Emulsion process using microchannel process technology

• US 20060120213A1
• Filed: 11/17/2005
• Published: 06/08/2006
• Est. Priority Date: 11/17/2004
• Status: Abandoned Application

• Current Assignee: Velocys Incorporated (Velocys PLC)
• Original Assignee: Velocys Incorporated (Velocys PLC)
• Inventors: Marchiando, Michael Alan, Yang, Barry L., Long, Richard Q., Qiu, Dongming, Yang, Bin, Tonkovich, Anna Lee, Yuschak, Thomas, Kuhlmann, David J., Daymo, Eric, Silva, Laura J., Neagle, Paul, Pagnotto, Kristina M., Marco, Jeffrey Dale, Rogers, William A. Jr., Freeman, Harley D., Glass, Amanda Rae Divan, Freeman, Jennifer Anne
• Application Number:
  US11/283,525
• Publication Number:
  US 20060120213A1
• Time in Patent Office: Days
• US Class Current: 366/144
• CPC Class Codes: B01F 2035/99 Heating
• CPC Class Codes: B01F 23/41 Emulsifying
• CPC Class Codes: B01F 23/411 using electrical or magnetic fields, heat or vibrations
• CPC Class Codes: B01F 25/10 Mixing by creating a vortex flow, e.g. by tangential introduction of flow components
• CPC Class Codes: B01F 25/3142 the conduit having a plurality of openings in the axial direction or in the circumferential direction
• CPC Class Codes: B01F 25/31421 the conduit being porous
• CPC Class Codes: B01F 25/31425 with a plurality of perforations in the axial and circumferential direction covering the whole surface
• CPC Class Codes: B01F 25/4317 Profiled elements, e.g. profiled blades, bars, pillars, columns or chevrons
• CPC Class Codes: B01F 25/43172 Profiles, pillars, chevrons, i.e. long elements having a polygonal cross-section
• CPC Class Codes: B01F 25/431971 Mounted on the wall
• CPC Class Codes: B01F 27/271 with means for moving the materials to be mixed radially between the surfaces of the rotor and the stator
• CPC Class Codes: B01F 33/30 Micromixers
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 2219/00756 Compositions, e.g. coatings, crystals, formulations
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/00822 Metal
• CPC Class Codes: B01J 2219/00826 Quartz
• CPC Class Codes: B01J 2219/00831 Glass
• CPC Class Codes: B01J 2219/00833 Plastic
• CPC Class Codes: B01J 2219/00835 Comprising catalytically active material
• CPC Class Codes: B01J 2219/00837 : comprising coatings other than catalytically active coatings
• CPC Class Codes: B01J 2219/00844 : Comprising porous material
• CPC Class Codes: B01J 2219/0086 : Dimensions of the flow channels
• CPC Class Codes: B01J 2219/00873 : Heat exchange
• CPC Class Codes: B01J 2219/00889 : Mixing micromixers B01F33/30
• CPC Class Codes: F28D 7/0008 : the conduits for one medium being in heat conductive contact with the conduits for the other medium
• CPC Class Codes: F28F 2260/02 : having microchannels

Abstract

The disclosed invention relates to a process for treating or making an emulsion in a microchannel. The emulsion comprises a first liquid and a second liquid, the first liquid forming a continuous phase, the second liquid forming droplets dispersed in the continuous phase.

Claims

68. A process for making an emulsion, comprising:

flowing a first liquid in a process microchannel, the process microchannel having an axial length extending parallel to the direction of flow of the first liquid, the process microchannel having at least one wall with at least one apertured section, the apertured section having an axial length extending parallel to the axial length of the process microchannel;

flowing a second liquid through the apertured section into the process microchannel in contact with the first liquid to form the emulsion, the first liquid forming a continuous phase, the second liquid forming droplets dispersed in the continuous phase; and

maintaining the flow of the second liquid through the apertured section at a rate that is substantially constant along the axial length of the apertured section.

69. The process of claim 68 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section, the liquid channel being parallel to the process microchannel, the apertured section being positioned between the liquid channel and the process microchannel, the first liquid undergoing a pressure drop as it flows in the process microchannel, the second liquid undergoing a pressure drop as it flows in the liquid channel, the pressure drop for the first liquid flowing in the process microchannel being substantially the same as the pressure drop for the second liquid flowing in the liquid channel.

70. The process of claim 69 wherein the liquid channel comprises a microchannel.

71. The process of claim 68 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section, the liquid channel being parallel to the process microchannel, the apertured section being positioned between the liquid channel and the process microchannel, the first liquid undergoing a pressure drop as it flows in the process microchannel, the internal pressure within the liquid channel being reduced along the length of the liquid channel to provide a pressure differential across the apertured section that is substantially constant along the length of the apertured section.

72. The process of claim 71 wherein the liquid channel comprises one or more internal flow restriction devices to reduce the internal pressure within the liquid channel along the length of the liquid channel.

73. The process of claim 71 wherein the liquid channel comprises one or more internal zones positioned along the length of the liquid channel, the second liquid flowing from the liquid channel through the internal zones and through the apertured section, the pressure within the internal zones being reduced along the length of the liquid channel to provide the substantially constant pressure differential across the apertured section along the length of the apertured section.

74. The process of claim 68 wherein heat is exchanged between the process microchannel and a heat source and/or heat sink.

75. The process of claim 68 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section, and heat is exchanged between the process microchannel and a heat source and/or heat sink, the liquid channel and a heat source and/or heat sink, or both the process microchannel and the liquid channel and a heat source and/or heat sink.

76. The process of claim 68 wherein the first liquid and the second liquid contact each other in a mixing zone in the process microchannel.

