Numerical simulation and verification of acoustic–fluid coupling in multi-source ultrasound enhancement processes

This study explores the innovative use of ultrasonic technology in process intensification using COMSOL multi-physics simulation. It investigates the effects of ultrasonic parameters like power (60–320 W), frequency (20–40 kHz), and horn diameter (8–30 mm) on sound-field distribution, fluid dynamics, and cavitation. The optimal frequency for sound-field uniformity and cavitation was found to be 28 kHz, with a maximum flow velocity of 0.352 mm/s. Increasing power from 60 to 320 W raised the maximum sound pressure from 1.05 × 105 to 2.43 × 106 Pa and cavitation area volume fraction from 2% to 17%. The horn diameter significantly influences sound wave diffusion and energy distribution, with larger diameters providing a higher energy density and covering larger areas with increased flow rates. Using multiple ultrasound sources enhances the acoustic and flow fields over a larger area. The simulation model's feasibility was confirmed through ultrasonic-enhanced ZnO crushing experiments with varying horn diameters. This research provides a scientific basis for optimizing ultrasonic process intensification, advancing theories on ultrasound-enhanced mass transfer and chemical reaction efficiency, and holds potential for improving the greening and efficiency of hydrometallurgical technologies.