GB2540545A

GB2540545A - Ultrasonic processor

Info

Publication number: GB2540545A
Application number: GB1512675.8A
Authority: GB
Inventors: Henry Caza John; George Caza Stanley
Original assignee: HILSONIC PROCESS SYSTEMS Ltd
Current assignee: HILSONIC PROCESS SYSTEMS Ltd
Priority date: 2015-07-20
Filing date: 2015-07-20
Publication date: 2017-01-25
Also published as: GB201512675D0; WO2017013424A1

Abstract

An ultrasonic processor comprising a hollow elongated enclosure 2 having an inlet end 3 and an outlet end 4 with flange mounts 5 and 6, and a plurality of ultrasonic transducers 7 coupled to the enclosure between the inlet and outlet ends. The ultrasonic transducers are capable of applying ultrasonic waves to a material passing through the enclosure such that small cavities are created that cause rapid localized heating can cooling (cavitation), and there is a control system for the transducers. The enclosure is sized so as to ensure that the ultrasonic waves are applied to substantially all of the material passing through the enclosure. This increases the efficiency of the process. Applications of the processor include the separating of oil from drill cuttings, the separation of contaminants from soil materials, and the preparation of a coating composition (such as paint).

Description

Ultrasonic Processor

Field to the Invention

The present invention provides an ultrasonic processor and uses of the ultrasonic processor. The ultrasonic processor has a number of different uses, including de-agglomerating, milling, mixing and/or cold boiling materials.

Background to the Invention

The phenomenon known as “cavitation” is known to arise when intense ultrasonic waves travel through liquids and generate small cavities that enlarge and then implode, creating tremendous heat. When cavitation is induced in a liquid (by applying ultrasonic waves) alternating regions of compression and expansion are created. This creates micrometre size bubbles which implode violently in less than a microsecond, heating their contents to about 5500SC. The surrounding liquid remains at ambient temperature however, so that “hot-spots” are created by the localised temperature increase. These hot spots rapidly dissipate and cool. This is known as cold boiling.

In the case of solid particles in a liquid carrier medium, the ultrasonic waves cause implosion as they pass through the liquid medium and this causes solid particles to clash at speeds of up to 500 km per hour. This can result in a number of effects, ranging from the melting of the solids (for example when the solid is a metal material) to separation of the solids from the liquids due to the inherent aggression of the process.

These effects of cavitation have led to the development of a number of apparatus that can induce cavitation, such as for industrial purposes.

For example, WO 97/02088 discloses an ultrasonic processor and its use for separating oil from drill cuttings and for separating contaminants from soil materials. Whilst the ultrasonic processor disclosed in WO 97/02088 is effective in these applications, it would be desirable to provide an improved such processor which acts in a more efficient manner and as such can be applied to a wider range of applications, particularly on an industrial scale.

Summary of the Invention

According to the present invention there is provided an ultrasonic processor and method as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

The present invention provides an ultrasonic processor comprising: a hollow elongate enclosure member having an inlet end and an outlet end; a plurality of ultrasonic transducers coupled to the hollow elongate enclosure member along at least a portion of a length thereof between the inlet end and the outlet end, the ultrasonic transducers being capable of applying ultrasonic waves to a material passing through the hollow elongate enclosure member; and a controller for controlling the ultrasonic transducers, wherein the hollow elongate enclosure member is sized so as to ensure that the ultrasonic waves are applied to substantially all of the material passing through the hollow elongate enclosure member.

The ultrasonic processor comprises a hollow elongate enclosure member having an inlet end and an outlet end. References to “hollow” mean that the elongate enclosure member is hollow when not in use, such that a material may be passed though its interior, for example from the inlet end to the outlet end. A material may be passed though the hollow elongate enclosure member, for example from the inlet end to the outlet end. In use, the ultrasonic processor may apply ultrasonic waves to material passing through the hollow elongate enclosure member so as to process and/or treat the material in some way. The ultrasonic waves are generated and applied to the material by means of a plurality of ultrasonic transducers.

