Physical and chemical effects of acoustic cavitation in selected ultrasonic cleaning applications

Possible Effects and Mechanisms of Ultrasonic Cavitation on Oxide Inclusions during Direct-Chill Casting of an Al Alloy

Oxide films or inclusions can reduce the continuity and integrity of materials and they always lead to a significant reduction in the mechanical properties of an aluminum alloy. They can greatly reduce the plastic flow behavior of materials, thus affecting the subsequent processing performance. Therefore, an effective ultrasonic assisted preparation technology has been applied to industrial manufacturing of large-scale aluminum alloy ingots (with diameter: Φ = 1250 mm and height: h = 3750 mm). However, the mechanisms of ultrasonic purification on the large-scale ingots are not clear. Therefore, a number of aluminum alloy casting experiments were carried out to produce a conventional hot top semi-continuous ingot (CHTI) and an ultrasonic hot top semi-continuous ingot (UHTI) in this work. The microstructures of CHTI and UHTI were analyzed by optical microscopy (OM) and scanning electron microscopy (SEM). The results indicated that there were some oxide film defects in the CHTI but some finely dispersed inclusion particles were discovered in the UHTI. The X-ray diffraction (XRD) data showed that the component of inclusion was Al2O3. According to the different cavitation effects of the different areas of the molten aluminum, the process of ultrasonic purification was divided into three periods and the mechanisms in each period were separately studied.

Degradation of 4-Chlorophenol in Aqueous Solution by Sono-Electro-Fenton Process

Electro-Fenton (EF) and ultrasound radiation (US) have been of interest for the removal of chlorinated compounds from water. This study evaluates the effects of different parameters on sono-electro-Fenton (SEF) for degradation of 4-chlorophenol (4-CP) in an aqueous solution. This study uses pulsing US waves along with Pd-catalyzed EF to degrade contaminants in water while maintaining temperature. The usage of pulsing US waves along with Pd catalyzed EF to remove contaminants while maintaining temperature has not been reported previously. SEF ability to degrade 4-CP was compared with the performance of each process (EF and sonolysis) alone. Initial pH, current density, background electrolyte, Fe²⁺ concentration, Pd/Al₂O₃ catalyst concentration, US waves, and sonifier amplitude were optimized in a two electrode (Ti/mixed metal oxide or Ti/MMO) batch system. The degradation of 4-CP increased from 1.85% by US to 83% by EF to nearly >99.9% by coupled SEF. With US radiation under 70% amplitude and 1:10 ON/OFF ratio, the removal rate of 4-CP increased to 98% compared to 62% under EF alone within the first 120 min in the presence of 80 mg L^-1 Fe²⁺, 16.94 mA cm^-2 of current density, 1 g L^-1 Pd/Al₂O₃ catalyst (10 mg Pd), and initial pH of 3. However, the degradation rate decreased after 120 min of treatment, and complete 4-CP removal was observed after 300 minutes. The sonolysis impacted the 4-CP removal under coupled SEF, mostly due to the contribution of mass transfer (micromixing), while radical formation was found to be absent under the conditions tested (20kHz). The pulsed US was found to increase the temperature by only 8.7°C, which was found not to impact the 4-CP volatilization or degradation. These results imply that low-level US frequency through pulses is a practical and efficient approach to support electro-Fenton reaction, improving reaction rates without the need for electrolyte cooling.

Ultrasound assisted process intensification of uricase and alkaline protease enzyme co-production in Bacillus licheniformis

Low energy ultrasound irradiation was used to enhance co-production of enzymes uricase and alkaline protease using Bacillus licheniformis NRRL 14209. Production of uricase and alkaline protease was evaluated for different ultrasound parameters such as ultrasound power, time of irradiation, duty cycle and growth stage of organisms at which irradiation is carried out. Maximum uricase production of 0.825 U/mL and alkaline protease of 0.646 U/mL have been obtained when fermentation broth was irradiated at 6 h of growth stage with 60 W power for 15 min of duration having 40% of duty cycle. The enzyme yield was found to be enhanced by a factor of 1.9-3.8 and 1.2-2.2 for uricase and alkaline protease respectively. Nevertheless, intracellular uricase was also observed in a fermentation broth after ultrasonic process intensification. The results indicate the effectiveness of low frequency ultrasound in improving enzyme yields with a vision of commercial applicability of the process.

Numerical modelling of acoustic pressure fields to optimize the ultrasonic cleaning technique for cylinders

Fouling build up is a well-known problem in the offshore industry. Accumulation of fouling occurs in different structures, e.g. offshore pipes, ship hulls, floating production platforms. The type of fouling that accumulates is dependent on environmental conditions surrounding the structure itself. Current methods deployed for fouling removal span across hydraulic, chemical and manual, all sharing the common disadvantage of necessitating halting production for the cleaning process to commence. Conventionally, ultrasound is used in ultrasonic baths to clean a submerged component by the generation and implosion of cavitation bubbles on the fouled surface; this method is particularly used in Reverse Osmosis applications. However, this requires the submersion of the fouled structure and thus may require a halt to production. Large fouled structures such as pipelines may not be accommodated. The application of high power ultrasonics is proposed in this work as a means to remove fouling on a structure whilst in operation. The work presented in this paper consists of the development of a finite element analysis model based on successful cleaning results from a pipe fouled with calcite on the inner pipe wall. A Polytec 3D Laser Doppler Vibrometer was used in this investigation to study the fouling removal process. Results show the potential of high power ultrasonics for fouling removal in pipe structures from the wave propagation across the structure under excitation, and are used to validate a COMSOL model to determine cleaning patterns based on pressure and displacement distributions for future transducer array design and optimization.

