Ultrasound-assisted multi-physics coupling numerical simulation and hydrophone verification

Ultrasonic external field enhancement technology overcomes many defects of traditional metallurgy with its cavitation, mechanical and thermal effects, and is widely applied in enhanced leaching and purification processes of hydrometallurgy. However, research on the acoustic field characteristics in the enhancement process remains limited. In this study, a multiphysics coupled model incorporating ultrasound, mechanical stirring, and thermal effects is developed using COMSOL Multiphysics. The effects of ultrasonic horn position, reactor geometry, ultrasonic frequency and power, ultrasonic horn diameter and immersion depth, stirring speed, temperature and solution properties were analyzed. In the experimental part, the sound pressure distribution inside the reaction tank was accurately measured by hydrophone. The simulation results were validated against experimental measurements under a selected reactor configuration with four different ultrasonic power levels, showing good agreement and confirming the model's accuracy under these specific conditions. This work provides a reliable theoretical framework for optimizing ultrasonic-assisted hydrometallurgical processes and offers predictive insights into the effects of parameter variations on flow and mixing behavior. The proposed approach facilitates efficient process design and opens new avenues for advanced ultrasonic reactor development.