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This investigation focuses on the influence of geometric factors on cavitational activity within a 20kHz sonoreactor containing water. Three vessels with different shapes were used, and the transducer immersion depth and liquid height were varied, resulting in a total of 126 experiments conducted under constant driving current. For each one, the dissipated power was quantified using calorimetry, while luminol mapping was employed to identify the shape and location of cavitation zones. The raw images of blueish light emission were transformed into false colors and corrected to compensate for refraction by the water–glass and glass-air interfaces. Additionally, all configurations were simulated using a sonoreactor model that incorporates a nonlinear propagation of acoustic waves in cavitating liquids. A systematic visual comparison between luminol maps and color-plots displaying the computed bubble collapse temperature in bubbly regions was conducted. The calorimetric power exhibited a nearly constant yield of approximately 70% across all experiments, thus validating the transducer command strategy. However, the numerical predictions consistently overestimated the electrical and calorimetric powers by a factor of roughly 2, indicating an overestimation of dissipation in the cavitating liquid model. Geometric variations revealed non-monotonic relationships between transducer immersion depth and dissipated power, emphasizing the importance of geometric effects in sonoreactor. Complex features were revealed by luminol maps, exhibiting appearance, disappearance, and merging of different luminol zones. In certain parametric regions, the luminol bright regions are reminiscent of linear eigenmodes of the water/vessel system. In the complementary parametric space, these structures either combine with, or are obliterated by typical elongated axial structures. The latter were found to coincide with an increased calorimetric power, and are conjectured to result from a strong cavitation field beneath the transducer producing acoustic streaming. Similar methods were applied to an additional set of 57 experiments conducted under constant geometry but with varying current, and suggested that the transition to elongated structures occurs above some amplitude threshold. While the model partially reproduced some experimental observations, further refinement is required to accurately account for the intricate acoustic phenomena involved.

In spite of the increasing interest in ultrasound processing applications, industrial scale-up remains limited, in particular by the unavailability of predictive computer tools. In this study, using a previously published model of cavitating liquids implementable as a non-linear Helmholtz equation, it is shown that a full sonoreactor can be modelled and simulated. The model includes the full transducer and the vibrations of the vessel walls, using the physics of elastic solids and piezo-electricity. The control-loop used by the generator to set the optimal frequency is also accounted for. Apart from the geometry, the unique input of the model is the current feeding the transducer whereas the dissipated electrical power, transducer complex impedance and working frequency are available as outputs. The model is put to the test against experiments realized in different geometries, varying either the input current or the transducer immersion depth. Despite the overestimation of the power dissipated in the liquid, the evolution of the acoustic load in both cases is reasonably well reproduced by simulation, which partially validates the method used.