2400 W Processor with Air-Cooled Transducer
SYSTEM OVERVIEW
Industrial Sonomechanics (ISM)’ 2400 W industrial-scale ultrasonic processor system is designed for high-volume continuous-mode commercial production. The system operates at the frequency of approximately 20 kHz. Barbell horns used in this system have large output tip diameters (Ø) and provide very high output amplitudes (A) and output power densities (Pd). For example, for FBH-type horns the following combinations are possible (water up to the nodal point, at 1 bar and 25 ºC):
Ø = 50 mm, A = 120 microns, Pd = 80 W/cm2;
Ø = 60 mm, A = 85 microns, Pd = 55 W/cm2;
Ø = 70 mm, A = 60 microns, Pd = 35 W/cm2.
Other types of Barbell horns can be used as well. These amplitudes and power densities are extremely high and are unprecedented for industrial-scale systems, which are commonly restricted to ultrasonic amplitudes below 25 microns and power densities below 10 W/cm2. ISM's Barbell Horn Ultrasonic Technology (BHUT) utilized in this processor makes it possible to implement even the most challenging ultrasonic processes in the commercial environment.
Batch Mode System Schematic
Schematic of the 2400 W ultrasonic processor 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 2400 W ultrasonic processor system is illustrated in its flow-through configuration. 2500 W ultrasonic electric generator, controlled form the front panel excites vibrations in the piezoelectric transducer (maximum output power - 2400 W), 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”.