The cellulose pulp refining process is crucial for achieving high-quality paper characteristics. This research aims to enhance energy efficiency while maintaining good fiber quality using hydrodynamic and acoustic cavitation (HAC). Experiments were conducted with an in-house developed flow-through sonicator combined with a novel Venturi nozzle for hydrodynamic cavitation. The Venturi design was determined by analytical modeling and verified by CFD simulation with multi-phase turbulence models to balance cavitation intensity and turbulence against the acoustic cavitation effect. Experimental evaluation of two batches of CTMP fibers, pre-processed in different ways, showed significant improvements in paper strength and fiber properties. The best results for Batch 1 (HC and LC) were obtained with 386 kWh/bdt for AC and 350 kWh/bdt for HC (60 °C, 2 % concentration). The tensile strength index increased by 26 %, and the TEA-index, related to freeness, increased by 55 %. HAC treatment (750 kWh/bdt, 70 °C, 1.5 % concentration) of the less refined Batch2 (HC) yielded results better than the Batch 1 reference. These findings confirm the energy-efficient potential of the sonicator concept compared to traditional industrial processes. The conclusion is that HAC-refining of softwood pulp requires a proper balance between hydrodynamic and acoustic cavitation intensities. Both fiber concentration by weight and temperature are critical for an energy-efficient process.

Fibrillation is identified as the most energy intensive process step in pulp and paper manufacturing and improved energy efficiency is the motivation for development of alternative technologies. The aim of this study is to explore the potential of a new refining concept based on cavitation, focusing on the optimization of acoustic cavitation efficiency of the proposed flow-through sonicator concept. The simulations utilize the linearized wave equation in the frequency domain with an addition of nonlinear attenuation introduced by cavitation bubbles. Verification is made by pressure measurements, calorimetry, and foil tests. The fibrillation capability was validated on chemi-thermo mechanical pulp fibers at low consistencies. Fiber properties was characterized by ultrasonic spectroscopy, fiber analysis and SEM. The objective is to optimize the energy transfer efficiency from electrical input power to acoustic cavitation intensity for efficient fibrillation of cellulose fibers. Results showed changes in fiber dimensions and fiber morphology, however, improvements in tensile strength index, measured and predicted by ultrasonic spectroscopy, was limited to 20 % at an energy level of 804 kWh/bdt. To enhance energy efficiency and paper strength properties, it is suggested to add a hydrodynamic cavitation device prior to the sonicator to initiate cavitation bubbles and to increase turbulence intensity.

The primary purpose of this study is to investigate the effects of hydrodynamic and acoustic cavitation (HAC) on the leaching efficiency of tungsten. The aim is to reduce energy use and to improve the recovery rate. The goal is also to carry out a leaching process at a much lower temperature than in an autoclave process that is currently used in the industry. Energy-efficient initiation and collapse of cavitation bubbles require optimization of (i) vibro-acoustic response of the reactor structure, (ii) multiple excitation frequencies adapted to the optimized reactor geometry, and (iii) hydrodynamic cavitation with respect to orifice geometry and flow conditions. The objective is to modify and apply a previously in house developed high power cavitation reactor in order to recover tungsten by leaching of the dissolution of scheelite in sodium hydroxide. In this process, various experimental conditions like dual-frequency excitation, different orifice geometry have been investigated. The numerically optimized reactor concept was excited by two frequencies 23 kHz and 39–43 kHz in various flow conditions. The effects of leaching time, leaching temperature, ultrasonic power and geometry of orifice plates have been studied. The leaching temperature was varied from 40 °C to 80 °C. The concentration of leaching reagent sodium hydroxide (NaOH) was 10 mol/L.The results were compared to conventional chemical leaching. Energy supplement with acoustic cavitation of 130 kWh/kg concentrate resulted in a leaching recovery of tungsten (WO3) of 71.5%, compared to 36.7% obtained in absence of ultrasound. The results confirm that the method developed is energy efficient and gives a recovery rate potentially better than current autoclave technology.

