Ultrasonic dispersion and emulsification technology is a novel processing technology based on physical processes. Its core principle lies in the cavitation effect induced by ultrasound in liquids. When high-frequency vibrations of 20kHz to 40kHz propagate in a liquid, they cause dramatic fluctuations in local pressure, generating numerous microbubbles. These bubbles grow and expand under the continuous action of ultrasonic energy, eventually collapsing instantaneously, releasing an instantaneous high temperature of approximately 5000K and an instantaneous high pressure of 1000atm, accompanied by a strong microjet. This process efficiently breaks up agglomerates of solid particles or promotes the fusion of immiscible liquids such as oil and water, forming a uniform and stable emulsion, providing key technical support for production and processing in multiple industries.
In practical applications, this technology has been widely adopted in various fields. In the food industry, it can be used to prepare emulsified beverages, sauces, margarine, and other products. It can also participate in the aging process of winemaking, not only making the food taste smoother but also improving product stability and effectively extending shelf life. In cosmetics production, it can evenly disperse active ingredients such as vitamins and plant extracts, helping emulsions and serums improve absorption efficiency and efficacy. In the pharmaceutical field, its value is particularly significant. It can be used to prepare nanoemulsions to improve drug solubility and bioavailability, and it can also be used in the extraction process of traditional Chinese medicine preparations, increasing the extraction rate of alkaloids, saponins, and flavonoids from medicinal materials by more than 50% compared to traditional processes. In the new energy industry, it is used to disperse lithium battery electrode slurries, optimizing battery energy density and cycle life, and it can also facilitate the extraction of polycrystalline silicon and monocrystalline silicon, as well as the preparation of graphene slurries. In the environmental protection field, it is used to emulsify oily wastewater into micron-sized particles, facilitating subsequent separation or degradation treatment, such as playing an important role in biodiesel extraction.
Compared to traditional processing technologies, ultrasonic dispersion emulsification technology has significant advantages. In terms of efficiency and uniformity, cavitation achieves powerful fragmentation. By adjusting power and processing time, particle size can be precisely controlled (e.g., nanoemulsion D50 ≤ 200 nm), exhibiting superior narrow particle size distribution compared to mechanical stirring and high-pressure homogenization. Low-temperature processing is another major highlight; processing temperatures are typically below 50℃, effectively protecting heat-sensitive components such as enzymes, probiotics, and vitamins, while reducing the amount of emulsifier added, meeting the stringent safety requirements of the food and pharmaceutical industries.
Furthermore, this technology boasts precise controllability; parameters such as frequency, amplitude, and processing time can be adjusted via programming to adapt to different systems with viscosities ranging from 1 to 10,000 cP. It can also be integrated with pipeline systems to achieve automated continuous production in industries such as dairy and cosmetics. Its versatility allows it to perform emulsification and dispersion at low frequencies as well as demulsification of oily wastewater at high frequencies, and it is compatible with multiphase mixtures such as liquid-liquid, solid-liquid, and gas-liquid. In terms of environmental and economic efficiency, its energy consumption is 30%-50% lower than that of high-pressure homogenizers (only 500W is needed for a processing capacity of 1L/min), and it has no mechanically worn parts. The ultrasonic probe has a lifespan of over 5000 hours, significantly reducing maintenance costs. More importantly, it can achieve full-scale coverage from laboratory milliliters to industrial tons, and process parameters can be seamlessly scaled up to meet the production needs of different stages.
With its core characteristics of high efficiency, precision, and environmental friendliness, ultrasonic dispersion and emulsification technology reduces reliance on chemical additives, providing a reliable guarantee for product performance optimization and continuous production in various industries. It is demonstrating increasingly important value in promoting green upgrading and high-quality development of industries.
