Ultrasonic Flow Reactors – Design, Applications and Advantages
Ultrasonic reactors allow for a continuous inline treatment of liquids and slurries applying powerful ultrasound waves. Ultrasonic reactors are used for homogenisation, mixing, emulsification, dispersing, extraction, cell disintegration, pasteurization, degasification, dissolving and the intensification of chemical reactions such as synthesis or catalysis. Read more about ultrasonic reactor technology and how your process can benefit from sonication!
What are Flow Cells used for in Sonication Processes?
A flow cell, also known as a flow-through cell or flow reactor, is a device used in various scientific and engineering applications to enable continuous flow processes. Flow cells are commonly used in sonication processes, especially when high volumes are treated with power ultrasound. A ultrasonic flow cell or sonochemical reactor is a specialized chamber or cell designed to allow a liquid or slurries to flow through it while undergoing sonication.
Flow cells are commonly used in fields such as mixing and homogenization, chemistry, biology, electrochemistry, and biotechnology. They offer several advantages over batch processes, including more uniform sonication, enhanced control, improved reaction kinetics, efficient mass transfer, and the ability to integrate the sonication process efficiently in an inline production process.
Applications for Ultrasonic Flow Cells and Sonochemical Reactors
Hielscher ultrasonic reactors, can be useful for a wide range of chemical reactions that involve liquid-solid, liquid-liquid, or liquid-gas interfaces. Some examples of reactions that can be enhanced using ultrasonic reactors include:
- Homogenization of emulsions: Ultrasonic reactors can help to break down and disperse particles in emulsions, leading to more stable and uniform products.
- Crystallization: Ultrasonic irradiation can induce crystallization in solutions, leading to the formation of small and uniform crystals with high purity.
- Degassing: Ultrasonic irradiation can be used to remove dissolved gases from liquids, which can improve the quality and stability of products.
- Extraction: Ultrasonic reactors can increase the efficiency of extraction processes by promoting the diffusion of solutes across membranes or interfaces.
- Polymerization: Ultrasonic irradiation can promote the initiation and propagation of polymerization reactions, leading to faster reaction rates and higher molecular weights.
- Synthesis of nanoparticles: Ultrasonic reactors can be used to synthesize nanoparticles with controlled size, shape, and surface properties.
- Sonocatalysis: Ultrasonic irradiation can enhance the catalytic activity of certain materials, leading to faster reaction rates and improved selectivity.
Sophisticated Ultrasonic Reactor Design for Superior Process Results
When it comes to inline reactors for liquid processing, several important factors should be considered. Hielscher ultrasonic reactors are designed and manufactured These factors can vary depending on the specific application and requirements, but here are some relevant considerations:
Sonicators and Sonochemical Reactors for Inline Flow-Processes
Hielscher Ultrasonics offer high-performance sonicators and ultrasonic reactors for liquid processing at any size.
Design, Manufacturing and Consulting – Quality Made in Germany
Hielscher sonicators and sonochemical reactors are well-known for their highest quality and design standards. Robustness and easy operation allow the smooth integration of our sonicators and ultrasonic flow cells into industrial facilities. Rough conditions and demanding environments are easily handled by Hielscher sonicators.
Hielscher Ultrasonics is an ISO certified company and put special emphasis on high-performance ultrasonicators featuring state-of-the-art technology and user-friendliness. Of course, Hielscher ultrasonicators are CE compliant and meet the requirements of UL, CSA and RoHs.
The table below gives you an indication of the approximate processing capacity of our ultrasonicators:
|Batch Volume||Flow Rate||Recommended Devices|
|0.5 to 1.5mL||n.a.||VialTweeter||1 to 500mL||10 to 200mL/min||UP100H|
|10 to 2000mL||20 to 400mL/min||UP200Ht, UP400St|
|0.1 to 20L||0.2 to 4L/min||UIP2000hdT|
|10 to 100L||2 to 10L/min||UIP4000hdT|
|15 to 150L||3 to 15L/min||UIP6000hdT|
|n.a.||10 to 100L/min||UIP16000|
|n.a.||larger||cluster of UIP16000|
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Literature / References
- Barrera-Salgado, Karen; Ramírez-Robledo, Gabriela; Alvarez-Gallegos, Alberto; Arellano, Carlos; Sierra, Fernando; Perez, J. A.; Silva Martínez, Susana (2016): Fenton Process Coupled to Ultrasound and UV Light Irradiation for the Oxidation of a Model Pollutant. Journal of Chemistry, 2016. 1-7.
- Han N.S., Basri M., Abd Rahman M.B. Abd Rahman R.N., Salleh A.B., Ismail Z. (2012): Preparation of emulsions by rotor-stator homogenizer and ultrasonic cavitation for the cosmeceutical industry. Journal of Cosmetic Science Sep-Oct; 63(5), 2012. 333-44.
- Antonia Tamborrino, Agnese Taticchi, Roberto Romaniello, Claudio Perone, Sonia Esposto, Alessandro Leone, Maurizio Servili (2021): Assessment of the olive oil extraction plant layout implementing a high-power ultrasound machine. Ultrasonics Sonochemistry, Volume 73, 2021.