Intensification
of ultrasonic processes for diversified applications,
including environmental remediation, extractions, food processes,
and synthesis of materials, has received attention from the scientific
community and industry. The mechanistic pathways involved in intensification
of ultrasonic processes that include the ultrasonic generation of
cavitation bubbles, radical formation upon their collapse, and the
possibility of fine-tuning operating parameters for specific applications
are all well documented in the literature. However, the scale-up of
ultrasonic processes with large-scale sonochemical reactors for industrial
applications remains a challenge. In this context, this review provides
a complete overview of the current understanding of the role of operating
parameters and reactor configuration on the sonochemical processes.
Experimental and theoretical techniques to characterize the intensity
and distribution of cavitation activity within sonoreactors are compared.
Classes of laboratory and large-scale sonoreactors are reviewed, highlighting
recent advances in batch and flow-through reactors. Finally, examples
of large-scale sonoprocessing applications have been reviewed, discussing
the major scale-up and sustainability challenges.