Process for forming an emulsion using microchannel process technology

Abstract

The disclosed invention relates to a process for making an emulsion. The process comprises: flowing a first liquid through a process microchannel, the process microchannel having a wall with an apertured section; flowing a second liquid through the apertured section into the process microchannel in contact with the first liquid, the first liquid forming a continuous phase, the second liquid forming a discontinuous phase dispersed in the continuous phase.

1 . A process for making an emulsion, comprising:
 flowing a first liquid in a process microchannel, the process microchannel having a wall with an apertured section;   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 a discontinuous phase dispersed in the continuous phase; and   exchanging heat between the liquid in the process microchannel and a heat exchanger.   
     
     
         2 . The process of  claim 1  wherein the second liquid flows from a liquid channel through the apertured section into the process microchannel. 
     
     
         3 . The process of  claim 1  wherein different temperature zones are positioned along the length of the process microchannel. 
     
     
         4 . The process of  claim 1  wherein the first liquid and the second liquid contact each other in a mixing zone in the process microchannel. 
     
     
         5 . The process of  claim 4  wherein heat is exchanged between the heat exchanger and the process microchannel in the mixing zone, upstream of the mixing zone, or downstream of the mixing zone. 
     
     
         6 . The process of  claim 1  wherein the emulsion is quenched in the process microchannel. 
     
     
         7 . The process of  claim 1  wherein the heat flux for heat exchange between the process microchannel and the heat exchanger is in the range from about 0.01 to about 250 watts per square centimeter of surface area of the process microchannel. 
     
     
         8 . The process of  claim 1  wherein the temperature gradient between the process microchannel wall and the bulk flow in the process microchannel is less than about 5° C. at the same axial position in the process microchannel. 
     
     
         9 . The process of  claim 1  wherein the process microchannel has walls that are spaced apart and apertured sections in each of the spaced apart walls, the second liquid flowing through each of apertured sections into the process microchannel. 
     
     
         10 . The process of  claim 1  wherein the process microchannel is in an emulsion forming unit comprising a first process microchannel, a second process microchannel, and a liquid channel positioned between the first process microchannel and the second process microchannel, each process microchannel having a wall with an apertured section, the first liquid flowing through the first process microchannel and the second process microchannel, the second liquid flowing from the liquid channel through the apertured section in the first process microchannel in contact with the first liquid and through the apertured section in the second process microchannel in contact with the first liquid. 
     
     
         11 . The process of  claim 1  wherein the heat exchanger comprises at least one heat exchange channel. 
     
     
         12 . The process of  claim 12  wherein the process microchannel exchanges heat with a heat exchange fluid in the heat exchange channel. 
     
     
         13 . The process of  claim 13  wherein the heat exchange fluid undergoes a phase change in the heat exchange channel. 
     
     
         14 . The process of  claim 12  wherein an endothermic process or an exothermic process is conducted in the heat exchange channel. 
     
     
         15 . The process of  claim 1  wherein the emulsion is cooled to room temperature within a time period of up to about 10 minutes. 
     
     
         16 . The process of  claim 1  wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels, each process microchannel having at least one wall with at least one apertured section, at least one liquid channel positioned adjacent to each process microchannel, the second liquid flowing 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 or plates, the heat exchanger comprising a plurality of heat exchange channels formed from parallel spaced sheets or plates, the heat exchange channels being adjacent to the process microchannels, the liquid channels or both the process microchannels and the liquid channels. 
     
     
         17 . The process of  claim 16  wherein the emulsion is made at a rate of at least about 0.01 liter per minute. 
     
     
         18 . The process of  claim 1  wherein the emulsion comprises a water-in-oil emulsion or an oil-in-water emulsion. 
     
     
         19 . The process of  claim 1  wherein the first liquid comprises an organic liquid. 
     
     
         20 . The process of  claim 1  wherein solids are dispersed in the emulsion. 
     
     
         21 . The process of  claim 1  wherein a chemical reaction, a biological process, a liquid adsorption process, a liquid-gas adsorption process, a liquid separation process, a solidification process, a gasification process, or a process for tracking charged particles is conducted in the process microchannel. 
     
     
         22 . The process of  claim 1  wherein the emulsion comprises a skin care product, a paint composition, a 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 liquid crystal composition, a wax emulsion, or a double emulsion. 
     
     
         23 . A process for making an emulsion, comprising:
 flowing a first liquid in a process microchannel, the process microchannel having a wall with an apertured section;   flowing a second liquid in a liquid channel, the liquid channel being adjacent to the process microchannel, the liquid channel having another wall with another apertured section;   flowing a third liquid through the another apertured section into the liquid channel in contact with the second liquid to form a liquid mixture in the liquid channel; and   flowing the liquid mixture from the liquid channel through the apertured section into the process microchannel in contact with the first liquid to form the emulsion.   
     
     
         24 . A process for making an emulsion, comprising:
 flowing a first liquid in a process microchannel, the process microchannel having two or more apertured sections;   flowing separate second liquids through each of the apertured sections into the process microchannel in contact with the first liquid to form the emulsion.   
     
     
         25 . The process of  claim 24  wherein the separate second liquids have different compositions and/or different properties.