Pulsed ultrasound for temperature control and clogging prevention in micro-reactors

Ultrasonic micro-reactors are frequently applied to prevent micro-channel clogging in the presence of solid materials. Continuous sonication will lead to a sizeable energy input resulting in a temperature increase in the fluidic channels and concerns regarding microchannel degradation. In this paper, we investigate the application of pulsed ultrasound as a less invasive approach to prevent micro-channel clogging, while also controlling the temperature increase. The inorganic precipitation of barium sulfate particles was studied, and the impact of the effective ultrasonic treatment ratio, frequency and load power on the particle size distribution, pressure and temperature was quantified in comparison to non-sonicated experiments. The precipitation reactions were performed in a continuous reactor consisting of a micro-reactor chip attached to a Langevin-type transducer. It was found that adjusting the pulsed ultrasound conditions prevented microchannel clogging by reducing the particle size to the same magnitude as observed for continuous sonication. Furthermore, reducing the effective treatment ratio from 100 to 12.5% decreases the temperature rise from 7 to 1 °C.