77. The process of claim 76 wherein heat is exchanged between the heat source and/or heat sink and the mixing zone.

78. The process of claim 76 wherein heat is exchanged between the heat source and/or heat sink and the process microchannel upstream of the mixing zone.

79. The process of claim 76 wherein heat is exchanged between the heat source and/or heat sink and the process microchannel downstream of the mixing zone.

80. The process of claim 76 wherein the emulsion is quenched in the process microchannel downstream of the mixing zone.

81. The process of claim 76 wherein the process microchannel has a restricted cross section in the mixing zone.

82. The process of claim 68 wherein the process microchannel is formed from parallel spaced sheets, plates or a combination of such sheets and plates.

83. The process of claim 82 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section into the process microchannel, the liquid channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the liquid channel being adjacent to the process microchannel.

84. The process of claim 83 wherein the first liquid and/or second liquid exchange heat with a heat exchange channel, the heat exchange channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the heat exchange channel being adjacent to the process microchannel, the liquid channel, or both the process microchannel and the liquid channel.

85. The process of claim 68 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels, the process microchannels having walls with apertured sections and adjacent liquid channels, the second liquid flowing in the liquid channels and from the liquid channels through the apertured sections into the process microchannels in contact with the first liquid, the process microchannels and liquid channels being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the process microchannels and liquid channels being adjacent to each other and aligned in interleaved side-by-side vertically oriented planes or interleaved horizontally oriented planes stacked one above another.

86. The process of claim 85 wherein the emulsion process unit further comprises a plurality of heat exchange channels formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the heat exchange channels exchanging heat with the process microchannels, the liquid channels, or both the process microchannels and the liquid channels.

87. The process of claim 68 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section into the process microchannel, the process microchannel and the liquid channel comprising circular tubes aligned concentrically.

88. The process of claim 87 wherein the process microchannel is in an annular space and the liquid channel is in the center space or an adjacent annular space.

89. The process of claim 87 wherein the process microchannel is in the center space and the liquid channel is in an adjacent annular space.

90. The process of claim 68 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels wherein separate emulsions are formed in each of the process microchannels, the emulsions formed in at least two of the process microchannels being different from each other.

91. The process of claim 90 wherein the emulsions formed in at least two of the process microchannels are different in composition.

92. The process of claim 90 wherein the emulsions formed in at least two of the process microchannels have one or more different physical properties.

93. The process of claim 68 wherein the process microchannel comprises two or more apertured sections and separate second liquids flow through each of the apertured sections.

94. The process of claim 93 wherein the separate second liquids flowing through each of the apertured sections have different compositions.

95. The process of claim 93 wherein the separate second liquids flowing through each of the apertured sections have different properties.

96. The process of claim 68 wherein the process microchannel has a mixing zone adjacent to the apertured section and a non-apertured region extending from the entrance to the process microchannel to the mixing zone.

97. The process of claim 68 wherein the apertured section comprises at least one sheet or plate with a plurality of apertures in the sheet or plate.

98. The process of claim 68 wherein the apertured section comprises a relatively thin sheet overlying a relatively thick sheet or plate, the relatively thin sheet containing a plurality of relatively small apertures, and the relatively thick sheet or plate containing a plurality of relatively large apertures, the relatively small apertures being aligned with the relatively large apertures sufficiently to permit liquid to flow from the relatively large apertures through the relatively small apertures.

99. The process of claim 98 with a coating overlying at least part of the sheet or plate and filling part of the apertures.

100. The process of claim 98 wherein the sheet or plate is heat treated.

101. The process of claim 68 wherein the apertured section has a wall thickness, the ratio of the wall thickness to the axial length of the apertured section being in the range from about 0.001 to about 1.

102. The process of claim 68 wherein the apertured section is made from a porous material.

103. The process of claim 102 wherein the porous material is metallic, nonmetallic and/or oxidized.

104. The process of claim 102 wherein the porous material is coated with an organic or inorganic material.

105. The process of claim 68 wherein the apertured section is made from a porous material, the surface of the porous material being treated by filling the pores on the surface with a liquid filler, solidifying the filler, grinding and/or polishing the surface, and removing the filler.

106. The process of claim 68 wherein the droplets having a volume-based mean diameter in the range up to about 200 microns, and a span in the range from about 0.01 to about 10.

107. The process of claim 68 wherein the process microchannel has an internal dimension perpendicular to the flow of liquid through the process microchannel of up to about 10 mm.

108. The process of claim 68 wherein the process microchannel has an internal dimension perpendicular to the flow of liquid through the process microchannel of up to about 2 mm.

109. The process of claim 68 wherein the process microchannel is made of a material comprising:

steel;

monel;

inconel;

aluminum;

titanium;

nickel;

copper;

brass;

an alloy of any of the foregoing metals;

a polymer;

ceramics;

glass;

a composite comprising a polymer and fiberglass;

quartz;

silicon;

or a combination of two or more thereof.

110. The process of claim 68 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section, the liquid channel having an internal dimension perpendicular to the flow of the second liquid in the liquid channel of up to about 100 cm.

111. The process of claim 74 wherein the heat source and/or heat sink comprises at least one heat exchange channel, a heat exchange fluid being in the heat exchange channel.

112. The process of claim 111 wherein the heat exchange fluid undergoes a phase change in the heat exchange channel.

113. The process of claim 111 wherein an endothermic process is conducted in the heat exchange channel.

114. The process of claim 111 wherein an exothermic process is conducted in the heat exchange channel.

115. The process of claim 111 wherein the heat exchange fluid comprises air, steam, liquid water, carbon monoxide, carbon dioxide, gaseous nitrogen, liquid nitrogen, a gaseous hydrocarbon or a liquid hydrocarbon.

