# Structural acoustic design of a sonicator to enhance energy transfer efficiency

## TL;DR

This paper presents a new design for a sonicator that improves energy transfer efficiency and performance in sonochemical applications.

## Contribution

A novel hexagonal ring-shaped excitation structure is introduced to reduce coupling losses and enhance acoustic pressure distribution.

## Key findings

- The hexagonal ring design reduces coupling losses and ensures uniform acoustic pressure distribution.
- The sonicator achieves three feasible resonance frequencies for different applications.
- Experimental validation supports the simulation results for mechanical and electrical impedance.

## Abstract

•Challenges in Adoption of sonochemistry is restricted by industrial demands and economic feasibility, due to complex interplay of variables and up-scaling.•Multiphysical simulation tools manage the interplay between piezo electric excitation and the wave propagation in structures and bubbly liquid.•Efficient Energy Transfer is achieved by optimization of the cylindrical sonicator structure, hexagonal rings, and properties of bubbly water.•Dual Frequency Excitation enhances efficiency and flexibility in sonochemical applications, in this case achieved by 18 uniform-size actuators.

Challenges in Adoption of sonochemistry is restricted by industrial demands and economic feasibility, due to complex interplay of variables and up-scaling.

Multiphysical simulation tools manage the interplay between piezo electric excitation and the wave propagation in structures and bubbly liquid.

Efficient Energy Transfer is achieved by optimization of the cylindrical sonicator structure, hexagonal rings, and properties of bubbly water.

Dual Frequency Excitation enhances efficiency and flexibility in sonochemical applications, in this case achieved by 18 uniform-size actuators.

The study focuses on developing a comprehensive design approach for a flow-through ultrasonic reactor (sonicator) to tackle challenges like low energy transfer efficiency and unstable system performance. The simulation accounts for structural vibrations, structural-fluid interactions, and pressure distributions within the cavitation zone under single-frequency excitation. Different geometrical designs of cylindrical sonicators are analyzed, with input parameters tailored to acquire higher acoustic cavitation intensity. The findings reveal a novel hexagonal ring-shaped excitation structure that reduces coupling losses, ensures uniform acoustic pressure distribution, and generates symmetric vibration mode shapes. The study emphasizes the separation of parasitic modes from the desired resonance frequency response and simulates the influence of bubbly liquid properties through complex wave numbers and harmonic responses. Experimental validation on a manufactured prototype, including mechanical and electrical impedance, sound pressure spectrum, and cavitation intensity, supports the simulated results. Ultimately, the sonicator exhibits three feasible resonance frequencies to be used pairwise at the certain temperature and input power interval for different applications.