Power ultrasonic transducers with extensive radiators for industrial processing

High-power ultrasonics (HPU) is a green emerging technology that offers a great potential for a wide range of industrial processes. Nevertheless such potential have remained restricted during many years to a limited number of applications which reached commercial development. The possible major problem for extending the range of HPU industrial applications has been the lack of power ultrasonic transducers for large-scale application, adapted to the requirements of each specific problem with high efficiency and power capacity.A new family of HPU transducers with extensive radiators have been recently introduced. It comprises a variety of transducer types designed with the radiators adapted to different specific uses in fluids and multi-phase media. Such transducers implement high power capacity, high efficiency and radiation pattern control. In addition, their design incorporate strategies to eliminate or reduce modal interactions produced at high power as a consequence of their nonlinear behaviour. The introduction of such new transducers has significantly contributed to the development at semi-industrial and industrial level of a number of processes in the food and beverage industry, in environment and in manufacturing. This paper deals with the basic structure and main characteristics of such transducers as well as their performance in the developed application processes.     

Power ultrasound and its applications: A state-of-the-art review

Ultrasonic processing has attracted increasing attention by people because ultrasonic technology may represent a flexible ‘green’ alternative for energy efficient processes. The major challenges for the power ultrasound application in real situations are the design and development of specific power ultrasonic systems for large-scale operations. Thus, new families of power ultrasonic transducers have been developed in recent years to meet actual needs, and this contributes to the implementation of power ultrasound of application in many fields such as chemical industry, food industry and manufacturing. This paper presents the current state of ultrasonic transducers of magnetostrictiv type and piezoelectric type as well as applications of power ultrasound in various industrial fields including chemical reactions, drying/dehydration, welding, extraction, heat transfer enhancement, de-ice, enhanced oil recovery, droplet atomization, cleaning and fine particle removal. The review paper helps to understand the current development of power ultrasonic technology and its applications in various situations, and induce extended applications of power ultrasound to more and more fields.     

Ultrasonics in food processing

In recent years, the physical and chemical effects of ultrasound in liquid and solid media have been extensively used in food processing applications. Harnessing the physical forces generated by ultrasound, in the absence and presence of cavitation, for specific food processing applications such as emulsification, filtration, tenderisation and functionality modification have been highlighted. While some applications, such as filtration and emulsification are "mature" industrial processes, other applications, such as functionality modification, are still in their early stages of development. However, various investigations discussed suggest that ultrasonic processing of food and dairy ingredients is a potential and viable technology that will be used by many food industries in the near future.     

Therapeutic ultrasound an overview

Therapeutic ultrasound is defined as the use of ultrasound for the treatment of diseased or injured organs or bodily structures and is quite distinct from diagnostic ultrasound. There were many early attempts in the past to use ultrasound in therapy for a variety of applications and while some of these have not been pursued others have led on to clinical applications which are now used routinely. Such progress has been made possible by a number of factors including advances in transducer design, more accurate measurement and calibration of acoustic power and careful experiments to determine the precise nature of chemical processes taking place during and following the exposure of tissue to ultrasound. Major advances have been made in some fields where ultrasound is used such as physiotherapy, surgical instruments, chemotherapy, drug delivery and more recently, high intensity focused ultrasound (HIFU). The last of these has seen enormous activity leading to the formation of the International Society of Therapeutic Ultrasound and a number of very well attended regular specialist meetings. In this review some historical perspectives of therapeutic ultrasound and progress in the field since the early 1990's will be presented.     

Macrosonics in industry: Ultrasonic soldering

Ultrasonic soldering is one of several uses of power ultrasonics that have been known for many years. Although it was discovered nearly 40 years ago, and has the unique capability of joining materials which are difficult to solder such as aluminium, ultrasonic soldering has never enjoyed widespread industrial use. There is a current resurgence of interest in the process, motivated mainly by the application of soldering all-aluminium heat exchangers. This and other new uses in the electronics field may yet permit ultrasonic soldering to achieve the status of a major use of power ultrasound.     

Food drying process by power ultrasound

Drying processes, which have a great significance in the food industry, are frequently based on the use of thermal energy. Nevertheless, such methods may produce structural changes in the products. Consequently, a great emphasis is presently given to novel treatments where the quality will be preserved. Such is the case of the application of high-power ultrasound which represents an emergent and promising technology. During the last few years, we have been involved in the development of an ultrasonic dehydration process, based on the application of the ultrasonic vibration in direct contact with the product. Such a process has been the object of a detailed study at laboratory stage on the influence of the different parameters involved. This paper deals with the development and testing of a prototype system for the application and evaluation of the process at a pre-industrial stage. Such prototype is based on a high-power rectangular plate transducer, working at a frequency of 20 kHz, with a power capacity of about 100 W. In order to study mechanical and thermal effects, the system is provided with a series of sensors which permit monitoring the parameters of the process. Specific software has also been developed to facilitate data collection and analysis. The system has been tested with vegetable samples.     

