CA2526965A1 - Process for forming an emulsion using microchannel process technology - Google Patents

Process for forming an emulsion using microchannel process technology Download PDF

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Publication number
CA2526965A1
CA2526965A1 CA002526965A CA2526965A CA2526965A1 CA 2526965 A1 CA2526965 A1 CA 2526965A1 CA 002526965 A CA002526965 A CA 002526965A CA 2526965 A CA2526965 A CA 2526965A CA 2526965 A1 CA2526965 A1 CA 2526965A1
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Prior art keywords
liquid
microchannel
channel
emulsion
heat exchange
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CA002526965A
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French (fr)
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CA2526965C (en
Inventor
Dongming Qiu
Anna Lee Tonkovich
Laura J. Silva
Richard Q. Long
Barry L. Yang
Kristina Marie Trenkamp
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Velocys Inc
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Individual
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Priority claimed from US10/440,056 external-priority patent/US7485671B2/en
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Priority to CA2747874A priority Critical patent/CA2747874C/en
Publication of CA2526965A1 publication Critical patent/CA2526965A1/en
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Publication of CA2526965C publication Critical patent/CA2526965C/en
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    • A—HUMAN NECESSITIES
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K2800/00—Properties of cosmetic compositions or active ingredients thereof or formulation aids used therein and process related aspects
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01F2215/0431—Numerical size values, e.g. diameter of a hole or conduit, area, volume, length, width, or ratios thereof
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01F23/414—Emulsifying characterised by the internal structure of the emulsion
    • B01F23/4144—Multiple emulsions, in particular double emulsions, e.g. water in oil in water; Three-phase emulsions
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F28F2260/02—Heat exchangers or heat exchange elements having special size, e.g. microstructures having microchannels
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Abstract

The disclosed invention relates to a process for making an emulsion. The process comprises: flowing a first liquid (116) through a process microchannel (110), the process microchannel having a wall (140) with an apertured section;
flowing a second liquid (172) 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.

Claims (154)

Claims
1. A process for making an emulsion, comprising:
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 to form the emulsion, the first liquid forming a continuous phase, the second liquid forming a discontinuous phase dispersed in the continuous phase.
2. The process of claim 1 wherein heat is exchanged between the process microchannel and a heat exchanger.
3. The process of claim 1 wherein the second liquid flows from a liquid channel through the apertured section.
4. The process of claim 3 wherein heat is exchanged between the process microchannel and a heat exchanger, the liquid channel and a heat exchanger, or both the process microchannel and the liquid channel and a heat exchanger.
5. The process of claim 1 wherein the first liquid and the second liquid contact each other in a mixing zone in the process microchannel.
6. The process of claim 5 wherein heat is exchanged between a heat exchanger and at least part of the process microchannel in the mixing zone.
7. The process of claim 5 wherein heat is exchanged between a heat exchanger and at least part of the process microchannel upstream of the mixing zone.
8. The process of claim 5 wherein heat is exchanged between a heat exchanger and at least part of the process microchannel downstream of the mixing zone.
9. The process of claim 5 wherein the emulsion is quenched in the process microchannel downstream of the mixing zone.
The process of claim 5 wherein the process microchannel has a restricted cross section in the mixing zone.
11. 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.
12. The process of claim 11 wherein the apertured sections in each of the spaced apart walls comprise a plurality of apertures, the apertures in the apertured section of one of the walls being aligned directly opposite the apertures in the apertured section of the other wall.
13. The process of claim 11 wherein the apertured sections in each of the spaced apart walls comprise a plurality of apertures, at least some of the apertures in the apertured section of one of the walls being offset from being aligned directly with the apertures in the apertured section of the other wall.
14. 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.
15. The process of claim 1 wherein the process microchannel is circular and is positioned between a circular disk and an apertured section, the circular disk rotating about its axis, the first liquid flowing through a center opening in the apertured section into the process microchannel onto the rotating disk, the second liquid flowing through the apertured section into the process microchannel where it contacts and mixes with the first liquid to form the emulsion, the emulsion flowing radially outwardly on the rotating disk.
16. The process of claim 15 wherein the second liquid flows from a liquid channel adjacent to the process microchannel, the liquid channel being formed from parallel spaced sheets or plates, the apertured section being in one of the sheets or plates.
