Sonochemical reactors are based on the generation of cavitational events using ultrasound and offer immense potential for the intensification of physical and chemical processing applications. The present work presents a critical analysis of the underlying mechanisms for intensification, available reactor configurations and overview of the different applications exploited successfully, though mostly at laboratory scales. Guidelines have also been presented for optimum selection of the important operating parameters (frequency and intensity of irradiation, temperature and liquid physicochemical properties) as well as the geometric parameters (type of reactor configuration and the number/position of the transducers) so as to maximize the process intensification benefits. The key areas for future work so as to transform the successful technique at laboratory/pilot scale into commercial technology have also been discussed. Overall, it has been established that there is immense potential for sonochemical reactors for process intensification leading to greener processing and economic benefits. Combined efforts from a wide range of disciplines such as material science, physics, chemistry and chemical engineers are required to harness the benefits at commercial scale operation.
Keywords: Design aspects; Guidelines; Operating parameters; Process intensification; Scale-up strategies; Sonochemical reactors.