Each ultrasonic transducer produces a wave front produced from multiple points along its face. In the area adjacent to the transducer, the intensity of the wave front varies due to constructive and destructive interference of the individual waves. The area in which the intensity varies is known as the near field. In the ultrasonic processor of the present invention, the ultrasonic transducers generate ultrasonic waves that are applied to substantially all of the material passing through the hollow elongate enclosure member. In other words, all of the material is ultrasonically radiated. In particular, substantially all of the material that passes through the hollow elongate enclosure member experiences the ultrasonic near field.

Without wishing to be bound by any theory, it is believed that when the material experiences the ultrasonic near field, this creates bubbles that are shaped with a spike, which spike improves the effectiveness of breaking up the material with which it contacts. It is also believed that the bubbles are made more rapidly when the material experiences the ultrasonic near field, compared to when they experience ultrasonic waves outside of the near field. This results in more efficient processing and/or treatment of the material.

By the term “substantially all” we mean that at least 95 weight %, particularly at least 99 weight %, more particularly 100 weight % of the material is ultrasonically irradiated and/or experiences the ultrasonic near field.

The hollow elongate enclosure member may be of any suitable shape in cross-section, such as for example circular, rectangular, oval or square. Preferably, the hollow elongate enclosure member has a circular cross section. Preferably, the hollow elongate enclosure member is in the form of a pipe, such as a pipe of circular cross-section.

It is preferred to use a hollow elongate enclosure member of a circular cross-section (such as a pipe of circular cross-section) because this provides a processor in which material can be passed through the hollow elongate enclosure member under elevated pressure, for example at a pressure of at least 100,000 Pa. Typically, the hollow elongate enclosure member is ATex approved, such that it may be used in an explosive environment.

The hollow elongate enclosure member is sized so as to ensure that the ultrasonic waves are applied to substantially all of the material passing through it. The reference to “sized” refers to the cross-sectional area, which is selected to be of a size that corresponds to the near field of the ultrasonic waves being applied to the material. In other words, the ultrasonic waves that are applied to the material are in the near field, such that substantially all of the material that passes through the hollow elongate enclosure member experiences the near field. This provides advantages in use, including increasing the efficiency of the ultrasonic processor.

Without wishing to be bound by any theory, it is believed that the ultrasonic processor of the present invention has an improved efficiency compared to previous ultrasonic processors, such as those disclosed in WO 97/02088, because the size of the hollow elongate enclosure member ensures that the material being acted upon is located in the ultrasonic near field. The ultrasonic near field affects the material being acted upon and gives improved break down of material. It is believed that when material is acted upon outside of the ultrasonic near field then material passing through a hollow elongate enclosure member is slowed at the side walls and quickened in the centre, such that the material in the centre of the hollow elongate enclosure member is not contacted with the ultrasonic waves.

The hollow elongate enclosure member may have a circular cross section and a diameter in the range of 6 to 8.5 cm, preferably in the range of 7 to 8 cm, most preferably in the range of 7.5 to 7.7 cm. The selection of this diameter provides advantages in use. For example, it causes liquid materials inside the hollow elongate enclosure member to spin and contact the interior side walls of the hollow elongate enclosure member where higher power is exerted on the materials. This increases efficiency.

The length of the hollow elongate enclosure member may be selected according to the proposed use. An example of a preferred length is in the range of from 1 to 3 m, such as from 1.5 to 2.5 m, particularly from 1.7 to 1.9 m, more particularly 1.8 m.

In one aspect, the hollow elongate enclosure member may have a circular cross section, a diameter in the range of 6 to 8.5 cm and a length in the range of from 1 to 3 m.

In another aspect, the hollow elongate enclosure member may have a circular cross section, a diameter in the range of 6 to 8.5 cm and a length in the range of from 1.5 to 2.5 m.

In another aspect, the hollow elongate enclosure member may have a circular cross section, a diameter in the range of 6 to 8.5 cm and a length in the range of from 1.7 to 1.9 m.

In one aspect, the hollow elongate enclosure member may have a circular cross section, a diameter in the range of 7 to 8 cm and a length in the range of from 1 to 3 m.

In another aspect, the hollow elongate enclosure member may have a circular cross section, a diameter in the range of 7.5 to 7.7 cm and a length in the range of from 1 to 3 m.

In another aspect, the hollow elongate enclosure member may have a circular cross section, a diameter in the range of 7.5 to 7.7 cm and a length in the range of from 1.7 to 1.9 m.

