1200 W Processor with Air-Cooled Transducer
SYSTEM OVERVIEW
Industrial Sonomechanics (ISM)’ 1200 W bench-top ultrasonic processor system is designed for batch and flow-through process investigations and small-scale production. The system operates at the frequency of approximately 20 kHz. Barbell horns used in this system can have output tip diameters of up to 35 mm and provide stable operation at output amplitudes up to 120 microns in aqueous loads at a normal pressure, corresponding to acoustic power intensities up to 80 W/cm2. This gives investigators a wide range of possible experimental conditions to determine optimal parameters for even the most challenging ultrasonic processes. When optimal process conditions are established, the same system can be used for medium-scale production. The process can also be transferred to commercial scale utilizing ISM’s 2400 W industrial-scale ultrasonic processor system.
Batch Mode System Schematic
Schematic of the 1200 W ultrasonic system is illustrated in its batch processing configuration. Ultrasonic generator excites vibrations in the piezoelectric transducer, which are subsequently amplified by the Full-wave Barbell horn. The horn delivers the ultrasonic energy to the liquid, contained in the beaker. The liquid may be cooled using an ice bath or a water-cooled jacketed beaker.
Flow-Through Mode System Schematic
Schematic of the 1200 W ultrasonic system is illustrated in its flow-through configuration. Ultrasonic electric generator, controlled form the front panel excites vibrations in the piezoelectric transducer, which are subsequently amplified by the Full-wave Barbell horn. The horn delivers the ultrasonic energy to the liquid, flowing through the reactor chamber. The reactor chamber may include a cooling/heating jacket. The working liquid inlet and outlet valves may be designed to enable adjustable, pressurized flow through the ultrasonic reactor chamber. The system can be configured to operate under pressures of up to 3 atmospheres.
WARNING: The piezoelectric transducer must be cooled with forced air, supplied through an air-hose connection at the top (not shown in this schematic). The air must be filtered, dry and not warmer than 30 degrees C (86 degrees F). The air flow rate must be at least 0.5 m^3/min (18 cfm). Operating the unit without the cooling air may irreversibly damage the transducer and is strictly prohibited.
The Ultrasonic System design corresponds to the International Patent Application PCT/US2008/068697, "High capacity ultrasonic reactor system“. The incorporated Barbell horn design corresponds to the US Patent 7,156,201, "Ultrasonic rod waveguide-radiator”.
Generator and Transducer-Horn Assemblies
Photographs are presented of: 1 – 1200 kW ultrasonic generator, 2 - piezoelectric transducer assembled with a Full-wave Barbell horn, 3 - piezoelectric transducer assembled with a Half-wave Barbell horn, 4 - piezoelectric transducer assembled with a conventional horn.
Examples of Available Horns and Reactor Chambers
Photographs of several types of horns and reactor chambers are presented. 1 – Full-wave Barbell horn with upper node attachment flange (works with reactor chamber #5; also used for medium-size batch processes), 2 – Full-wave Barbell horn with lower node attachment flange (works with reactor chamber #6; also used for medium-size batch processes), 3 – Half-wave Barbell horn (works with reactor chamber #6; also used for medium-size batch processes), 4 – conventional converging horn (for small-size batch studies), 5 - long reactor chamber (works with Barbell horn #1), 6 - short reactor chamber (works with Barbell horns #2 and #3).
Setup Configuration 1
Batch configuration with a conventional converging horn (CH) is illustrated. Small batch studies may be carried out using the setup illustrated in this example. Typical processing volumes are 10 – 100 ml. The working liquid inside the beaker may be cooled by using an ice bath. Alternatively, a jacketed beaker equipped with a water cooling jacket may be used.
Setup Configuration 2
Batch configuration with a Full-wave Barbell horn (FBH) is illustrated. Medium batch studies and processes may be carried out using this setup. Typical processing volumes are 200 – 1000 ml, however, up to 20 liters processing volume is possible if independent batch mixing is provided. Using a beaker equipped with a water cooling jacket is recommended in order to cool the working liquid. This setup is recommended when high amplitudes (on the order of 100 microns) and/or homogeneous exposure intensities are required.
Setup Configuration 3
Batch configuration with a Half-wave Barbell horn (HBH) is illustrated. Medium batch studies and processes may be carried out using this setup. Typical processing volumes are 400 – 2000 ml, however, up to 20 liters processing volume is possible if independent batch mixing is provided. Using a beaker equipped with a water cooling jacket is recommended in order to cool the working liquid.
Setup Configuration 4
Flow-through configuration with a Full-wave Barbell horn (FBH) is illustrated. Flow-through studies and processes may be carried out using this setup at the productivity rates of 50 – 5000 ml/min, depending on the process. A heat exchanger (not shown) is commonly used in conjunction with this setup, however, jacketed water-cooled reactor chambers are available if additional cooling is desired. This setup is recommended when high amplitudes (up to about 120 microns) are required.
Setup Configuration 5
This configuration is commonly preferred for flow-though processes requiring high productivity rates and is based on Half-wave Barbell horns (HBH). Flow-through studies and processes may be carried out using this setup at the productivity rates of 100 – 10000 ml/min, depending on the process. A heat exchanger (not shown) is typically used in conjunction with this setup, however, jacketed water-cooled reactor chambers are available if additional cooling is desired. This high-productivity setup is recommended when amplitudes on the order of 90 microns and homogeneous exposure intensities are required.