17. The process of claim 1 wherein the second liquid flows in a liquid channel, the liquid channel having another wall with another apertured section, the process further comprising:
flowing a third liquid through the another apertured section in contact with the second liquid to form a liquid mixture; and flowing the liquid mixture through the apertured section into the process microchannel in contact with the first liquid.
18. The process of claim 17 wherein the liquid mixture is dispersed as a discontinuous phase in the first liquid.
19. The process of claim 17 wherein the liquid mixture comprises another emulsion.
20. The process of claim 17 wherein the third liquid is dispersed in the second liquid.
21. The process of claim 17 wherein at least part of the second liquid is in the form of droplets dispersed in the first liquid, and at least part of the third liquid is in the form of droplets encapsulated within the droplets of the second liquid.
22. The process of claim 1 wherein the process microchannel is formed from parallel spaced sheets, plates or a combination of such sheets and plates.
23. The process of claim 22 wherein the second liquid flows from a liquid channel through the apertured section into the process microchannel, the liquid channel being formed from parallel spaced sheets or plates, the liquid channel being adjacent to the process microchannel.
24. The process of claim 22 wherein the first liquid and second liquid exchange heat with a heat exchange channel, the heat exchange channel being formed from parallel spaced sheets or plates, the heat exchange channel being adjacent to the process microchannel, the liquid channel, or both the process microchannel and the liquid channel.
25. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels, the process microchannels having walls with apertured sections and adjacent liquid channels, 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 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.
26. The process of claim 25 wherein the microchannel mixer further comprises 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.
27. The process of claim 1 wherein the second liquid flows from a liquid channel through the apertured section into the process microchannel, the process microchannel and the liquid channel comprising circular tubes aligned concentrically.
28. The process of claim 27 wherein the process microchannel is in an annular space and the liquid channel is in the center space or an adjacent annular space.
29. The process of claim 27 wherein the process microchannel is in the center space and the liquid channel is in an adjacent annular space.
30. The process of claim 1 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.
31. The process of claim 30 wherein the emulsions formed in at least two of the process microchannels are different in composition.
32. The process of claim 30 wherein the emulsions formed in at least two of the process microchannels have one or more different physical properties.
33. The process of claim 1 wherein the process microchannel comprises two or more apertured sections and separate second liquids flow through each of the apertured sections.
34. The process of claim 33 wherein the separate second liquids flowing through each of the apertured sections have different compositions.
35. The process of claim 33 wherein the separate second liquids flowing through each of the apertured sections have different properties.
36. The process of claim 1 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.
37. The process of claim 1 wherein the apertured section comprises a sheet or plate with a plurality of apertures in the sheet or plate.
38. The process of claim 1 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.
39. The process of claim 34 with a coating overlying at least part of the sheet or plate and filling part of the apertures.
40. The process of claim 34 wherein the sheet or plate is heat treated.
41. The process of claim 1 wherein the apertured section has a wall thickness and a length along the flow path of the first liquid flowing through the process microchannel, the ratio of the wall thickness to the length along the flow path being in the range from about 0.001 to about 1.
42. The process of claim 1 wherein the apertured section is made from a porous material.
43. The process of claim 42 wherein the porous material is metallic.
44. The process of claim 42 wherein the porous material is nonmetallic.
45. The process of claim 42 wherein the porous material is oxidized.
46. The process of claim 42 wherein the porous material is coated with alumina, nickel, or a combination thereof.
47. The process of claim 1 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.
48. The process of claim 1 wherein the discontinuous phase is in the form of droplets having a volume-based mean diameter in the range of up to about microns.
49. The process of claim 1 wherein the discontinuous phase comprises 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.
50. The process of claim 1 wherein the first liquid comprises water.
51. The process of claim 1 wherein the first liquid comprises an organic liquid.
52. The process of claim 1 wherein the first liquid comprises an oil.
53. The process of claim 1 wherein the second liquid comprises water.
54. The process of claim 1 wherein the second liquid comprises an organic liquid.
55. The process of claim 1 wherein the second liquid comprises an oil.
56. The process of claim 17 wherein the third liquid comprises water.
57. The process of claim 17 wherein the third liquid comprises an organic liquid.
58. The process of claim 17 wherein the third liquid comprises an oil.
59. The process of claim 1 wherein the process microchannel has an internal dimension perpendicular to the flow of liquid through the process microchannel of up to about 50 mm.