116. The process of claim 111 wherein the heat exchange fluid comprises the first liquid, the second liquid, or the emulsion.

117. The process of claim 74 wherein the heat source and/or heat sink comprises an electric heating element, resistance heater and/or non-fluid cooling element.

118. The process of claim 74 wherein the heat source and/or heat sink is adjacent to the process microchannel.

119. The process of claim 74 wherein the heat source and/or heat sink is remote from the process microchannel.

120. The process of claim 68 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels connected to at least one first liquid manifold, the first liquid flowing through the at least one first liquid manifold to the process microchannels.

121. The process of claim 120 wherein liquid channels are adjacent to the process microchannels, the emulsion process unit further comprising at least one second liquid manifold connected to the liquid channels, the second liquid flowing through the at least one second liquid manifold to the liquid channels.

122. The process of claim 120 wherein heat exchange channels are adjacent to the process microchannels and/or liquid channels, the emulsion process unit further comprising at least one heat exchange manifold connected to the heat exchange channels, a heat exchange fluid flowing through the at least one heat exchange manifold to the heat exchange channels.

123. The process of claim 68 wherein the emulsion is an oil-in-water emulsion.

124. The process of claim 68 wherein the emulsion is a water-in-oil emulsion.

125. The process of claim 68 wherein the emulsion comprises a skin care product, a paint or coating composition, an adhesive composition, a glue composition, a caulk composition, a sealant composition, a food composition, an agricultural composition, a pharmaceutical composition, a fuel composition, a lubricant composition, a surface dressing composition, a silicone emulsion, a crystal containing composition, a liquid crystal composition, or a wax emulsion.

126. The process of claim 68 wherein the second liquid flows in a liquid channel, part of the second liquid flowing from the liquid channel through the apertured section, and part of the second liquid flowing through the liquid channel and out of the liquid channel.

127. The process of claim 68 wherein the apertured section extends along about 1% to about 100% of the axial length of the process microchannel.

128. The process of claim 68 wherein the process microchannel comprises surface features formed in and/or on one or more interior walls for modifying flow and/or enhancing mixing within the process microchannel.

129. The process of claim 69 wherein the liquid channel comprises surface features formed in and/or on one or more interior walls for modifying flow and/or enhancing mixing within the liquid channel.

130. The process of claim 111 wherein the heat exchange channel comprises surface features formed in and/or on one or more interior walls for modifying flow and/or enhancing mixing within the heat exchange channel.

131. The process of claim 128 wherein the surface features are in the form of depressions in and/or projections from one or more of the microchannel interior walls and are oriented at angles relative to the direction of flow of liquid through the process microchannel.

132. The process of claim 128 wherein the surface features comprise at least two surface feature regions where mixing of the first liquid reactant and second liquid is conducted in a first surface feature region followed by flow in a second surface feature region where the flow pattern in the second surface feature region is different than the flow pattern in the first surface feature region.

133. The process of claim 132 wherein the emulsion is formed in the first surface feature region and flows in the second surface feature region where one or more liquids and/or gases are separated from the emulsion.

134. The process of claim 68 wherein the apertured section comprises an interior portion that forms part of one or more of the interior walls of the process microchannel and a surface feature sheet overlies the interior portion of the apertured section, and wherein surface features are in and/or on the surface feature sheet.

135. The process of claim 128 wherein the surface features comprise two or more layers stacked on top of each other and/or intertwined in a three-dimensional pattern.

136. The process of claim 128 wherein the surface features are in the form of circles, oblongs, squares, rectangles, checks, chevrons, wavy shapes, or combinations thereof.

137. The process of claim 128 wherein the surface features comprise sub-features where the major walls of the surface features further contain smaller surface features in the form of notches, waves, indents, holes, burrs, checks, scallops, or combinations thereof.

138. The process of claim 68 wherein the emulsion comprises at least one emulsifier and/or surfactant.

139. The process of claim 68 wherein solids are dispersed in the emulsion.

140. The process of claim 68 wherein a catalyst is dispersed in the emulsion.

141. The process of claim 68 wherein the superficial velocity of the emulsion flowing in the process microchannel is at least about 0.01 meter per second.

142. The process of claim 68 wherein the process further comprises exchanging heat between the process microchannel and a heat source and/or heat sink to increase or decrease the temperature of the emulsion by at least about 10°

C. within a period of up to about 750 milliseconds.

209. The process of claim 70 wherein the process microchannel, liquid channel and/or apertured section is coated with a lipophobic coating.

213. The process of claim 68 wherein the liquid channel comprises a flow-through channel with a liquid channel outlet, a first part of the second liquid flowing through the apertured section, a second part of the second liquid flowing out of the liquid channel through the liquid channel outlet.

214. The process of claim 213 wherein the flow of the second liquid through the liquid channel outlet is controlled to control the pressure within the liquid channel.

220. The process of claim 69 wherein the apertured section is in the form of a tube with an apertured tubular wall, an axial length and a circular cross section, the interior of the tube comprising the liquid channel, the process microchannel being positioned on the outer surface of the tube, the axial length of the process microchannel extending parallel to the axial length of the tube, the first liquid flowing in the process microchannel, the second liquid flowing from the interior of the tube through the apertured tubular wall into the process microchannel in contact with the first liquid to form the emulsion.

221. The process of claim 220 wherein a plurality of the process microchannels are positioned on the outer surface of the tube.