Emulsification processes: on-line study by multiple light scattering measurements

The use of ultrasound in various processes of the chemical industry has been a subject of research and development for many years. As regards in emulsification, apart from formulation variables, power is the most important parameter. Efficiency of emulsification processes may be followed and evaluated by measuring particle size distribution, which mainly governs the kinetic stability of such dispersions. Unfortunately, this kind of measurement must be performed at high dilution (low volume fraction of dispersed phase). The present work is devoted to the on-line study of ultrasound emulsification by means of a newly developed apparatus based on multiple light scattering, which allows us to determine average droplet diameter and its variations directly on concentrated media. The model system was an oil (kerosene)-in-water emulsion stabilized by a polyethoxylated sorbitan monostearate.     

Power ultrasound in the meat industry (freezing,cooking and fermentation): Mechanisms,advances and challenges

High intensity ultrasound (HIUS) has a wide range of applications in different sectors of food processing. It is a promising and emerging technology demonstrating the potential to promote food processes without or at least damage to the quality of products. Among the processes of the meat industry, freezing, thawing, cooking and fermentation are very sensitive and important, because they have significant effects on product quality and are also very energy and time consuming. This review paper provides an interpretation of high intensity ultrasound (HIUS) applications, a summary of recent outstanding published research and an overview of the freezing/thawing, cooking/frying and fermentation processes in meat and its products assisted by HIUS. The effects, benefits and drawbacks as well as the challenges ahead in the commercialization of this technology in the meat industry are studied. The research results confirmed that the use of HIUS in the meat freezing/thawing, cooking/frying and fermentation in combination with the corresponding processing methods demonstrates a great potential to promote the process, improve the general quality of the final product and reduce the time and energy required. However, many issues remain that require further research to address these challenges. These challenges and subsequent research that is useful for developing and increasing the efficiency of this technology have been reviewed. After the literature review, it is concluded that HIUS may be a useful technology for meat processing because of its significant effects on the quality factors and related process variables that leads to the preservation of the initial nutritional and sensory properties of meat and its products. Of course, research must be continued to eliminate the disadvantages or minimize the undesirable effects of this technology on the final product and to remove barriers to commercialization and optimization of this method.     

Perspectives in clinical uses of high-intensity focused ultrasound

Focused ultrasound holds promise in a large number of therapeutic applications. It has long been known that high intensity focused ultrasound can kill tissue through coagulative necrosis. However, it is only in recent years that practical clinical applications are becoming possible, with the development of high power ultrasound phased arrays and noninvasive monitoring methods. These technologies, combined with more sophisticated treatment planning methods allow noninvasive focusing in areas such as the brain, that were once thought to be unreachable. Meanwhile, exciting investigations are underway in microbubble-enhanced heating which could significantly reduce treatment times. These developments have promoted an increase in the number of potential applications by providing valuable new tools for medical research. This paper provides an overview of the scientific and engineering advances that are allowing the growth in clinical focused ultrasound applications. It also discusses some of these prospective applications, including the treatment of brain disorders and targeted drug delivery.     

Thick aluminium nitride films deposited by room-temperature sputtering for ultrasonic applications

Materials in film form for electromechanical transduction have a number of potential applications in ultrasound. They are presently under investigation in flexural transducers for air-coupled ultrasound and underwater sonar operating at frequencies up to a few megahertz. At higher frequencies, they have the potential to be integrated with electronics for applications of ultrasound requiring high spatial resolution. However, a number of fabrication difficulties have arisen in studies of such films. These include the high temperatures required in many thick and thin film deposition processes, making them incompatible with other stages in transducer fabrication, and difficulties maintaining film quality when thin film--typically sub-1 microm--processes are extended to higher thicknesses. In this paper, we first outline a process which has allowed us to deposit aluminium nitride (AlN) films capable of electromechanical transduction at thicknesses up to more than 5 microm without substrate heating. As an ultrasonic transduction material, AlN has functional disadvantages, particularly a high acoustic velocity and weak electromechanical transduction. However, it also has a number of advantages relating to practicality of fabrication and functionality. These include the ability to be deposited on a variety of amorphous substrates, a very high Curie temperature, low permittivity, and low electrical and mechanical losses. Here, we present experimental results highlighting the transduction capabilities of AlN deposited on aluminium electrodes on glass and lithium niobate. We compare the results with those from standard simulation processes, highlighting the reasons for discrepancies and discussing the implications for incorporation of AlN into standard ultrasonic transducer design processes.