Process for preparing a water continuous emulsion from heavy crude fraction

Claim 2

A process for preparing an oil-in-aqueous phase emulsion comprising: agitating a hydrocarbon with an emulsifying composition at a temperature to form an oil-in-aqueous phase emulsion, wherein said emulsifying composition comprises an aqueous phase and a minor amount of an emulsifying agent and said temperature is above 200° F., wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 15% to about 60% by weight, wherein the emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said emulsifying agent comprises at least one ethoxylated alkylphenol compound having the general formula: ##STR50## wherein n 1 is an integer having a value of from about 7 to about 20, and y 1 is an integer having a value of from about 4 to about 1000; and said at least one ethoxylated alkylphenol compound has a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about I966 to about 9188; and wherein at least about 50% by weight of the emulsifying agent comprises said at least one ethoxylated alkylphenol compound having a molecular weight of from about 1966 to about 9188.

Claim 3

The process of claim 1 additionally comprising transporting said oil-in-aqueous phase emulsion.

Claim 4

The process of claim 1 wherein said emulsifying agent comprises from about 30% by weight to about 80% by weight of said at least one ethoxylated alkylphenol compound, and said emulsifying agent additionally comprises at least one ethoxylated dialkylphenol compound having the general formula: ##STR51## wherein n 2 is an integer having a value of from about 7 to about 18, and n 3 is an integer having a value of from about 7 to about 18, and y 2 is an integer having a value of from about 4 to about 1000; and wherein said at least one ethoxylated dialkylphenol compound and said at least one ethoxylated alkylphenol compound have a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about 1966 to about 11,627; and wherein at least about 50% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound having a molecular weight of from about 2519 to about 11,627; and from 1% by weight to 90% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound wherein y2 is greater than 100.

Claim 5

The process of claim 3 wherein said formed oil-in-aqueous phase emulsion contains an oil droplet phase dispersed in an aqueous continuous phase and said process additionally comprises transporting the formed oil-in-aqueous phase emulsion of claim 3 through a pipeline until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase having a viscosity higher than the viscosity of the formed oil-in-aqueous phase emulsion of claim 3 and a residual oil-in-aqueous phase emulsion without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion, and wherein said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion has a viscosity lower than or equal to the viscosity of the formed oil-in-aqueous phase emulsion of claim 3.

Claim 6

The process of claim 3 wherein said agitating comprises (a) positioning a portion of a mixture comprising said hydrocarbon and said emulsifying composition in a first shearing and mixing means having a first predetermined shear rate to produce a first oil-in-aqueous phase emulsion having a first viscosity, leaving a remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition that is not positioned in the first shearing and mixing means; (b) positioning said remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition in a second shearing and mixing means having a second predetermined shear rate which is different from said first shear rate to produce a second oil-in-aqueous phase emulsion having a second viscosity; and (c) mixing the first oil-in-aqueous phase emulsion with the second oil-in-aqueous phase emulsion to form said oil-in-aqueous phase emulsion that has a viscosity lower than the first viscosity and lower than the second viscosity.

Claim 7

The process of claim 3 additionally comprising separating thereafter a substantial portion of the hydrocarbon from the formed oil-in-aqueous phase emulsion.

Claim 8

The process of claim 3 additionally comprising transporting said formed oil-in-aqueous phase emulsion through a pipeline for burning said formed oil-in-aqueous phase emulsion to a combustion chamber.

Claim 9

The process of claim 1 wherein said formed oil-in-aqueous phase emulsion contains an oil droplet phase dispersed in an aqueous continuous phase and said process additionally comprises transporting the formed oil-in-aqueous phase emulsion of claim 1 through a pipeline until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase having a viscosity higher than the viscosity of the formed oil-in-aqueous phase emulsion of claim 1 and a residual oil-in-aqueous phase emulsion without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion, and wherein said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion has a viscosity lower than or equal to the viscosity of the formed oil-in-aqueous phase emulsion of claim 1.

Claim 10

The process of claim 8 additionally comprising reformulating said oil-in-aqueous phase emulsion containing said oil droplet phase dispersed in said aqueous continuous phase, transporting and said reformulated oil-in-aqueous phase emulsion for burning purposes.

Claim 11

The process of claim 8 additionally comprising adding additional aqueous phase to the mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion; and transporting said additional aqueous phase and said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase through said pipeline; and transporting said oil-in-aqueous phase emulsion.

Claim 12

The process of claim 8 additionally comprising adding additional emulsifying agent to the mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion; and transporting said additional emulsifying agent and said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase through said pipeline; and burning said oil-in-aqueous phase emulsion.

Claim 13

The process of claim 8 additionally comprising transporting said mixture comprising said partially coalesced oil droplet phase and said residual oil-in-aqueous phase through said pipeline for burning said oil-in-aqueous phase emulsion.

Claim 14

The process of claim 1 additionally comprising transporting said formed oil-in-aqueous phase emulsion through a pipeline; and adding additional emulsifying agent to the formed oil-in-aqueous phase emulsion as it is being transported through the pipeline, for burning said formed oil-in-aqueous phase emulsion.

Claim 15

The process of claim 1 additionally comprising separating thereafter a substantial portion of the hydrocarbon from the formed oil-in-aqueous phase emulsion.

Claim 16

The process of claim 1 additionally comprising transporting said formed oil-in-aqueous phase emulsion through a pipeline for burning said formed oil-in-aqueous phase emulsion.

Claim 17

The process of claim 1 additionally comprising transporting said formed oil-in-aqueous phase emulsion to a combustion chamber, and said temperature is from about 210° F. to about 240° F.

Claim 18

The process of claim 1 wherein from 1% by weight to 90% by weight of the emulsifying agent comprises said at least one ethoxylated alkylphenol compound wherein y 1 has a value greater than 100.