222. The process of claim 220 wherein a heat exchange channel is adjacent to the process microchannel, the process microchannel being positioned between the outer surface of the tube and the heat exchange channel.

227. The process of claim 68 wherein the apertured section comprises at least two sheets overlying each other, a first sheet having a first array of apertures in it, a second sheet having a second array of apertures in it, the apertures in the first sheet being larger than the apertures in the second sheet, the second sheet at least partially blocking some of the apertures in the first sheet.

231. The process of claim 68 wherein the apertured section comprises a porous substrate coated with at least one metal, the metal being applied to the porous substrate by electroless plating.

232. The process of claim 231 wherein the metal comprises platinum.

247. The process of claim 68 wherein the apertured section comprises a porous material and a plurality of adjacent ribs supporting the porous material.

250. The process of claim 68 wherein the first liquid and/or the second liquid is a non-Newtonian fluid.

253. The process of claim 68 wherein a surface feature section is positioned in the process microchannel upstream of the apertured section.

143. A process, comprising:

flowing an emulsion in a process microchannel in contact with surface features formed in and/or on one or more interior walls of the process microchannel, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising droplets of a second liquid, the flow of the emulsion being at a superficial velocity sufficient to reduce the average size of the droplets.

1. A process, comprising:

flowing an emulsion in a process microchannel, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid; and

exchanging heat between the process microchannel and a heat source and/or heat sink to increase or decrease the temperature of the emulsion by at least about 10°

C. within a period of up to about 750 milliseconds.

2. The process of claim 1 wherein the dispersed phase is in the form of liquid droplets, the liquid droplets having a volume-based mean diameter in the range up to about 200 microns, and a span in the range from about 0.005 to about 10.

3. The process of claim 1 wherein the flow rate of the emulsion in the process microchannel is at least about 0.01 liters per minute.

4. The process of claim 1 wherein the superficial velocity of the emulsion flowing in the process microchannel is at least about 0.01 meter per second.

5. The process of claim 1 wherein the first liquid and the second liquid are mixed to form the emulsion in the process microchannel.

6. The process of claim 1 wherein the process microchannel comprises at least one side wall and at least one apertured section extending along at least part of the axial length of the side wall, the second liquid flowing through the apertured section into the process microchannel in contact with the first liquid to form the emulsion.

7. The process of claim 6 wherein the second liquid flows from a liquid channel through the apertured section.

8. The process of claim 1 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels and at least one header for distributing the liquids to the process microchannels, the process further comprising mixing the first liquid and the second liquid to form the emulsion in the header, the emulsion flowing from the header into the process microchannels.

9. The process of claim 8 wherein the header comprises at least one first liquid zone, at least one second liquid zone, and an apertured section positioned between the first liquid zone and the second liquid zone, the second liquid flowing from the second liquid zone through the apertured section into the first liquid zone in contact with the first liquid to form the emulsion, the emulsion flowing from the first liquid zone into the process microchannels.

10. The process of claim 8 wherein a stream of the second liquid contacts a stream of the first liquid in the header to form the emulsion.

11. The process of claim 5 wherein a stream of the second liquid contacts a stream of the first liquid in the process microchannel to form the emulsion.

12. The process of claim 1 wherein the process microchannel comprises surface features formed in and/or on one or more interior walls for modifying flow and/or mixing within the process microchannel.

13. The process of claim 7 wherein the liquid channel comprises surface features formed in and/or on one or more interior walls of the liquid channel for modifying flow and/or mixing within the liquid channel.

14. The process of claim 1 wherein the heat source and/or heat sink comprises at least one heat exchange channel, the heat exchange channel comprising surface features formed in and/or on one or more interior walls of the heat exchange channel for modifying flow and/or mixing within the heat exchange channel.

15. The process of claim 12 wherein the surface features are in the form of depressions in and/or projections from one or more of the microchannel interior walls that are oriented at angles relative to the direction of flow of fluid through the process microchannel.

16. The process of claim 12 wherein the surface features comprise at least two surface feature regions where mixing of the first liquid and second liquid is conducted in a first surface feature region followed by flow in a second surface feature region where the flow pattern in the second surface feature region is different than the flow pattern in the first surface feature region.

17. The process of claim 6 wherein the apertured section comprises an interior portion that forms part of one or more of the interior walls of the process microchannel and surface features positioned in and/or on the interior portion of the apertured section.

18. The process of claim 12 wherein the surface features comprise two or more layers stacked on top of each other and/or intertwined in a three-dimensional pattern.

19. The process of claim 12 wherein the surface features are in the form of circles, oblongs, squares, rectangles, checks, chevrons, wavy shapes, or combinations thereof.

20. The process of claim 12 wherein the surface features comprise sub-features where the major walls of the surface features further contain smaller surface features in the form of notches, waves, indents, holes, burrs, checks, scallops, or combinations thereof.

21. The process of claim 1 wherein the process microchannel has an internal dimension of width or height of up to about 10 mm.

22. The process of claim 1 wherein the process microchannel has an internal dimension of width or height of up to about 2 mm.

23. The process of claim 1 wherein the process microchannel is made of a material comprising:

steel;

monel;

inconel;

aluminum;

titanium;

nickel;

copper;

brass;

an alloy of any of the foregoing metals;

a polymer;

ceramics;

glass;

a composite comprising a polymer and fiberglass;

quartz;

silicon;

or a combination of two or more thereof.

24. The process of claim 7 wherein the liquid channel comprises a microchannel.

25. The process of claim 7 wherein the process microchannel is adjacent to the liquid channel, the process microchannel and the liquid channel having a common wall with the apertured section in the common wall.

