• Applications of power ultrasound for petroleum industry are reviewed. • Physical and chemical characteristics of acoustic cavitation are discussed. • Improved crude oil properties by ultrasound breaking long chains of oil molecules. • Promising future of low frequency high power ultrasound applications.

The current understanding and developments of phase separation technology based on ultrasonic standing waves (USWs) are reviewed. Most previous reviews have focused on microscale applications of this technology in the fields of biological materials and food processing. This review covers different applications of ultrasonic separation technology, especially in petrochemical industry. The kinetic mechanism of ultrasonic, design of reactors, separation principles, and related applications are discussed in detail. We lay special stress on the motion characteristics of particles in USWs. According to the particle numbers, particle properties, and frequency characteristics, the separation principles are reasonably categorized as: (1) Bands effect; (2) Acoustophoretic coefficient; (3) Particle density; (4) Sweep frequency. Diverse separation principles improve the universality of ultrasonic separation technology. However, acoustic streaming and acoustic cavitation are two of the main challenges in the application of ultrasonic separation. Based on the current research, the future research can focus on the following aspects: (1) Explore the mechanism of ultrasonic demulsification; (2) Establish unified evaluation criteria for acoustic separation systems; (3) Develop the basis for determination of acoustic cavitation and non-cavitation.

Ultrasound is an emerging and promising method for demulsification, which is highly affected by acoustic parameters and emulsion properties. Herein, a series of microscopic and dehydration experiments are carried out to investigate the parameter optimization of ultrasonic separation. The results show that the optimal acoustic parameters highly depend on the emulsion properties. For low frequency ultrasonic standing waves (USWs), mechanical vibrations not only facilitate droplet collision and coalescence, but also disperse the surfactant absorbed on the interface to decrease the interfacial strength. Therefore, low frequency ultrasound is suitable for separating emulsions with high viscosity and high interfacial strength. Increasing the energy density to produce moderate cavitation can increase demulsification efficiency. However, excessive cavitation results in secondary emulsification. In high frequency USWs, the droplets migrate directionally and form bandings, thereby promoting droplet coalescence. Therefore, high frequency ultrasound is favorable for separating emulsions with low dispersed phase content and small droplet size. Increasing the energy density can accelerate the aggregation of droplets, however, excessive energy density causes acoustic streaming that disturbs the aggregated droplets, resulting in reduced demulsification efficiency. This work presents rules for acoustic parameter optimization, further advancing industrial applications of ultrasonic separation.