The hollow elongate enclosure member may be constructed from any suitable material, as would be appreciated by persons skilled in the art. Suitable materials include metals such as titanium, stainless steel or Hastelloy®. The hollow elongate enclosure member may be constructed from Hastelloy® for example when an acid material is being processed. Preferably the hollow elongate enclosure member has a wall thickness of from 0.5 to 1 cm, more preferably of about 0.5 to 0.65 cm.

The ultrasonic processor comprises a plurality of ultrasonic transducers coupled to the hollow elongate enclosure member along at least a portion of the length thereof between the inlet end and the outlet end. By “a plurality” we mean more than one. For example, the ultrasonic processors may comprise from 10 to 40, preferably from 15 to 35, more preferably from 25 to 35 ultrasonic transducers.

Preferably, the plurality of ultrasonic transducers are coupled to the hollow elongate enclosure member along the whole of its length. This reduces ultrasonic energy losses and ensures that the ultrasonic radiation is being applied effectively to the material.

Any suitable ultrasonic transducer may be used in the ultrasonic processor of the invention. For example, suitable ultrasonic transducers include piezoelectric, ceramic and magno-restrictive transducers.

The plurality of ultrasonic transducers may each have any suitable power output. For example, the plurality of ultrasonic transducers may be selected so as to provide an overall power output of from 2 to 4 kW, such as a power output of about 3 Kw. In one aspect, a plurality of transducers each individually having a power output of from 50 to 150 W may be selected so as to provide an overall power output of 3 kW. For example, thirty transducers each individually having a power output of 100 W may be selected so as to provide an overall power output of 3 kW.

By using a plurality of ultrasonic transducers to achieve the desired power output, the ultrasonic processor of the present invention does not cause localised heating of the material being processed and/or treated. This ensures that the material being processed and/or treated is not damaged by overheating.

The ultrasonic transducers may be coupled to the hollow elongate enclosure member using any suitable method. For example, the ultrasonic transducers may be mechanically fixed to the hollow elongate enclosure member or functionally coupled to the hollow elongate enclosure member, for example by means of a coupling medium. In one aspect, the ultrasonic transducers may comprise at least a part (optionally all) of the hollow elongate enclosure member.

The ultrasonic transducers may be coupled to the exterior and/or the interior of the hollow elongate enclosure member.

Preferably, the ultrasonic transducers are coupled to the exterior of the hollow elongate enclosure member. This ensures that the ultrasonic transducers do not become corroded by material passing through the hollow elongate enclosure member. For example, the plurality of ultrasonic transducers may be mechanically fixed to the exterior of the hollow elongate enclosure member. A plurality of ultrasonic transducers may be mechanically fixed to the exterior of the hollow elongate enclosure member and arranged so as to effectively apply ultrasonic waves to substantially all of the material passing through the hollow elongate enclosure member.

For example, the ultrasonic transducers may be coupled (such as mechanically fixed) at suitable intervals along at least a portion of the length of the hollow elongate enclosure member. The ultrasonic transducers may be coupled (such as mechanically fixed) at suitable intervals along the whole of the length of the hollow elongate enclosure member. This arrangement provides effective treatment of the material passing through the hollow elongate enclosure member. It also allows for the ultrasonic transducers to act without significant heating and for efficient use of space in the environments in which the ultrasonic processors are housed.

The ultrasonic transducers may be mechanically fixed to the interior and/or exterior of the hollow elongate enclosure member by means of a suitable mount structure. For example, two or more of the ultrasonic transducers may be mounted on a mount structure, which mount structure may be mechanically fixed to the exterior of the hollow elongate enclosure member. The mount structure may be profiled to mirror the shape of the interior and/or exterior of the hollow elongate enclosure member to enable it to be easily fixed thereto. The mount structure may comprise an amplifier bar to which one or more ultrasonic transducers are mechanically fixed. The amplifier bar may be profiled to mirror the shape of the exterior of the hollow elongate enclosure member.