A new approach for bioethanol production from sugarcane bagasse using hydrodynamic cavitation assisted-pretreatment and column reactors

Hydrodynamic cavitation (HC) was adopted to assist alkaline-hydrogen peroxide pretreatment of sugarcane bagasse (SCB). In the following condition: 0.29 M of NaOH, 0.78% (v/v) of H₂O₂, 9.95 min of process time and 3 bar of inlet pressure, 95.4% of digestibility of cellulosic fraction was achieved. To take the best use of the pretreated biomass, the overall process was intensified by way of employing a packed bed flow-through column reactor and thus enabling to handle a high solid loading of 20%, thereby leading to cellulose and hemicellulose conversions to 74.7% and 75%, respectively. In the fermentation step, a bubble column reactor was introduced to maximize ethanol production from the pretreated SCB by Scheffersomyces stipitis NRRL-Y7124, resulting in 31.50 g/L of ethanol, 0.49 g/g of ethanol yield and 0.68 g/L.h of productivity. All this showed that our HC-assisted NaOH-H₂O₂ pretreatment strategy along with the process intensification approach might offer an option for SCB-based biorefineries.

Degradation of organic wastewater by hydrodynamic cavitation combined with acoustic cavitation

In this paper, the decomposition of Rhodamine B (RhB) by hydrodynamic cavitation (HC), acoustic cavitation (AC) and the combination of these individual methods (HAC) have been investigated. The degradation of 20 L RhB aqueous solution was carried out in a self-designed HAC reactor, where hydrodynamic cavitation and acoustic cavitation could take place in the same space simultaneously. The effects of initial concentration, inlet pressure, solution temperature and ultrasonic power were studied and discussed. Obvious synergies were found in the HAC process. The combined method achieved the best conversion, and the synergistic effect in HAC was even up to 119% with the ultrasonic power of 220 W in a treatment time of 30 min. The time-independent synergistic factor based on rate constant was introduced and the maximum value reached 40% in the HAC system. Besides, the hybrid HAC method showed great superiority in energy efficiency at lower ultrasonic power (88-176 W). Therefore, HAC technology can be visualized as a promising method for wastewater treatment with good scale-up possibilities.

Stability mechanisms of oscillating vapor bubbles in acoustic fields

Vapor bubble instability could enhance the sonochemical activities and accelerate the reaction rate. In the present paper, vapor bubble instability in acoustic fields is investigated through combining both the spherical and stiffness stabilities within a wide range of parameter zone (consisting of bubble radius, acoustic frequency and pressure amplitude) in order to determine the stability states of vapor bubbles. The status of bubble oscillations are divided into four zones in terms of their stability characteristics. Influences of several paramount parameters on the bubble stability are demonstrated in detail. Different orders of spherical instability are quantitatively given together with cases in high-frequency and low-frequency limits. The practical applications of the present work are twofold: identification of the parameter zones with rapid sonochemical reactions; validity of the spherical bubble assumption for simplification of the numerical studies.

Controlled "golf ball shape" structuring of Mg surface under acoustic cavitation

This manuscript describes the original structuring of Mg materials under ultrasound irradiation in mild conditions. Golf ball like extended structures can be prepared in dilute oxalic solutions at 20°C under high frequency ultrasound (200kHz). An original approach carried out through iterative 3D reconstruction of sonicated surfaces is used to describe surface evolutions and characterize the formed microstructures. A combination of SEM, ICP-AES, contact-angle measurements, and 3D image analyses allows to characterize the roughness and mass loss evolutions, and investigate the mechanism of formation for such architectures. A screening of the sonication experiments clearly points out an ultrasound frequency dependency for the effects generated at the surface. 200kHz sonication in 0.01M oxalic acid provides an unprecedented manufacturing of Mg samples which result from a controlled and localized dissolution of the material and characterized by a strong wetting surface with a roughness of 170nm. The additional formation of newly formed secondary phases appearing with surface dissolution progress is also deciphered. More generally, the ultrasonic procedure used to prepare these engineered surfaces opens new alternatives for the nano- and micro-structuring of metallic materials which may exhibit advanced physical and chemical properties of potential interest for a large community.