26. The process of claim 6 wherein the apertured section comprises a relatively thin sheet overlying a relatively thick sheet or plate, the relatively thin sheet containing an array of relatively small apertures, and the relatively thick sheet or plate containing an array of relatively large apertures, at least some of the relatively small apertures being aligned with the relatively large apertures.

27. The process of claim 6 wherein the apertured section comprises apertures that are partially filled with a coating material.

28. The process of claim 6 wherein the apertured section is heat treated.

29. The process of claim 6 wherein the apertured section is made from a porous material.

30. The process of claim 29 wherein the porous material is metallic, nonmetallic and/or oxidized.

31. The process of claim 29 wherein the porous material is coated with an organic or an inorganic material.

32. The process of claim 6 wherein the apertured section is made from a porous material, the surface of the porous material being treated by filling the pores on the surface with a liquid filler, solidifying the filler, grinding or polishing the surface, and removing the filler.

33. The process of claim 6 wherein the apertured section extends along about 1% to about 100% of the axial length of the process microchannel.

34. The process of claim 1 wherein the heat source and/or heat sink is adjacent to the process microchannel.

35. The process of claim 1 wherein the heat source and/or heat sink is remote from the process microchannel.

36. The process of claim 1 wherein the heat source and/or heat sink comprises at least one heat exchange channel.

37. The process of claim 36 wherein the heat exchange channel comprises a microchannel.

38. The process of claim 1 wherein the heat source and/or heat sink comprises at least one electric heating element, resistance heater and/or non-fluid cooling element.

39. The process of claim 36 wherein a heat exchange fluid is in the heat exchange channel.

40. The process of claim 39 wherein the heat exchange fluid undergoes a phase change in the heat exchange channel.

41. The process of claim 1 wherein the heat flux between the heat source and/or heat sink and the process microchannel is in the range from about 0.01 to about 250 watts per square centimeter of surface area of the process microchannel.

42. The process of claim 36 wherein an endothermic process is conducted in the heat exchange channel.

43. The process of claim 36 wherein an exothermic process is conducted in the heat exchange channel.

44. The process of claim 36 wherein the emulsion flows in the process microchannel in a first direction, and a heat exchange fluid flows in the heat exchange channel in a second direction, the second direction being cross current relative to the first direction.

45. The process of claim 36 wherein the emulsion flows in the process microchannel in a first direction, and a heat exchange fluid flows in the heat exchange channel in a second direction, the second direction being cocurrent or counter current relative to the first direction.

46. The process of claim 36 wherein a heat exchange fluid is in the heat exchange channel, the heat exchange fluid comprising the first liquid, the second liquid, or the emulsion.

47. The process of claim 36 wherein a heat exchange fluid is in the heat exchange channel, the heat exchange fluid comprising one or more of air, steam, liquid water, carbon monoxide, carbon dioxide, gaseous nitrogen, liquid nitrogen, inert gas, gaseous hydrocarbon, oil, and liquid hydrocarbon.

48. The process of claim 1 wherein the emulsion is quenched in the process microchannel.

49. The process of claim 1 wherein the process microchannel is formed from parallel spaced sheets, plates or a combination of such sheets and plates.

50. The process of claim 6 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section into the process microchannel, the liquid channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the liquid channel being adjacent to the process microchannel.

51. The process of claim 1 wherein the heat source and/or heat sink comprises a heat exchange channel, the heat exchange channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates.

52. The process of claim 1 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels, the process microchannels having walls with apertured sections and adjacent liquid channels, the second liquid flowing in the liquid channels and from the liquid channels through the apertured sections into the process microchannels in contact with the first liquid, the process microchannels and liquid channels being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the process microchannels and liquid channels being adjacent to each other and aligned in interleaved side-by-side vertically oriented planes or interleaved horizontally oriented planes stacked one above another.

53. The process of claim 52 wherein the emulsion process unit further comprises a plurality of heat exchange channels formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the heat exchange channels exchanging heat with the process microchannels, the liquid channels, or both the process microchannels and the liquid channels.

54. The process of claim 6 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section into the process microchannel, the process microchannel and the liquid channel comprising circular tubes aligned concentrically.

55. The process of claim 54 wherein the process microchannel is in an annular space and the liquid channel is in the center space or an adjacent annular space.

56. The process of claim 54 wherein the process microchannel is in the center space and the liquid channel is in an adjacent annular space.

57. The process of claim 1 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels wherein separate emulsions are formed in each of the process microchannels, the emulsions formed in at least two of the process microchannels being different from each other.

58. The process of claim 6 wherein the process microchannel comprises two or more apertured sections and separate second liquids flow through each of the apertured sections.

59. The process of claim 6 wherein the process microchannel has a mixing zone adjacent to the apertured section and a non-apertured region extending from the entrance to the process microchannel to the mixing zone.

60. The process of claim 6 wherein the apertured section has a wall thickness, the ratio of the wall thickness to the axial length of the apertured section being in the range from about 0.001 to about 1.

61. The process of claim 1 wherein the emulsion comprises a water-in-oil emulsion.

62. The process of claim 1 wherein the emulsion comprises an oil-in-water emulsion.

63. The process of claim 1 wherein the emulsion comprises at least one organic liquid.

64. The process of claim 1 wherein the emulsion comprises a skin care product, a paint or coating composition, an adhesive composition, a glue composition, a caulk composition, a sealant composition, a food composition, an agricultural composition, a pharmaceutical composition, a fuel composition, a lubricant composition, a surface dressing composition, a silicone emulsion, a crystal containing composition, a liquid crystal composition, or a wax emulsion.