Process industries are cornerstones in today’s industrialized world. They contribute significantly to the development of diverse commodities and materials that are used in our daily lives. Process intensification is an approach implemented to boost manufacturing efficiency and capacities in a more sustainable and energy efficient way. The focus of this thesis is to utilize the concept and advantages of hydrodynamic and acoustic cavitation in the ultrasonic range. High-intensity cavitation can improve the physical and chemical properties of a wide range of materials and provides a sustainable alternative for process intensification. Although the use of hydrodynamic and acoustic cavitation techniques have become advantageous, applications in process industry are still limited, as the approach needs thorough refinement based on several process parameters and complications encountered in a large-scale implementation. In order to address challenges such as stability and robustness as well as energy conservation and high flow speeds, scalable reactor designs are essential for industrial applications. 

 This research focuses on the methods to develop and maximize cavitation activity in a flow-through reactor. The application comprises of hydrodynamic activation of tiny gas bubbles in the fluid to be excited and collapsed by high intensity ultrasound. The transient collapse of cavitation bubbles and clouds of bubbles generates high temperatures, extreme pressures and shockwaves in a microscale, leading to both a physical and chemical impact. To achieve an efficient energy transfer and conversion optimization with respect to physical and process related parameters are needed. The optimization of the reactor design requires both experimental and numerical investigations. Numerical simulations have been carried out with the help of a commercially accessible multiphysics simulation software that incorporates acoustics, structural dynamics, fluid dynamics and piezoelectrics. The reactor design methodology is validated by measurements of impedance and acoustic pressure as well as aluminum foil erosion and calorimetric tests. The developed cavitation reactors have been implemented in two case studies: I) Modification of cellulose fiber properties and II) Leaching of metals from mineral concentrates.

 In case study I, the developed method for fibrillation of cellulose fibers enables an energy-efficient change in mechanical properties of the fiber wall. As a consequence of cavitation, fibers are exposed to shear forces and micro-jets, inducing peeling, swelling, delamination and external and internal fibrillation. The parameters of significance are excitation frequency, electrical power, flow characteristics, concentration (viscosity), static pressure and temperature.  The maximum flow rate of the reactor is 80 l/min and power density is 0.45 W/cm3. The developed reactor has a 36 % power conversion efficiency and is well adapted for scale-up. The critical aspect is to balance the contribution of hydrodynamic and acoustic cavitation to the pulp properties. For high temperature chemi–thermomechanical pulp (HT-CTMP) from spruce, the best quality of fiber properties was obtained at 1.5 % concentration and 60° C using an electrical energy supply of 386 kWh/bdt. 

 In case study II, the aim of the investigation was to explore the impact of hydrodynamic and acoustic cavitation (HAC) on the leaching ability of tungsten. The objectives were to minimize leaching time, reduce energy usage and increase the recovery rate. Various experimental conditions such as dual-frequency excitation and various orifice geometries have been explored during this investigation. The reactor was excited by 23 kHz and 39 - 43 kHz frequencies in different flow settings. The effects of leaching time, temperature, acoustic pressure and geometry of the orifice plate have been studied. The leaching temperature varied from 40°C to 80°C. The concentration of sodium hydroxide (NaOH) leaching agent was 10 mol/L. The results has been compared to traditional chemical and laboratory autoclave leaching. The energy enhancement of 130 kWh/kg concentrates acoustic cavitation resulting in a 71.5 % leaching recovery of tungsten (WO3), relative to 36.7 % obtained in the absence of ultrasound. The developed method is found to be energy effective and provides a higher recovery rate than current chemical methods at lower temperature and static pressure.