The ultrasonic transducer(s) may be mechanically fixed to the mount structure (such as the amplifier bar) by means of a mesh material which acts as a washer and a bonding material such as an epoxy resin (for example aircraft epoxy). This mechanical fixing means provides advantages in use, as it prevents the ultrasonic transducers from generating heat. In particular, the use of the mesh material reinforces the mount structure and prevents cracking of the bonding material.

Two or more ultrasonic transducers may be mounted on a mount structure in a stacked arrangement, for example from two to five, particularly three or four, ultrasonic transducers may be mounted on a mount structure in a stacked arrangement, which mount structure may be mechanically fixed to the exterior of the hollow elongate enclosure member. This stacked arrangement surprisingly provides an increase in power of the ultrasonic waves that are produced, which in turn increases the efficiency of the ultrasonic processor in use. When the ultrasonic transducers are provided in a stacked arrangement, they may be fixed to one another by any suitable means. Preferably the ultrasonic transducers are fixed to one another in a stacked arrangement using a bonding material such as an epoxy resin (for example aircraft epoxy) and a mesh material as discussed above.

The mount structure may be coupled to the hollow elongate enclosure member using any suitable means. For example, the mount structure may be mechanically fixed to the exterior of the hollow elongate enclosure member using any suitable means. For example, the mount structure may be fixed to the exterior of the hollow elongate enclosure member using a bonding material such as an epoxy resin (for example aircraft epoxy) and a mesh material as discussed above. This fixing means provides optical flatness and enables the ultrasonic transducers to generate ultrasonic waves in a stacked arrangement without generating undesirable heat. Alternatively, a vacuum bonding or brazing method may be used to fix the mount structure to the exterior of the hollow elongate enclosure member.

The mesh material may comprise an aluminium or a bronze mesh (for example a phosphor bronze mesh). In particular, the mesh material may comprise an aluminium mesh for fixing the stacked transducers to one another. In particular, the mesh material may comprise a bronze mesh (for example a phosphor bronze mesh) for fixing the mount structure (for example the amplifier bar) to the hollow elongate enclosure member.

The plurality of ultrasonic transducers may be coupled to the hollow elongate enclosure member in any suitable arrangement. For example, the ultrasonic transducers may be arranged in pairs diametrically opposite to one another, or arranged in multiples that are arranged around the circumference of the hollow elongate enclosure member.

The ultrasonic processor comprises a controller for controlling the ultrasonic transducers. For example the ultrasonic processor may control and/or regulate the frequency and power of the ultrasonic waves produced by each of the ultrasonic transducers.

The ultrasonic waves produced by each of the ultrasonic transducers typically have a frequency of from 20 to 35 kHz, more preferably of from 30 to 32 kHz.

Any suitable controller may be used.

The ultrasonic processor may further comprise a sensing means for determining the nature of the material passing through the interior of the hollow elongate enclosure member. The sensing means may actuate the ultrasonic transducers to produce ultrasonic waves at the required frequency in accordance with the nature of the material to be processed and/or treated.

The ultrasonic processor of the present invention may comprise one or more mounts for attaching it to further apparatus in use. The mounts may be located towards the inlet and outlet ends of the hollow elongate enclosure member. Any suitable mounts may be used, for example flange mounts may be used.

The ultrasonic processor of the present invention may comprise a suitable gasket (such as a rubber or neoprene gasket) located at the inlet end and/or the outlet end of the hollow elongate enclosure member for isolating the ultrasonic waves generated by the ultrasonic transducers from the surrounding environment. These gaskets may also isolate other external signals.

The ultrasonic processor of the present invention is intended to be used for processing and/or treating any material requiring a type of processing and/or treatment. For example, the ultrasonic processor may be used to mill, mix, disperse, emulsify, dissolve and/or de-agglomerate one or more materials. The ultrasonic processor of the present invention may also be used for cold boiling.

References herein to “a material” are intended to refer to any one or more materials that require processing and/or treatment, which materials comprise one or more liquids. For example, the material may comprise a liquid material or a suspension of solid materials in a liquid carrier medium. Typically, the material is a mixture of one or more liquids, optionally comprising one or more solids. When the material comprises a solid, the weight ratio of solid to liquid is preferably 1:2. Examples of suitable materials are discussed below.