60. The process of claim 1 wherein the process microchannel has an internal dimension perpendicular to the flow of liquid through the process microchannel of up to about 10 mm.
61. The process of claim 1 wherein the process microchannel has an internal dimension perpendicular to the flow of liquid through the process microchannel of up to about 2 mm.
62. 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.
63. The process of claim 1 wherein the second liquid flows from a liquid channel through the apertured section.
64. The process of claim 3 wherein the liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of up to about 100 cm.
65. The process of claim 3 wherein the liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of about 0.05 mm to about 10 mm.
66. The process of claim 3 wherein the liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of about 0.05 to about 2 mm.
67. The process of claim 3 wherein the liquid channel 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 polymer and fiberglass; quartz; silicon; or a combination of two or more thereof.
68. The process of claim 2 wherein the heat exchanger comprises at least one heat exchange channel.
69. The process of claim 68 wherein the heat exchange channel has an internal dimension perpendicular to the flow of heat exchange fluid through the heat exchange channel of up to about 50 mm.
70. The process of claim 68 wherein the heat exchange channel has an internal dimension perpendicular to the flow of heat exchange fluid through the heat exchange channel of up to about 10 mm.
71. The process of claim 68 wherein the heat exchange channel has an internal dimension perpendicular to the flow of heat exchange fluid through the heat exchange channel of up to about 2 mm.
72. The process of claim 68 wherein the heat exchange channel 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 polymer and fiberglass; quartz; silicon; or a combination of two or more thereof.
73. The process of claim 68 wherein the process microchannel exchanges heat with a heat exchange fluid flowing through the heat exchange channel.
74. The process of claim 73 wherein the heat exchange fluid undergoes a phase change as it flows through the heat exchange channel.
75. The process of claim 73 wherein an endothermic process is conducted in the heat exchange channel.
76. The process of claim 73 wherein an exothermic process is conducted in the heat exchange channel.
77. The process of claim 73 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.
78. The process of claim 73 wherein the heat exchange fluid comprises the first liquid, the second liquid, or a mixture of the first liquid and the second liquid.
79. The process of claim 17 wherein at least one heat exchange channel is adjacent to the process microchannel and/or liquid channel, a heat exchange fluid flows through the heat exchange channel, the heat exchange fluid comprising the first liquid, second liquid and/or third liquid.
80. The process of claim 4 wherein the heat exchanger comprises an electric heating element, resistance heater and/or non-fluid cooling element.
81. The process of claim 80 wherein the electric heating element, resistance heater and/or non-fluid cooling element is adjacent to the process microchannel and/or liquid channel.
82. The process of claim 80 wherein the electric heating element, resistance heater and/or non-fluid cooling element is built into one or more walls of the process microchannel and/or liquid channel.
83. The process of claim 80 wherein one or more walls of the process microchannel and/or liquid channel are formed from the electric heating element, resistance heater and/or non-fluid cooling element.
84. The process of claim 4 wherein the heat exchanger is adjacent to the process microchannel and/or liquid channel.
85. The process of claim 4 wherein the heat exchanger is remote from the process microchannel and/or liquid channel.
86. The process of claim 17 wherein the third liquid flows from another liquid channel through the another apertured section.
87. The process of claim 86 wherein the another liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of up to about 100 cm.
88. The process of claim 86 wherein the another liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of about 0.05 mm to about 10 mm.
89. The process of claim 86 wherein the another liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of about 0.05 to about 2 mm.
90. The process of claim 86 wherein the another liquid channel 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 polymer and fiberglass; quartz; silicon; or a combination of two or more thereof.
91. The process of claim 1 wherein the emulsion is cooled to room temperature within a time period of up to about 10 minutes.
92. The process of claim 1 wherein the emulsion is filtered.
93. The process of claim 1 wherein the emulsion comprises a water-in-oil emulsion.
94. The process of claim 1 wherein the emulsion comprises an oil-in-water emulsion.
95. The process of claim 17 wherein the emulsion comprises a water-in-oil-in-water emulsion.
96. The process of claim 17 wherein the emulsion comprises an oil-in-water-in-oil emulsion.
97. The process of claim 1 wherein the emulsion comprises at least one organic liquid.
98. The process of claim 1 wherein the emulsion comprises at least one liquid hydrocarbon.
99. The process of claim 1 wherein the emulsion comprises at least one natural oil, synthetic oil, or mixture thereof.
100. The process of claim 1 wherein the emulsion comprises at least one liquid derived from a vegetable source, a mineral source, or mixture thereof.