65. The process of claim 1 wherein the emulsion comprises at least one emulsifier and/or surfactant.

66. The process of claim 1 wherein solids are dispersed in the emulsion.

67. The process of claim 1 wherein a catalyst is dispersed in the emulsion.

144. The process of claim 143 wherein the liquid droplets have a volume-based mean diameter in the range up to about 200 microns, and a span in the range from about 0.005 to about 10.

145. The process of claim 143 with the step of exchanging heat between the process microchannel and a heat source and/or heat sink.

146. The process of claim 143 wherein the first liquid and the second liquid are mixed to form the emulsion in the process microchannel.

147. The process of claim 143 wherein the process microchannel comprises at least one side wall and at least one apertured section extending along at least part of the axial length of the side wall, the second liquid flowing through the apertured section into the process microchannel in contact with the first liquid to form the emulsion.

148. The process of claim 147 wherein the second liquid flows from a liquid channel through the apertured section.

149. The process of claim 143 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels and at least one header for distributing the first liquid and the second liquid to the process microchannels, the process further comprising mixing the first liquid and the second liquid to form the emulsion in the header, the emulsion flowing from the header into the process microchannels.

150. The process of claim 149 wherein the header comprises a first liquid zone, at least one second liquid zone, and an apertured section positioned between the first liquid zone and the second liquid zone, the second liquid flowing from the second liquid zone through the apertured section into the first liquid zone in contact with the first liquid to form the emulsion, the emulsion flowing from the first liquid zone into the process microchannels.

151. The process of claim 149 wherein a stream of the second liquid contacts a stream of the first liquid in the header to form the emulsion.

152. The process of claim 146 wherein a stream of the second liquid contacts a stream of the first liquid in the process microchannel to form the emulsion.

153. The process of claim 148 wherein the liquid channel comprises surface features formed in and/or on one or more interior walls for modifying flow and/or mixing within the liquid channel.

154. The process of claim 145 wherein the heat source and/or heat sink comprises at least one heat exchange channel, the heat exchange channel comprising surface features formed in and/or on one or more interior walls of the heat exchange channel for modifying flow and/or mixing within the heat exchange channel.

155. The process of claim 143 wherein the surface features are in the form of depressions in and/or projections from one or more of the interior walls of the process microchannel, the surface features being oriented at angles relative to the direction of flow through the process microchannel.

156. The process of claim 143 wherein the surface features comprise at least two surface feature regions where mixing of the first liquid and second liquid is conducted in a first surface feature region followed by flow in a second surface feature region where the flow pattern in the second surface feature region is different than the flow pattern in the first surface feature region.

157. The process of claim 147 wherein the apertured section comprises an interior portion that forms part of one or more of the interior walls of the process microchannel and surface features positioned in and/or on the interior portion of the apertured section.

158. The process of claim 143 wherein the surface features comprise two or more layers stacked on top of each other and/or intertwined in a three-dimensional pattern.

159. The process of claim 143 wherein the surface features are in the form of circles, oblongs, squares, rectangles, checks, chevrons, wavy shapes, or combinations thereof.

160. The process of claim 143 wherein the surface features comprise sub-features where the major walls of the surface features further contain smaller surface features in the form of notches, waves, indents, holes, burrs, checks, scallops, or combinations thereof.

161. The process of claim 143 wherein the process microchannel has an internal dimension of width or height of up to about 10 mm.

162. The process of claim 143 wherein the process microchannel has an internal dimension of width or height of up to about 2 mm.

163. The process of claim 143 wherein the process microchannel is made of a material comprising:

steel;

monel;

inconel;

aluminum;

titanium;

nickel;

copper;

brass;

an alloy of any of the foregoing metals;

a polymer;

ceramics;

glass;

a composite comprising a polymer and fiberglass;

quartz;

silicon;

or a combination of two or more thereof.

164. The process of claim 148 wherein the liquid channel comprises a microchannel.

165. The process of claim 148 wherein the process microchannel is adjacent to the liquid channel, the process microchannel and the liquid channel having a common wall with the apertured section in the common wall.

166. The process of claim 147 wherein the apertured section comprises a relatively thin sheet overlying a relatively thick sheet or plate, the relatively thin sheet containing an array of relatively small apertures, and the relatively thick sheet or plate containing an array of relatively large apertures, at least some of the relatively small apertures being aligned with the relatively large apertures.

167. The process of claim 147 wherein the apertured section comprises apertures that are partially filled with a coating material.

168. The process of claim 147 wherein the apertured section is heat treated.

169. The process of claim 147 wherein the apertured section is made from a porous material.

170. The process of claim 169 wherein the porous material is metallic, nonmetallic and/or oxidized.

171. The process of claim 169 wherein the porous material is coated with alumina or nickel.

172. The process of claim 147 wherein the apertured section is made from a porous material, the surface of the porous material being treated by filling the pores on the surface with a liquid filler, solidifying the filler, grinding or polishing the surface, and removing the filler.

173. The process of claim 147 wherein the apertured section extends along about 1% to about 100% of the axial length of the process microchannel.

174. The process of claim 145 wherein the heat source and/or heat sink is adjacent to the process microchannel.

175. The process of claim 145 wherein the heat source and/or heat sink is remote from the process microchannel.

176. The process of claim 145 wherein the heat source and/or heat sink comprises at least one heat exchange channel.

177. The process of claim 176 wherein the heat exchange channel comprises a microchannel.

178. The process of claim 145 wherein the heat source and/or heat sink comprises at least one electric heating element, resistance heater and/or non-fluid cooling element.