Energy efficient process intensification requires hydrodynamic initiation of cavitation bubbles, high acoustic cavitation strength by several excitation frequencies tailored to the reactor's optimized design and optimum process pressure and temperature concerning the materials to be processed. The cavitation effect improves extensively in the flow-through mode and offers stable results. The effect of flow conditions and hydrodynamic cavitation at the same ultrasonic power input is essential and nearly doubles the yield.

A new model for turbulent fibre suspension flow is proposed by introducing a model for the fibre orientation distribution function (ODF). The coupling between suspended fibres and the fluid momentum is then introduced through the second and fourth order fibre orientation tensors, respectively. From the modelled ODF, a method to construct explicit expressions for the components of the orientation tensors as functions of the flow field is derived. The implementation of the method provides a fibre model that includes the anisotropic detail of the stresses introduced due to presence of the fibres, while being significantly cheaper than solving the transport of the ODF and computing the orientation tensors from numerical integration in each iteration. The model was validated and trimmed using experimental data from flow over a backwards facing step. The model was then further validated with experimental data from a turbulent fibre suspension channel flow. Simulations were also carried out using a Bingham viscoplastic fluid model for comparison. The ODF model and the Bingham model performed reasonably well for the turbulent flow areas, and the latter model showed to be slightly better given the parameter settings tested in the present study. The ODF model may have good potential, but more rigorous study is needed to fully evaluate the model.

The pulp and paper industry is in continuous need for energy-efficient production processes. In the refining process of mechanical pulp, fibrillation is one of the essential unit operations that count for up to 80% of the total energy use. This initial study explores the potential and development of new type of scalable ultrasound reactor for energy efficient mechanical pulping. The developed reactor is of continuous flow type and based on both hydrodynamic and acoustic cavitation in order to modify the mechanical properties of cellulose fibers. A comparison of the prototype tube reactor is made with a batch reactor type where the ultrasonic horn is inserted in the fluid. The pulp samples were sonicated by high-intensity ultrasound, using tuned sonotrodes enhancing the sound pressure and cavitation intensity by a controlled resonance in the contained fluid. The resonant frequency of the batch reactor is 20.8 kHz and for the tube reactor it is 22.8 kHz. The power conversion efficiency for the beaker setup is 25% and 36% in case of the tube reactor in stationary mode. The objective is to verify the benefit of resonance enhanced cavitation intensity when avoiding the effect of Bjerkenes forces. The setup used enables to keep the fibers in the pressure antinodes of the contained fluid. In case of the continuous flow reactor the effect of hydrodynamic cavitation is also induced. The intensity of the ultrasound in both reactors was found to be high enough to produce cavitation in the fluid suspension to enhance the fiber wall treatment. Results show that the mechanical properties of the fibers were changed by the sonification in all tests. The continuous flow type was approximately 50% more efficient than the beaker. The effect of keeping fibers in the antinode of the resonant mode shape of the irradiation frequency was also significant. The effect on fiber properties for the tested mass fraction was determined by a low-intensity ultrasound pulse-echo based measurement method, and by a standard pulp analyzer.

Ultrasound has many uses, such as in medical imaging, monitoring of crystallization, characterization of emulsions and suspensions, and disruption of cell membranes in the food industry. It can also affect microbial cells by promoting or slowing their growth and increasing the production of some metabolites. However, the exact mechanism explaining the effect of ultrasound has not been identified yet. Most equipment employed to study the effect of ultrasound on microorganisms has been designed for other applications and then only slightly modified. This results in limited control over ultrasound frequency and input power, or pressure distribution in the reactor. The present study aimed to obtain a well-defined reactor by simulating the pressure distribution of a sonobioreactor. Specifically, we optimized a sonotrode to match the bottle frequency and compared it to measured results to verify the accuracy of the simulation. The measured pressure distribution spectrum presented the same overall trend as the simulated spectrum. However, the peaks were much less intense, likely due to non-linear events such as the collapse of cavitation bubbles. To test the application of the sonobioreactor in biological systems, two biotechnologically interesting microorganisms were assessed: an electroactive bacterium, Geobacter sulfurreducens, and a lignocellulose-degrading fungus, Fusarium oxysporum. Sonication resulted in increased malate production by G. sulfurreducens, but no major effect on growth. In comparison, morphology and growth of F. oxysporum were more sensitive to ultrasound intensity. Despite considerable morphological changes at 4 W input power, the growth rate was not adversely affected; however, at 12 W, growth was nearly halted. The above findings indicate that the novel sonobioreactor provides an effective tool for studying the impact of ultrasound on microorganisms.