The present invention further provides a method of processing and/or treating a material, the method comprising passing a material through the hollow elongate enclosure member of an ultrasonic processor as described herein and applying ultrasonic waves to the material by means of the plurality of ultrasonic transducers. In use, one or more ultrasonic processors of the present invention may be connected for use in series. The method is repeated until the desired requirements are met for the material being processed and/or treated.

References herein to passing a material through the hollow elongate enclosure member refer to passing it through the interior of the hollow elongate enclosure member once, or more particularly, to passing it through the interior of the hollow elongate enclosure member multiple times. For example, typically, the material is circulated through the hollow elongate enclosure member multiple times. Whilst substantially all of the material that passes through the hollow elongate enclosure member experiences the ultrasonic near field, it is typically necessary to circulate the material multiple times to achieve the desired requirement for the material being processed and/or treated.

Any suitable method of passing the material through the hollow elongate enclosure member may be used. Typically, the material is pumped through the hollow elongate enclosure member from the inlet end to the outlet end. Suitable pumps include centrifugal, piston and diaphragm pumps.

The method of the present invention may be used to prepare an engine oil composition, such as a lubricant oil, by blending a suitable base oil and dispersing additives therein. For example, in a first step, one or more mineral oils may be mixed with one or more synthetic oils using the ultrasonic processor of the present invention. The mineral and synthetic oils may be passed together through the hollow elongate enclosure member and ultrasonic waves applied to the resultant mixture (by means of the plurality of ultrasonic transducers) so as to mix the oils and produce a blended base oil in a single phase. The blended base oil may be passed through the hollow elongate enclosure member of the ultrasonic processor of the present invention in the presence of one or more engine oil additives and ultrasonic waves applied to the resultant mixture (by means of the plurality of ultrasonic transducers) so as to mix the base oil with the additive(s) and provide an engine oil composition (such as a lubricant oil). Typically, the blended base oil is mixed with the engine oil additives one at a time. The ultrasonic waves produced by the ultrasonic transducers induce cavitation and shear mixing of the components of the engine oil composition.

The present invention further provides a method of preparing an engine oil composition (such as a lubricant oil), the method comprising passing a mixture of one or more mineral oils and one or more synthetic oils through the hollow elongate enclosure member of an ultrasonic processor as described herein and applying ultrasonic waves to the mixture by means of the plurality of ultrasonic transducers to provide a blended base oil in a single phase. The method may further comprise the step of passing the blended base oil and one or more engine oil additives together through the hollow elongate enclosure member of the ultrasonic processor and applying ultrasonic waves thereto by means of the plurality of ultrasonic transducers to provide the engine oil composition.

Typically, in the method of preparing an engine oil additive, the mineral and synthetic oils are circulated together (as a mixture) through the hollow elongate enclosure member of the ultrasonic processor multiple times in order to provide the blended base oil. Once the blended base oil has been prepared then the engine oil additives may be combined with the blended base oil as it circulates through the hollow elongate enclosure member. For practical reasons, it is preferred to introduce the engine oil additives into the blended base oil one at a time. The addition of the engine oil additives to the blended base oil may be conducted manually or by means of an automated process.

Mineral oils are typically hydrocarbon oils. Suitable mineral oils include paraffins, naphthenes and aromatics.

Suitable synthetic oils include polyalphaolefins, alkylated aromatics, polybutenes, polyolesters and polyalkyleneglycols.

Suitable additives include solid and/or liquid additives, such as antioxidants (for example zinc dithiophosphates), viscosity index improvers (for example polymethacrylates), anti-wear agents (for example zinc dialkyldithiophosphate), pour point depressants (for example co-polymers of methacrylates), corrosion inhibitors (for example alkaline compounds, esters), rust inhibitors (for example alkaline compounds, organic acids), friction modifiers (for example graphite, molybdenum disulfide), extreme pressure agents (for example chlorinated paraffins), antifoaming agents (for example dimethyl silicones), demulsifying and emulsifying agents (for example polyamines), detergents (for example phenaltes, sulphonates, naphthenates), dispersants (for example polyisobutylene succinimides) and anti wear load carrying agents (for example zinc dialkyldithiophosphates).

The method of the present invention of preparing an engine oil composition offers the advantages of not requiring any agitation or heating, compared to methods of the prior art in which it is necessary to heat and mix a base oil and appropriate additives. This saves energy, which has cost and environmental benefits.

