Acoustic optimization of a flow through sonicator for fibrillation of cellulose fibers

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.