179. The process of claim 176 wherein a heat exchange fluid is in the heat exchange channel.

180. The process of claim 179 wherein the heat exchange fluid undergoes a phase change in the heat exchange channel.

181. The process of claim 145 wherein the heat flux between the heat source and/or heat sink and the process microchannel is in the range from about 0.01 to about 250 watts per square centimeter of surface area of the process microchannel.

182. The process of claim 176 wherein an endothermic process is conducted in the heat exchange channel.

183. The process of claim 176 wherein an exothermic process is conducted in the heat exchange channel.

184. The process of claim 176 wherein the emulsion flows in the process microchannel in a first direction, and a heat exchange fluid flows in the heat exchange channel in a second direction, the second direction being cross current relative to the first direction.

185. The process of claim 176 wherein the emulsion flows in the process microchannel in a first direction, and a heat exchange fluid flows in the heat exchange channel in a second direction, the second direction being cocurrent or counter current relative to the first direction.

186. The process of claim 176 wherein a heat exchange fluid is in the heat exchange channel, the heat exchange fluid comprising the first liquid, the second liquid, or the emulsion.

187. The process of claim 176 wherein a heat exchange fluid is in the heat exchange channel, the heat exchange fluid comprising one or more of air, steam, liquid water, carbon monoxide, carbon dioxide, gaseous nitrogen, liquid nitrogen, inert gas, gaseous hydrocarbon, oil, and liquid hydrocarbon.

188. The process of claim 143 wherein the emulsion is quenched in the process microchannel.

189. The process of claim 143 wherein the process microchannel is formed from parallel spaced sheets, plates or a combination of such sheets and plates.

190. The process of claim 147 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section into the process microchannel, the liquid channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the liquid channel being adjacent to the process microchannel.

191. The process of claim 145 wherein the heat source and/or heat sink comprises a heat exchange channel, the heat exchange channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the heat exchange channel being adjacent to the process microchannel.

192. The process of claim 143 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels, the process microchannels having walls with apertured sections and adjacent liquid channels, the second liquid flowing in the liquid channels and from the liquid channels through the apertured sections into the process microchannels in contact with the first liquid, the process microchannels and liquid channels being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the process microchannels and liquid channels being adjacent to each other and aligned in interleaved side-by-side vertically oriented planes or interleaved horizontally oriented planes stacked one above another.

193. The process of claim 192 wherein the emulsion process unit further comprises a plurality of heat exchange channels formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the heat exchange channels exchanging heat with the process microchannels, the liquid channels, or both the process microchannels and the liquid channels.

194. The process of claim 147 wherein the second liquid flows in a liquid channel and from the liquid channel through the apertured section into the process microchannel, the process microchannel and the liquid channel comprising circular tubes aligned concentrically.

195. The process of claim 194 wherein the process microchannel is in an annular space and the liquid channel is in the center space or an adjacent annular space.

196. The process of claim 194 wherein the process microchannel is in the center space and the liquid channel is in an adjacent annular space.

197. The process of claim 143 wherein the process is conducted in an emulsion process unit, the emulsion process unit comprising a plurality of the process microchannels wherein separate emulsions are formed in each of the process microchannels, the emulsions formed in at least two of the process microchannels being different from each other.

198. The process of claim 147 wherein the process microchannel comprises two or more apertured sections and separate second liquids flow through each of the apertured sections.

199. The process of claim 147 wherein the process microchannel has a mixing zone adjacent to the apertured section and a non-apertured region extending from the entrance to the process microchannel to the mixing zone.

200. The process of claim 147 wherein the apertured section has a wall thickness, the ratio of the wall thickness to the axial length of the apertured section being in the range from about 0.001 to about 1.

201. The process of claim 143 wherein the emulsion comprises a water-in-oil emulsion.

202. The process of claim 143 wherein the emulsion comprises an oil-in-water emulsion.

203. The process of claim 143 wherein the emulsion comprises at least one organic liquid.

204. The process of claim 143 wherein the emulsion comprises a skin care product, a paint or coating composition, an adhesive composition, a glue composition, a caulk composition, a sealant composition, a food composition, an agricultural composition, a pharmaceutical composition, a fuel composition, a lubricant composition, a surface dressing composition, a silicone emulsion, a crystal containing composition, a liquid crystal composition, or a wax emulsion.

205. The process of claim 143 wherein the emulsion comprises at least one emulsifier and/or surfactant.

206. The process of claim 143 wherein solids are dispersed in the emulsion.

207. The process of claim 143 wherein a catalyst is dispersed in the emulsion.

208. The process of claim 7 wherein the process microchannel, liquid channel and/or apertured section is coated with a lipophobic coating.

210. The process of claim 148 wherein the process microchannel, liquid channel and/or apertured section is coated with a lipophobic coating.

211. The process of claim 7 wherein the liquid channel comprises a flow-through channel with a liquid channel outlet, a first part of the second liquid flowing through the apertured section, a second part of the second liquid flowing out of the liquid channel through the liquid channel outlet.

212. The process of claim 211 wherein the flow of the second liquid through the liquid channel outlet is controlled to control the pressure within the liquid channel.

215. The process of claim 148 wherein the liquid channel comprises a flow-through channel with a liquid channel outlet, a first part of the second liquid flowing through the apertured section, a second part of the second liquid flowing out of the liquid channel through the liquid channel outlet.

216. The process of claim 215 wherein the flow of the second liquid through the liquid channel outlet is controlled to control the pressure within the liquid channel.