The method of the present invention may be used to de-agglomerate and/or mill solid material. For example, the method of the present invention may be used to process and/or treat additive material, such as metal oxides (for example titanium dioxide), useful in the preparation of coatings such as paints and inks. The method may be used to de-agglomerate the additive material and/or to mill the additive material. For example, metal oxides, such as titanium dioxide, may be de-agglomerated and milled to an average particle size of 5 micrometres. The ultrasonic waves produced by the ultrasonic transducers induce implosion and particles to clash, which in turn causes the de-agglomeration and/or milling.

Once the additive materials have been de-agglomerated and/or milled, they may be passed through the hollow elongate enclosure member together with one or more components of a coating composition such that ultrasonic waves are applied thereto (by means of the plurality of ultrasonic transducers) and cause shear mixing to provide a coating composition. Thus, the method of the present invention may be used for the shear mixing of coating components (for example of paint and ink components).

The present invention further provides a method of preparing an additive suitable for use in a coating composition (such as a paint or ink composition), the method comprising passing an additive material (such as a metal oxide, for example titanium dioxide) through the hollow elongate enclosure member of an ultrasonic processor as described herein and applying ultrasonic waves thereto (by means of the plurality of ultrasonic transducers) to provide a de-agglomerated and/or milled additive material. When the additive material is a solid (such as titanium dioxide), a suspension of the solid is prepared in a suitable liquid carrier medium, and the suspension is passed through the hollow elongate enclosure member. A suitable liquid carrier medium for preparing the suspension would be well known to persons skilled in the art and includes water and hydrocarbon solvents such as white spirit.

The present invention further provides a method of preparing a coating composition (such as a paint or ink composition), the method comprising passing a de-agglomerated and/or milled additive material (such as a metal oxide, for example titanium dioxide) and one or more components of a coating composition through the hollow elongate enclosure member of an ultrasonic processor as described herein and applying ultrasonic waves thereto (by means of the plurality of ultrasonic transducers) to cause shear mixing and to provide the coating composition.

The present invention further provides a method of preparing a coating composition (such as a paint or ink composition), the method comprising passing an additive material (such as a metal oxide, for example titanium dioxide) through the hollow elongate enclosure member of an ultrasonic processor as described herein and applying ultrasonic waves thereto (by means of the plurality of ultrasonic transducers) to provide a de-agglomerated and/or milled additive material, and passing the de-agglomerated and/or milled additive material and one or more components of a coating composition through the hollow elongate enclosure member of the ultrasonic processor and applying ultrasonic waves thereto (by means of the plurality of ultrasonic transducers) to cause shear mixing and to provide the coating composition. A person skilled in the art would readily understand what additive materials and further components would be included in a coating composition, such as a paint or ink composition.

The ultrasonic processor of the present invention is useful to replace bead mills, agitators and blenders in the preparation of coating (such as paint and ink) compositions. The method of the present invention is advantageous because it does not require any cooling, such that energy usage is minimised.

The method of the present invention may be used to process and/or treat components of pharmaceutical compositions, for example which are to be administered as powders or emulsions.

In the preparation and processing of heavy fuel oil, catalysts agglomerate with asphaltenes and form a sludge like material. It can be difficult to separate and recover the catalysts from the asphaltenes. The method of the present invention may be useful in the separation of a catalyst from asphaltenes. A composition comprising asphaltenes and a catalyst may be passed through the hollow elongate enclosure member of an ultrasonic processor as described herein and ultrasonic waves applied thereto (by means of the plurality of ultrasonic transducers). It is believed that the ultrasonic waves cause de-agglomeration of the asphaltenes and release of the catalyst. The catalyst may, if desired, be recovered, for example by use of a centrifuge.

The method of the present invention may be used to kill bacterial (such as yeast, mould and fungi) in a material. For example, a material comprising bacteria may be passed through the hollow elongate enclosure member of an ultrasonic processor as described herein and ultrasonic waves applied thereto (by means of the plurality of ultrasonic transducers) so as to kill the bacteria. It is believed that the bacteria are killed effectively because the material (comprising the bacteria) experiences the ultrasonic near field, which is effective to kill the bacteria. This method is particularly useful for treating fuel compositions (such as aviation fuel) that are infected with bacteria.

