Intensification of liquid mixing was investigated in domestic fabricated ultrasonic microreactors. Under the ultrasonic field, cavitation bubbles were generated, which undergo vigorous translational motion and surface oscillation with different modes (volume, shape oscillation, and transient collapse). These cavitation phenomena induce intensive convective mixing and reduce the mixing time from 24–32 s to 0.2–1.0 s. The mixing performance decreases with the channel size, due to the weaker cavitation activity in smaller channel. The energy efficiency is comparable to that of the conventional T‐type and higher than the Y‐type and Caterpillar microreactors. Residence time distribution was also measured by a stimulus‐response experiment and analyzed with axial dispersion model. Axial dispersion was significantly reduced by the ultrasound‐induced radial mixing, leading to the increasing of Bo number with ultrasound power. © 2016 American Institute of Chemical Engineers AIChE J, 63: 1404–1418, 2017

The effects of ultrasound on the hydrodynamic and mass transfer behaviors of immiscible liquid–liquid two‐phase flow was investigated in a domestic ultrasonic microreactor. Under ultrasonic irradiation, cavitation bubble was generated and underwent violent oscillation. Emulsification of immiscible phases was initiated by virtue of oscillating bubbles shuttling through the water/oil interface. The pressure drop was found to decrease with increasing ultrasound power, with a maximum decrement ratio of 12% obtained at power 30 W. The mass transfer behavior was characterized by extraction of Rhodamine B from water to 1‐octanol. An enhancement factor of 1.3–2.2 on the overall mass‐transfer coefficient was achieved under sonication. The mass transfer performance was comparable to passive microreactor at similar energy dissipation rate (61–184 W/kg). The extraction equilibrium was reached under a total flow velocity 0.01 m/s and input power 20 and 30 W, exhibiting its potential use in liquid‐liquid extraction process. © 2017 American Institute of Chemical Engineers AIChE J, 64: 1412–1423, 2018