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Ultrasonic Pure Technologies

#1556.2


Environmental Friendly Technologies: Application of High Power Sonic and Ultrasonic Elastic Vibrations in the Production and Processing of Materials and Substances

Tech Area / Field

  • CHE-IND/Industrial Chemistry and Chemical Process Engineering/Chemistry
  • ENV-WPC/Water Pollution and Control/Environment
  • INS-OTH/Other/Instrumentation

Status
8 Project completed

Registration date
11.12.2002

Completion date
21.02.2008

Senior Project Manager
Suh G W

Leading Institute
Institute of General and Inorganic Chemistry (IONKh), Russia, Moscow

Collaborators

  • NRS Technologies Limited, UK, Shropshire, Shrewsbury\nViatech, UK, Bristol\nKACU Systemic GmbH, Germany, Auenwald

Project summary

The work in the framework of the project encompasses a wide range of issues that involve both fundamental scientific problems and the application of ultrasound. Such an approach seems to be advisable and well grounded because the use of ultrasound in physical and chemical technologies depends on the same effects, namely: cavitation, acoustic streaming, structure changes in crystals and the surface damage of solids (in liquid-solid systems). The point of great importance is the problem of measuring the acoustic parameters of processes taking place under ultrasonic vibrations.

The present project includes the studies of physicochemical fundamentals of the influence of IEV on SP and, in particular, nonlinear acoustic effects (N-L.A.E.) in gases, liquids and solids, as well as in heterogeneous liquid-gas and liquid-solid systems. The project also includes the investigations of kinetic characteristics and mechanism of the effect of intense ultrasound and low-frequency vibration on heat and mass transfer in the course of chemical, phase and structural transformations (Appendix 9). The studies of the energy characteristics of these processes represent the most important part of the research project.

The project includes the theoretical analysis of the relation between mass transfer and nonlinear effects in an ultrasonic field.

The main objective of the project is the scale-up demonstration of the opportunities of the use of IEV (Intense Elastic Vibration) for stimulation (intensification) of technological processes and improvement of the quality of obtained product for a number of new applications in the oil and gas industry, metallurgy, machine-building, chemical and biochemical technologies, food and light industries and environmental protection.

To achieve this objective, it is necessary:

– To carry out an analysis of physicochemical fundamentals of the use of IEV in technological processes selected for investigations and, in particular, energy aspects of the problem, which will make it possible to provide a change from laboratory studies to industrial testing of IEV methods.


– To design and manufacture a new generation of ultrasonic equipment that is of higher power and efficiency, computer-controlled, and provides the opportunity of continuous operation in long-duration production cycles.
– To construct prototypes of ultrasonic equipment intended for use in technological processes selected for investigations.
– To test and optimize the technology of the use of IEV in processes selected for investigations.
– To develop recommendations on the design and manufacture of prototypes of IEV equipment and the technology of industrial use of IEV methods for investigated and qualitatively analogous technological processes.

In the course of the project, technologies appropriate for industrial purposes, such as the technologies of ultrasonic stimulation of processes and the technologies used for the improvement of products due to ultrasonic effects, should be tested.

For scale-up testing, the following SP (Selected Processes) were chosen:

In the oil and gas industry:

– Recovery of spent catalysts with ultrasonic.


– Recovery of heavy crude oil from tank with acoustic effect.

In metallurgy:

– Ultrasonic treatment of molten steel for desulfurization process.


– Ultrasonic treatment of molten aluminum and magnesium alloys for degassing process.
– Ultrasonic application for producing as-cast metal matrix composite on the base of aluminium and magnesium alloys.

In machine-building:

– Ultrasonic action on arc welding process of HSLA steels, titanium and nickel based alloys for improvement of the quality of a welded joint.


– Ultrasonic impact treatment method for metal surface hardening of HSLA steels, titanium and nickel based alloys.
– Ultrasonic surface burnishing of a cutting tool.
– Ultrasonic stimulation of microoxidation processes.
– Ultrasonic cleaning of parts with internal spaces and cutting elements of saws.
– Ultrasonic cleaning of castings from molding sand.
– Acoustic stabilization of engineering cutting fluids.

In chemical and biochemical technologies:

– Ultrasonic dispersion of powders of organic and inorganic substances.


– Ultrasonic methods of action on different species of cells for their modification
– Ultrasonic stimulation of the processes of calcium hydroxyapatite production.
– Ultrasonic production of metal nanocrystalline powders.

In the food and light industries:

– Ultrasonic stimulation of the processes of the extraction of useful components from vegetable raw materials.


– Ultrasonic stimulation of de-oiling process in textile.
– Ultrasonic stimulation of enzyme activity at textile industry.

In environmental protection:

– Ultrasonic stimulation of the processes of waste water treatment.


– Ultrasonic stimulation of electrocoagulation processes in recovery of the waste of metallurgical production.
– Ultrasonic stimulation of the precious metals extraction.
– Ultrasonic stimulation of rubber devulcanisation.

The part of the project related to the design and manufacture of ultrasonic equipment includes the development of the following: ultrasonic generators of frequency 12-60 kHz and power of up to10 kW, magnetostrictive and piezoceramic transducers, sonotrode systems having a well-developed surface and providing the excitation of intense acoustic vibrations in a load, and computer control systems for ultrasonic technological processes.


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