101. The process of claim 1 wherein the emulsion comprises at least one normally liquid hydrocarbon fuel.
102. The process of claim 1 wherein the emulsion comprises at least one fatty alcohol, fatty acid ester, or a mixture thereof.
103. The process of claim 1 wherein the emulsion comprises: at least one ester of a linear fatty acid of about 6 to about 22 carbon atoms with linear or branched fatty alcohol of about 6 to about 22 carbon atoms; an ester of a branched carboxylic acid of about 6 to about 13 carbon atoms with a linear or branched fatty alcohol of about 6 to about 22 carbon atoms; or a mixture thereof.
104. The process of claim 1 wherein the emulsion comprises: an ester of an alkyl hydroxycarboxylic acid of about 18 to about 38 carbon atoms with a linear or branched fatty alcohol of about 6 to about 22 carbon atoms; an ester of a linear or branced fatty acid of about 6 to about 22 carbon atoms with a polyhydric alcohol and/or a Guerbet alcohol; a triglyceride based on one or more fatty acids of about 6 to about 18 carbon atoms; a mixture of mono-, di- and/or triglycerides based on one or more fatty acids of about 6 to about 18 carbon atoms; an ester of one or more fatty alcohols and/or Guerbet alcohols of about 6 to about 22 carbon atoms with one or more aromatic carboxylic acids; an ester of one or more dicarboxylic acids of 2 to about 12 carbon atoms with one or more linear or branched alcohols containing 1 to about 22 carbon atoms, or one or moe polyols containing 2 to about carbon atoms and 2 to about 6 hydroxyl groups, or a mixture of one or more of such alcohols and one or more of such polyols; an ester of one or more dicarboxylic acids of 2 to about 12 carbon atoms with one or more alcohols of 1 to about 22 carbon atoms; an ester of benzoic acid with a linear and/or branched alcohol of about 6 to about 22 carbon atoms; or mixture of two or more thereof.
105. The process of claim 1 wherein the emulsion comprises: one or more branched primary alcohols of about 6 to about 22 carbon atoms; one or more linear and/or branched fatty alcohol carbonates of about 6 to about 22 carbon atoms;
one or more Guerbet carbonates based on one or more fatty alcohols of about 6 to about 22 carbon atoms; one or more dialkyl naphthalates wherein each alkyl group contains 1 to about 12 carbon atoms; one or more linear or branched, symmetrical or nonsymmetrical dialkyl ethers containing about 6 to about 22 carbon atoms per alkyl group; one or more ring opening products of epoxidized fatty acid esters of about 6 to about 22 carbon atoms with polyols containing 2 to about 10 carbon atoms and 2 to about 6 hydroxyl groups; or a mixture of two or more thereof.
106. The process of claim 1 wherein the emulsion comprises at least one emulsifier and/or surfactant.
107. The process of claim 106 wherein the emulsifier and/or surfactant comprises an alkylaryl sulfonate, amine oxide, carboxylated alcohol ethoxylate, ethoxylated alcohol, ethoxylated alkyl phenol, ethoxylated amine, ethoxylated amide, ethoxylated fatty acid, ethoxylated fatty esters, ethoxylated fatty oil, fatty ester, glycerol ester, glycol ester, sorbitan ester, imidazoline derivative, lecithin, lecithin derivative, lignin, lignin derivative, monoglyceride, monoglyceride derivative, olefin sulfonate, phosphate ester, phosphate ester derivative, propoxylated fatty acid, ethoxylated fatty acid, propoxylated alcohol or alkyl phenol, ethoxylated alcohol or alkyl phenol, sorbitan derivative, sucrose ester, sulfonate of dodecyl or tridecyl benzene, naphthalene sulfonate, petroleum sulfonate, tridecyl or dodecyl benzene sulfonic acid, sulfosuccinate, sulfosuccinate derivative, or mixture of two or more thereof.
108. The process of claim 106 wherein the emulsifier and/or surfactant comprises: at least one polyalkylene glycol; at least one partial ester of glycerol and/or sorbitan and one or more fatty acids; or a mixture thereof.
