric factors on cavitational activity within a 20kHz sonoreactor containing water. Three vessels with different shapes were used, and the transducer immersion depth and liquid height were varied, resulting in a total of 126 experiments conducted under constant driving current. For each one, the dissipated power was quantified using calorimetry, while luminol mapping was employed to identify the shape and location of cavitation zones. The raw images of blueish light emission were transformed into false colors and corrected to compensate for refraction by the water-glass and glass-air interfaces. Additionally, all configurations were simulated using a sonoreactor model that incorporates a nonlinear propagation of acoustic waves in cavitating liquids. A systematic visual comparison between luminol maps and color-plots displaying the computed bubble collapse temperature in bubbly regions was conducted. The calorimetric power exhibited a nearly constant yield of approximately 70% across all experiments, thus validating the transducer command strategy. However, the numerical predictions consistently overestimated the electrical and calorimetric powers by a factor of roughly 2, indicating an overestimation of dissipation in the cavitating liquid model. Geometric variations revealed non-monotonic relationships between transducer immersion depth and dissipated power, emphasizing the importance of geometric effects in sonoreactor. Complex features were revealed by luminol maps, exhibiting appearance, disappearance, and merging of different luminol zones. In certain parametric regions, the luminol bright regions are reminiscent of linear eigenmodes of the water/vessel system. In the complementary parametric space, these structures either combine with, or are obliterated by typical elongated axial structures. The latter were found to coincide with an increased calorimetric power, and are conjectured to result from a strong cavitation field beneath the transducer producing acoustic streaming. Similar methods were applied to an additional set of 57 experiments conducted under constant geometry but with varying current, and suggested that the transition to elongated structures occurs above some amplitude threshold. While the model partially reproduced some experimental observations, further refinement is required to accurately account for the intricate acoustic phenomena involved.

Understanding the ultrasound field of high viscosity mixtures: Experimental and numerical investigation of a lab scale batch reactor

In this work, mixtures of increasing viscosity (from 0.9 to ≈720 mPas) are sonicated directly using an ultrasonic horn at 30 kHz to investigate the effect of viscosity on the ultrasound field both from an experimental and numerical point of view. The viscosity of the mixtures is modified by preparing water-polyethylene glycol solutions. The impact of the higher viscosity on the acoustic pressure distribution is studied qualitatively and semi-quantitatively using sonochemiluminescence. The velocity of light scattering particles added in the mixtures is also explored to quantify acoustic streaming effects using Particle Image Velocimetry (PIV). A numerical model is developed that is able to predict cavitationally active zones accounting for both thermoviscous and cavitation based attenuation. The results show that two cavitation zones exist: one directly under the horn tip and one around the part of the horn body that is immersed in the liquid. The erosion patterns on aluminum foil confirm the existence of both zones. The intensity of the cavitationally active zones decreases considerably with increasing viscosity of the solutions. A similar reduction trend is observed for the velocity of the particles contained in the jet directly under the tip of the horn. Less erratic flow patterns relate to the high viscosity mixtures tested. Finally, two numerical models were made combining different boundary conditions related to the ultrasonic horn. Only the model that includes the radial horn movements is able to qualitatively predict well the location of the cavitation zones and the decrease of the zones intensity, for the highest viscosities studied. The current findings should be taken into consideration in the design and modelling phase of horn based sonochemical reactors.

Probing the pressure dependence of sound speed and attenuation in bubbly media: Experimental observations, a theoretical model and numerical calculations

The problem of attenuation and sound speed of bubbly media has remained partially unsolved. Comprehensive data regarding pressure-dependent changes of the attenuation and sound speed of a bubbly medium are not available. Our theoretical understanding of the problem is limited to linear or semi-linear theoretical models, which are not accurate in the regime of large amplitude bubble oscillations. Here, by controlling the size of the lipid coated bubbles (mean diameter of ≈5.4μm), we report the first time observation and characterization of the simultaneous pressure dependence of sound speed and attenuation in bubbly water below, at and above microbubbles resonance (frequency range between 1-3 MHz). With increasing acoustic pressure (between 12.5-100 kPa), the frequency of the peak attenuation and sound speed decreases while maximum and minimum amplitudes of the sound speed increase. We propose a nonlinear model for the estimation of the pressure dependent sound speed and attenuation with good agreement with the experiments. The model calculations are validated by comparing with the linear and semi-linear models predictions. One of the major challenges of the previously developed models is the significant overestimation of the attenuation at the bubble resonance at higher void fractions (e.g. 0.005). We addressed this problem by incorporating bubble-bubble interactions and comparing the results to experiments. Influence of the bubble-bubble interactions increases with increasing pressure. Within the examined exposure parameters, we numerically show that, even for low void fractions (e.g. 5.1×10-6) with increasing pressure the sound speed may become 4 times higher than the sound speed in the non-bubbly medium.