A survey on the effects of ultrasonic irradiation, reaction time and concentration of initial reagents on formation of kinetically or thermodynamically stable copper(I) metal-organic nanomaterials

In order to evaluation the effects of ultrasonic irradiations, concentration of initial reagents and reaction time on formation [Cu₄(MBT)₄] or [Cu₆(MBT)₆] copper(I) metal-organic nanomaterials, [HMBT=2-Mercaptobenzothiazole]_, we designed some experiments and synthesized six samples under different conditions. These nanostructures were characterized by IR spectroscopy, X-ray powder diffraction (XRD) and Scanning Electron Microscopy (SEM). It seems that the tetranuclear cluster of [Cu₄(MBT)₄] (2) is the kinetically stable product which is formed at the initial time of the reaction and as the time went, it converts to thermodynamically stable product of [Cu₆(MBT)₆] (1) with hexanuclear cluster unit. In the samples which synthesized with low concentration of initial reagents, against to those synthesized with high concentration of initial reagents, the ultrasonic irradiation does not have any effect on formation of any special morphology.

Reactions of hydroxyl radicals with benzoic acid and benzoate

Density functional theory was used to study the mechanism and kinetics of benzoic acid with hydroxyl radicals in both gas and aqueous phases as well as benzoate with hydroxyl radicals in the aqueous phase at the M06-2X/6-311+G(d,p) level of theory.

The size of active bubbles for the production of hydrogen in sonochemical reaction field

The sonication of aqueous solution generates microscopic cavitation bubbles that may growth and violently collapse to produce highly reactive species (i.e. OH, HO2 and H2O2), hydrogen and emit light, sonoluminescence. The bubble size is a key parameter that influences the chemical activity of the system. This wok aims to study theoretically the size of active bubbles for the production of hydrogen in ultrasonic cavitation field in water using a single bubble sonochemistry model. The effect of several parameters such as frequency of ultrasound, acoustic intensity and liquid temperature on the range of sonochemically active bubbles for the production of hydrogen was clarified. The numerical simulation results showed that the size of active bubbles is an interval which includes an optimum value at which the production rate of H2 is maximal. It was shown that the range of ambient radius for an active bubble as well as the optimum bubble radius for the production of hydrogen increased with increasing acoustic intensity and decreased with increasing ultrasound frequency and bulk liquid temperature. It was found that the range of ambient bubble radius dependence of the operational conditions followed the same trend as those reported experimentally for sonoluminescing bubbles. Comparison with literature data showed a good agreement between the theoretical determined optimum bubble sizes for the production of hydrogen and the experimental reported sizes for sonoluminescing bubbles.

A new approach involving a multi transducer ultrasonic system for cleaning turbine engines' oil filters under practical conditions

The purpose of this paper is to provide a green technology that can clean turbine engine oil filters effectively in ships using ultrasound, with ultrasonic devices having a frequency of 25kHz and different powers of 300W and 600W, respectively. The effects of temperature, ultrasonic cleaning times, pressure losses through the oil filter, solvent washing, and ultrasonic power devices were investigated. In addition, the cleaning efficiency of three modes (hand washing, preliminary washing and ultrasonic washing) were compared to assess their relative effectiveness. Experimental results revealed that the necessary ultrasonic time varied significantly depending on which solvent was used for washing. For instance, the optimum ultrasonic cleaning time was 50-60min when the oil filter was cleaned in a solvent of kerosene oil (KO) and over 80min when in a solvent of diesel oil (DO) using the same ultrasonic generator device (25kHz, 600W) and experimental conditions. Furthermore, microscopic examination did not reveal any damage or breakdown on or within the structure of the filter after ultrasonic cleaning, even in the filter's surfaces at a constantly low frequency of 25kHz and power specific capacity (100W/gal). Overall, it may be concluded that ultrasound-assisted oil filter washing is effective, requiring a significantly shorter time than manual washing. This ultrasonic method also shows promise as a green technology for washing oil filters in turbine engines in general and Vietnamese navy ships in particular, because of its high cleaning efficiency, operational simplicity and savings.

Synergetic Effect of Ultrasound, the Heterogeneous Fenton Reaction and Photocatalysis by TiO₂ Loaded on Nickel Foam on the Degradation of Pollutants

The synergistic effect of ultrasound, the heterogeneous Fenton reaction and photocatalysis was studied using a nickel foam (NF)-supporting TiO₂ system and rhodamine B (RhB) as a target. The NF-supporting TiO₂ system was prepared by depositing TiO₂ on the skeleton of NF repeatedly and then calcining it. To optimize the conditions and parameters, the catalytic activity was tested in four systems (ultrasound alone (US), nickel foam (NF), US/NF and NF/US/H₂O₂). The optimal conditions were fixed at 0.1 g/mL NF, initial 5.00 mg/L RhB, 300 W ultrasonic power, pH = 3 and 5.00 mg/L H₂O₂. The effects of the dissolution of nickel from NF and quenching of the Fenton reaction were studied on degradation efficiency. When the heterogeneous Fenton reaction is combined with TiO₂-photocatalysis, the pollutant removal efficiency is enhanced significantly. Through this synergistic effect, 22% and 80% acetochlor was degraded within 10 min and 80 min, respectively.