217. The process of claim 7 wherein the apertured section is in the form of a tube with an apertured tubular wall, an axial length and a circular cross section, the interior of the tube comprising the liquid channel, the process microchannel being positioned on the outer surface of the tube, the axial length of the process microchannel extending parallel to the axial length of the tube, the first liquid flowing in the process microchannel, the second liquid flowing from the interior of the tube through the apertured tubular wall into the process microchannel in contact with the first liquid to form the emulsion.

218. The process of claim 217 wherein a plurality of the process microchannels are positioned on the outer surface of the tube.

219. The process of claim 217 wherein a heat exchange channel is adjacent to the process microchannel, the process microchannel being positioned between the outer surface of the tube and the heat exchange channel.

223. The process of claim 148 wherein the apertured section is in the form of a tube with an apertured tubular wall, an axial length and a circular cross section, the interior of the tube comprising the liquid channel, the process microchannel being positioned on the outer surface of the tube, the axial length of the process microchannel extending parallel to the axial length of the tube, the first liquid flowing in the process microchannel, the second liquid flowing from the interior of the tube through the apertured tubular wall into the process microchannel in contact with the first liquid to form the emulsion.

224. The process of claim 223 wherein a plurality of the process microchannels are positioned on the outer surface of the tube.

225. The process of claim 224 wherein a heat exchange channel is adjacent to the process microchannel, the process microchannel being positioned between the outer surface of the tube and the heat exchange channel.

226. The process of claim 6 wherein the apertured section comprises at least two sheets overlying each other, a first sheet having a first array of apertures in it, a second sheet having a second array of apertures in it, the apertures in the first sheet being larger than the apertures in the second sheet, the second sheet at least partially blocking some of the apertures in the first sheet.

228. The process of claim 147 wherein the apertured section comprises at least two sheets overlying each other, a first sheet having a first array of apertures in it, a second sheet having a second array of apertures in it, the apertures in the first sheet being larger than the apertures in the second sheet, the second sheet at least partially blocking some of the apertures in the first sheet.

229. The process of claim 6 wherein the apertured section comprises a porous substrate coated with at least one metal, the metal being applied to the porous substrate by electroless plating.

230. The process of claim 229 wherein the metal comprises platinum.

233. The process of claim 147 wherein the apertured section comprises a porous substrate coated with at least one metal, the metal being applied to the porous substrate by electroless plating.

234. The process of claim 233 wherein the metal comprises platinum.

246. The process of claim 6 wherein the apertured section comprises a porous material and a plurality of adjacent ribs supporting the porous material.

248. The process of claim 147 wherein the apertured section comprises a porous material and a plurality of adjacent ribs supporting the porous material.

249. The process of claim 1 wherein the first liquid and/or the second liquid is a non-Newtonian fluid.

251. The process of claim 143 wherein the first liquid and/or the second liquid is a non-Newtonian fluid.

252. The process of claim 6 wherein a surface feature section is positioned in the process microchannel upstream of the apertured section.

254. The process of claim 147 wherein a surface feature section is positioned in the process microchannel upstream of the apertured section.

145-1. The process of claim 143 wherein the superficial velocity of the emulsion flowing in the process microchannel is at least about 0.01 meter per second.

235. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid;

the process comprising;

flowing the first liquid in a rotating flow pattern in a cylindrical cavity, the cylindrical cavity including a side wall with apertured section; and

flowing the second liquid through the apertured section into the cylindrical cavity in contact with the first liquid to form the emulsion.

236. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid, the process comprising:

flowing the first liquid in a rotating flow pattern in an annular space of a cylindrical cavity, the cylindrical cavity including a hollow cylinder positioned inside the annular space and having apertures pointing radially outward from the hollow cylinder toward the annular space; and

flowing the second liquid through the apertures into contact with the first liquid to form the emulsion.

237. The process of claim 236 wherein the first liquid flows in a rotating pattern in a first direction, and the hollow cylinder rotates in a direction opposite the first direction.

238. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid, the process comprising:

flowing the first liquid on an apertured substrate, the apertured substrate including cylindrical posts extending into the flow path of the first liquid and containing capillary pores; and

flowing the second liquid through the capillary pores in the cylindrical posts into contact with the first liquid to form the emulsion.

239. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid, the process comprising:

flowing the first liquid tangentially to or in impinging contact with an apertured section; and

flowing the second section through the apertured section in contact with the first liquid to form the emulsion.

240. The process of claim 239 wherein the first liquid flows through a jet into contact with the apertured section.

241. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid, the process comprising:

flowing the first liquid in a process microchannel, the process microchannel having an apertured section in one side wall and a ramped structure in the side wall opposite the apertured section; and

flowing the second liquid through the apertured section into the process microchannel in contact with the first liquid to form the emulsion.

242. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid, the process comprising:

flowing the first liquid in a process microchannel, the process microchannel having a wavy apertured section; and

flowing the second liquid through the apertured section into the process microchannel in contact with the first liquid to form the emulsion.

243. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid;

the process comprising;

flowing the second liquid through a porous substrate and then flowing the second liquid through a rotating blade into contact with the first liquid to form the emulsion.

244. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid;

the process comprising;

flowing the second liquid through at least two parallel apertured substrates into contact with the first liquid to form the emulsion, one of the apertured substrates moving relative to the other apertured substrate.

245. A process for making an emulsion, the emulsion comprising a continuous phase and a dispersed phase, the continuous phase comprising a first liquid, the dispersed phase comprising a second liquid;

the process comprising;

forming a first dispersion comprising droplets of the first liquid dispersant in an inert gas;

forming a second dispersion comprising droplets of the second liquid dispersed in an inert gas;

combining the first dispersion and the second dispersion to form a combined dispersion; and

separating the inert gas from the combined dispersion to form the emulsion.