The present invention further provides a method of treating a material (such as a fuel composition) to kill bacteria therein, the method comprising passing the material through the hollow elongate enclosure member of an ultrasonic processor as described herein and applying ultrasonic waves to the material by means of the plurality of ultrasonic transducers to provide a composition that is substantially free of bacteria.

In use, the hollow elongate enclosure member may be disposed vertically, horizontally, diagonally or, for example, in a multiple configuration such as a serpentine for maximum use of available space.

The preferred rate of flow of the material through the hollow elongate enclosure member of the ultrasonic processor of the present invention depends on the nature of the material being processed and/or treated. As a person skilled in the art would appreciate, the flow rate can be optimised for each material.

In use, the ultrasonic processor of the present invention may be encased within a housing (such as a metal housing) in order to meet safety requirements.

Brief Description of the Drawings

The present invention will now be described, by way of example only, and with reference to the following drawings, in which:

Figure 1 shows a plan view of an ultrasonic processor of the present invention;

Figure 2 shows a cross-sectional view of an ultrasonic processor of the present invention;

Figure 3 shows a plan view of a mount structure comprising an ultrasonic transducer of the present invention; and

Figure 4 shows a schematic representation of an ultrasonic processor of the present invention in combination with apparatus for conducting the process for preparing an engine oil composition of the present invention.

Description of the Preferred Embodiments

As shown in Figure 1, an ultrasonic processor 1 comprises a hollow elongate enclosure member 2 having a circular cross-section. The hollow elongate enclosure member 2 has an inlet end 3 and an outlet end 4. A flange mount 5 is located at the inlet end 3 of the hollow elongate enclosure member 2 and a flange mount 6 is located at the outlet end 4 of the hollow elongate enclosure member 2. The flange mounts enable the ultrasonic processor 1 of the invention to be connected to and used in combination with other apparatus. A plurality of ultrasonic transducers 7 are mounted on the exterior of the hollow elongate enclosure member 2 by means of a mount structure 8. The mount structure 8 is profiled to mirror the shape of the exterior of the hollow elongate enclosure member 2.

Figure 2 shows an ultrasonic processor 1 of the present invention which has a hollow elongate enclosure member 2 of a circular cross-section. A plurality of ultrasonic transducers 7 are mechanically fixed to the exterior of the hollow elongate enclosure member 2 by means of a mount structure 9. The circular cross-section of the hollow elongate enclosure member 2 is sized so as to ensure that the ultrasonic waves generated by the ultrasonic transducers 7 are applied to substantially all of the material passing through the interior of the hollow elongate enclosure member 2.

Figure 3 shows a mount structure 9 for mechanically fixing the ultrasonic transducers to the exterior of the hollow elongate enclosure member 2. The mount structure 9 comprises an amplifier bar 10 that is profiled to mirror the shape of the exterior of a hollow elongate enclosure member 2 of circular cross-section. The amplifier bar 9 has two ultrasonic transducers 7 fixed thereto in a stacked arrangement at two locations. The ultrasonic transducers 7 are mechanically fixed to amplifier bar 9 by means of a mesh material which acts as a washer and a bonding material such as aircraft epoxy (not shown). A retaining bolt 11 supplements the securement. The stacked ultrasonic transducers 7 are fixed to each other by a similar arrangement of a mesh and bonding material, and also by means of a retaining bolt 11.

Figure 4 shows an apparatus 20 used for the preparation of an engine oil composition. The apparatus 20 comprises an ultrasonic processor 1 of the present invention. The ultrasonic processor comprises a hollow elongate enclosure member 2 having a circular cross-section. The hollow elongate enclosure member 2 has an inlet end 3 and an outlet end 4. A flange mount 5 is located at the inlet end 3 of the hollow elongate enclosure member 2 and a flange mount 6 is located at the outlet end 4 of the hollow elongate enclosure member 2. The flange mounts 5, 6 enable the ultrasonic processor 1 of the invention to be connected to and used in combination with the other apparatus.