109. The process of claim 1 wherein the emulsion comprises one or more:
UV protection factors; waxes; consistency factors; thickeners; superfatting agents;
stabilizers; cationic, anionic, zwitterionic, amphoteric or nonionic polymers;
silicone compounds; fats; waxes; lecithins; phospholipids; biogenic agents;
antioxidants;
deodorants; antiperspirants; antidandruff agents; swelling agents; insect repellents;
self-tanning agents; tyrosine inhibitors; solubilizers; preservatives; perfume oils; or dyes; or a mixture of two or more thereof.
110. The process of claim 1 wherein solids are dispersed in the emulsion.
111. The process of claim 1 wherein pigment is dispersed in the emulsion.
112. The process of claim 1 wherein a catalyst is dispersed in the emulsion.
113. The process of claim 1 wherein optical or thermal-optical features of the emulsion are adjusted in the process microchannel.
114. The process of claim 1 wherein a chemical reaction is conducted in the process microchannel.
115. The process of claim 1 wherein a biological process is conducted in the process microchannel.
116. The process of claim 1 wherein a liquid adsorption process is conducted in the process microchannel.
117. The process of claim 1 wherein a liquid-gas adsorption process is conducted in the process microchannel.
118. The process of claim 1 wherein a liquid separation process is conducted in the process microchannel.
119. The process of claim 1 wherein a solidification process is conducted in the process microchannel.
120. The process of claim 1 wherein a gasification process is conducted in the process microchannel.
121. The process of claim 1 wherein the emulsion is used to track charged particles.
122. The process of claim 1 wherein the process produced at least 1 liter of emulsion per minute.
123. The process of claim 1 wherein the process produces at least 1 liter of emulsion per second.
124. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least two of the process microchannels.
125. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least about 1000 of the process microchannels.
126. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least about 10 of the process microchannels.
127. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least about 100 of the process microchannels.
128. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer 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.
129. The process of claim 128 wherein liquid channels are adjacent to the process microchannels, the microchannel mixer 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.
130. The process of claim 129 wherein heat exchange channels are adjacent to the process microchannels and/or liquid channels, the microchannel mixer 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.
131. A process for making an emulsion in a microchannel mixer, the microchannel mixer comprising a plurality of emulsion forming units aligned side-by-side or stacked one above another, each emulsion forming unit comprising a process microchannel and an adjacent liquid channel, the process microchannel and adjacent liquid channel having a common wall with an apertured section in the common wall, the apertured section being suitable for flowing a liquid from the liquid channel through the apertured section into the process microchannel, each process microchannel and liquid channel being formed from parallel spaced sheets, plates, or a combination of such sheets and plates, the process comprising:
flowing a first liquid in the process microchannel;
flowing a second liquid from the liquid channel through the apertured section into the process microchannel; and mixing the first liquid and the second liquid in the process microchannel to form the emulsion.
132. The process of claim 131 wherein each emulsion forming unit further comprises a heat exchange channel adjacent to the process microchannel, the liquid channel, or both the process microchannel and the liquid channel.
133. The process of claim 131 wherein the first liquid flows through a header into the process microchannel.
134. The process of claim 131 wherein the second liquid flows through a header into the liquid channel.
135. The process of claim 131 wherein the emulsion flows out of the process microchannel through a footer.
136. The process of claim 132 wherein the microchannel mixer further comprises a heat exchange manifold, a heat exchange fluid flows from the heat exchange manifold through the heat exchange channel to the heat exchange manifold.
137. An emulsion made by the process of claim 1.
138. A skin care product made by the process of claim 1.
139. A paint or coating composition made by the process of claim 1.
140. An adhesive composition made by the process of claim 1.
141. A glue composition made by the process of claim 1.
142. A caulk composition made by the process of claim 1.
143. A sealant composition made by the process of claim 1.~
144. A food composition made by the process of claim 1.
145. An agricultural composition made by the process of claim 1.
146. A pharmaceutical composition made by the process of claim 1.
147. A fuel composition made by the process of claim 1.
148. A lubricant composition made by the process of claim 1.
149. A surface dressing composition made by the process of claim 1.
150. A silicone emulsion made by the process of claim 1.
151. A composition comprising crystals made by the process of claim 1.~
152. A liquid crystal composition made by the process of claim 1.
153. A wax emulsion made by the process of claim 1.
154. A double emulsion made by the process of claim 17.
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