Energy-efficient process intensification is a key aspect for a sustainable industrial production. To improve energy conversion efficiency high intensity cavitation is a promising method, especially in cases where the material to be treated is valuable and on the micro meter scale. Transient collapsing cavitation bubbles gives powerful effects on objects immersed in fluids, like cellulose fibers, mineral particles, enzymes, etc. The cavitation process needs optimization and control, since optimal conditions is multivariate challenge. This study focuses on different design principles to achieve high intensity cavitation in a specific volume in a continuous flow. This study explores some potential design principles to obtain energy efficient process intensification. The objective is to tune several different resonance phenomena to create a powerful excitation of a flowing suspension (two-phase flow and cavitation bubbles). The reactor is excited by sonotrodes, connected to two coupled resonant tube structures, at the critical frequency. Finally cavitation bubbles are initiated by a flow through a venturi nozzle. The acoustically optimised reactor geometry is modelled in Comsol Multiphysics®, and excited by dedicated ultrasound signals at three different frequencies. The effect of the high intensity cavitation is experimentally evaluated by calorimetric method, foil tests and degree of fibrillation on cellulose fibers.

This study investigate the impact of high-intensity ultrasound treatment on the mechanical properties of pulp fibers. The pulp fiber samples are sonicated in an acoustically optimized beaker where high-intensity ultrasound is generated using a tuned sonotrode device. The idea is to create a controlled resonance to efficiently enhance the sound pressure in the beaker. Input power was 90 W. The objective is to define the difference between freely suspended fibers in a beaker compared to keeping fibers in a fixed position. The hypothesis is that fiber treatment at a specific input power will be more efficient in the case when fibers are kept in a high pressure zone. Since the fiber wall is a layered structure, it is likely to delaminate internally which will affect the mechanical properties of the fiber. The effect on fiber properties is verified by measuring the ultrasound attenuation spectra for the treated fibers. The attenuation measurements are based on measurements of a low-intensity ultrasound pulse-echo technique. On a macroscopic scale, changes in the attenuation spectra relates to a change in mechanical properties of the fiber wall, since the suspended fibers more or less retain their diameter and length distributions.

The pulp and paper industry is in continuous need for energy-efficient production processes. Therefore, there is a focus in reducing electrical energy use in the production of paper.  The most energy demanding processes are related to fibrillation, which in some cases use up to 80% of required electrical power, with a net efficiency of 1%. The presented work focus on ultrasound controlled cavitation in concentrating the processing energy to provide an energy efficient development of cellulose fibers. The objectives are to develop a scalable cavitation reactor to obtain energy-efficient fibrillation of cellulose fibers aiming at reducing the energy use by 50%. Our goal is to develop a methodology based on multiphysic simulation for the design of an alternative refiner based on ultrasound cavitation. The reactor concept is of a flow through type where cavitation bubbles are initiated in the fiber suspension by the pressure release when the pulp flow through a venturi nozzle. The induced cavitation bubbles are collapsed by high intensity ultrasound at resonant frequencies. The collapsing bubbles and their associated shock waves modify the fiber wall properties which enables fibrillation.  Energy efficient fibrillation of cellulose fibers is therefore possible to achieve through an optimized combination of hydrodynamic and ultrasonic controlled cavitation. Initial results shows a positive effect on fiber quality. However, further optimization of process parameters like temperature and static pressure is required.