The apparatus 20 comprises a tank 22 (such as a 10 tonne tank) in which the engine oil composition is housed. A pump 21 pumps materials around the apparatus. The apparatus 20 comprises pre-mixing vessels 23, 24 which house the mineral and synthetic oils respectively. Non-return valves 26 are included. The apparatus 20 further comprises pre-mixing vessels 25 which each house an engine oil additive. In use, the mineral oil from pre-mixing vessel 24 and the synthetic oil from the pre-mixing vessel 23 are pumped into the ultrasonic processor 2 via the inlet end 3 and are pumped together through the hollow elongate enclosure member 2 where ultrasonic waves are applied to the oils by means of the plurality of ultrasonic transducers (not shown) so as to mix the oils and produce a blended base oil in a single phase. The oil mixture is circulated through the ultrasonic processor multiple times until the desired blended base oil is prepared. The blended base oil continues to be pumped and passed through the hollow elongate enclosure member 2 and one by one the engine oil additives are added (from the pre-mixing vessels 25), such that ultrasonic waves are applied to the resulting mixture. This process continues until the required engine oil composition has been obtained.

Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. An ultrasonic processor comprising: a hollow elongate enclosure member having an inlet end and an outlet end; a plurality of ultrasonic transducers coupled to the hollow elongate enclosure member along at least a portion of a length thereof between the inlet end and the outlet end, the ultrasonic transducers being capable of applying ultrasonic waves to a material passing through the hollow elongate enclosure member; and a controller for controlling the ultrasonic transducers, wherein the hollow elongate enclosure member is sized so as to ensure that the ultrasonic waves are applied to substantially all of the material passing through the hollow elongate enclosure member.

2. An ultrasonic processor as claimed in claim 1, wherein substantially all of the material that passes through the hollow elongate enclosure member experiences an ultrasonic near field.

3. An ultrasonic processor according to claim 1 or 2, wherein the hollow elongate enclosure member has a circular cross-section.

4. An ultrasonic processor as claimed in claim 3, wherein the hollow elongate enclosure member has a diameter in the range of 6 to 8.5 cm.

5. An ultrasonic processor as claimed in claim 4, wherein the diameter is in the range of 7 to 8 cm.

6. An ultrasonic processor as claimed in any preceeding claim, wherein the plurality of ultrasonic transducers are coupled to an exterior of the hollow elongate enclosure member.

7. An ultrasonic processor as claimed in any preceeding claim, wherein the plurality of ultrasonic transducers are mechanically fixed to an exterior of the hollow elongate enclosure member.

8. An ultrasonic processor as claimed in claim 7, wherein two or more of the ultrasonic transducers are mounted on a mount structure, which mount structure is mechanically fixed to the exterior of the hollow elongate enclosure member.

9. An ultrasonic processor as claimed in claim 8, wherein the two or more ultrasonic transducers are mounted on the mount structure in a stacked arrangement.

10. An ultrasonic processor as claimed in claim 8 or 9, wherein the mount structure comprises an amplifier bar.

11. A method of processing and/or treating a material, the method comprising passing a material through the hollow elongate enclosure member of an ultrasonic processor as claimed in any preceeding claim and applying ultrasonic waves to the material by means of the plurality of ultrasonic transducers.

12. A method of preparing an engine oil composition, the method comprising: passing a mixture of one or more mineral oils and one or more synthetic oils through the hollow elongate enclosure member of an ultrasonic processor as claimed in any of claims 1 to 10 and applying ultrasonic waves to the mixture by means of the plurality of ultrasonic transducers to provide a blended base oil in a single phase; and passing the blended base oil and one or more engine oil additives together through the hollow elongate enclosure member and applying ultrasonic waves thereto by means of the plurality of ultrasonic transducers to provide the engine oil composition.

13. A method of preparing an additive suitable for use in a coating composition, the method comprising passing an additive material through the hollow elongate enclosure member of an ultrasonic processor as claimed in any of claims 1 to 10 and applying ultrasonic waves thereto by means of the plurality of ultrasonic transducers to provide a de-agglomerated and/or milled additive material.

14. An ultrasonic processor substantially as herein described, with particular reference to the accompanying drawings.

15. A method of processing and/or treating a material substantially as herein described, with particular reference to the accompanying drawings.