Numerical simulation and verification of acoustic–fluid coupling in multi-source ultrasonic enhancement under mechanical stirring

Ultrasonic and stirring technologies are widely applied due to their strengthening effects in hydrometallurgical processes. However, practical applications often face challenges arising from the randomness in equipment layout and the absence of standardized technical criteria, which result in inconsistencies in process parameters and fluctuations in production efficiency. Therefore, COMSOL finite element software is utilized to establish a multiphysics numerical model coupling ultrasonic and mechanical stirring temperature fields. Through simulation experiments, the study investigates the effects of the distance between the ultrasonic probe and reactor wall, ultrasonic frequency, number of horns, and positioning on the absolute average sound pressure, uniformity of the sound field, and sound speed. The results indicated that the distance between the probe and the container wall, frequency, and probe quantity significantly influence the uniformity of the sound field. The optimal parameter combination achieves maximum efficiency and optimal uniformity. The sound pressure in the reaction tank was measured using a hydrophone. The experimental results align closely with the simulation findings, confirming the numerical model's validity. This model predicts the influence of process parameters on mixing and provides valuable theoretical support for future experimental designs and process optimization.