Claim 19

The process of claim 1 wherein said agitating comprises passing the hydrocarbon and emulsifying composition through 12 or more baffle elements of a static mixer.

Claim 20

The process of claim 18 additionally comprising adding xanthan biopolymer.

Claim 21

The process of claim 1 wherein said agitating comprises (a) position a portion of a mixture comprising said hydrocarbon and said emulsifying composition in a first shearing and mixing means having a first predetermined shear rate to produce a first oil-in aqueous phase emulsion having a first viscosity, leaving a remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition that is not positioned in the first shearing and mixing means; (b) positioning said remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition in a second shearing and mixing means having a second predetermined shear rate which is different from said first shear rate to produce a second oil-in-aqueous phase emulsion having a second viscosity; and (c) mixing the first oil-in-aqueous phase emulsion with the second oil-in-phase emulsion to form said oil-in-aqueous phase emulsion that has a viscosity lower than the first viscosity and lower than the second viscosity.

Claim 22

The process of claim 20 wherein said first shearing and mixing means is a dynamic mixer, and said second shearing and mixing means is a static mixer.

Claim 23

The process of claim 20 wherein said first shearing and mixing means is a static mixer, and said second shearing and mixing means is a dynamic mixer.

Claim 24

The process of claim 20 wherein said first shearing and mixing means is a first dynamic mixer, and said second shearing and mixing means is a second dynamic mixer.

Claim 25

The process of claim 20 wherein said first shearing and mixing means is a first static mixer, and said second shearing and mixing means is a second static mixer.

Claim 26

The process of claim 1 wherein said agitating comprises passing said hydrocarbon and said emulsifying composition through a static mixer at varying flow and shear rates to form a multimodal oil-in-aqueous emulsion.

Claim 27

The process of claim 1 wherein said hydrocarbon comprises a hydrocarbon having a TBP of about 650° F. or above.

Claim 28

The process of claim 1 wherein said formed oil-in-aqueous phase emulsion is formed with a layer of skim up to about 3% by wt. of the formed oil-in-aqueous phase emulsion; and said layer of skim is removed and admixed with said hydrocarbon and/or said emulsifying composition for forming a second oil-in-aqueous phase emulsion.

Claim 29

The process of claim 1 wherein said formed oil-in-aqueous phase emulsion has a d 50 as being from about 10 to about 20, and said formed oil-in-aqueous phase emulsion is transported to a combustion chamber for burning with the absence of unconverted or unburned material.

Claim 30

A process for preparing an oil-in-aqueous phase emulsion comprising: agitating a hydrocarbon with an emulsifying composition at a temperature to form an oil-in-aqueous phase emulsion, wherein said emulsifying composition comprises an aqueous phase and a minor amount of an emulsifying agent and said temperature is above 200° F., wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 15% to about 60% by weight, wherein the emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said emulsifying agent comprises at least one ethoxylated dialkylphenol compound having the general formula: ##STR52## wherein n 1 is an integer having a value of from about 7 to about 18, and n 2 is an integer having a value of from about 7 to about 18, and y 1 is an integer having a value of from about 4 to about 1000; and said at least one ethoxylated dialkylphenol compound has a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about 2519 to about 11,627; and wherein at least about 50% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound having a molecular weight of from about 2519 to about 11,627.

Claim 31

A process for preparing an oil-in-aqueous phase emulsion comprising: agitating a hydrocarbon with an emulsifying composition at a temperature to form an oil-in-aqueous phase emulsion, wherein said emulsifying composition comprises an aqueous phase and a minor amount of an emulsifying agent and said temperature is above 200° F., wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 15% to about 60% by weight, wherein the emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said emulsifying agent comprises at least one ethoxylated dialkylphenol compound having the general formula: ##STR52## wherein n 1 is an integer having a value of from about 7 to about 18, and n 2 is an integer having a value of from about 7 to about 18, and y 1 is an integer having a value of from about 4 to about 1000; and said at least one ethoxylated dialkylphenol compound has a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about 2519 to about 11,627; and wherein at least about 50% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound having a molecular weight of from about 2519 to about 11,627.

Claim 32

The process of claim 29 wherein said formed oil-in-aqueous phase emulsion contains an oil droplet phase dispersed in an aqueous continuous phase and said process additionally comprises transporting the formed oil-in-aqueous phase emulsion of claim 10 through a pipeline until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase having a viscosity higher than the viscosity of the formed oil-in-aqueous phase emulsion of claim 10 and a residual oil-in-aqueous phase emulsion, without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion, and wherein said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion has a viscosity lower than or equal to the viscosity of the formed oil-in-aqueous phase emulsion of claim 10.

Claim 33

The process of claim 30 additionally comprising reformulating said oil-in-aqueous phase emulsion containing said oil droplet phase dispersed in said aqueous continuation phase, and transporting said reformulated oil-in-aqueous emulsion for burning purposes.

Claim 34

The process of claim 30 additionally comprising adding additional aqueous phase to the mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion; and transporting said additional aqueous phase and said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase through said pipeline for burning purposes.

Claim 35

The process of claim 30 additionally comprising adding additionally emulsifying agent to the mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion; and transporting said additional emulsifying agent and said mixture comprising said coalesced oil droplet phase and said residual oil-in-aqueous phase through said pipeline for burning purposes phase emulsion.

Claim 36

The process of claim 30 additionally comprising transporting said mixture comprising said partially coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion through said pipeline to a combustion chamber for burning said oil-in-aqueous phase emulsion.

Claim 37

The process of claim 29 wherein from 1% by weight to 90% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound wherein y 1 has a value greater than 100.

Claim 38

The process of claim 29 wherein said agitating comprises passing the hydrocarbon and emulsifying composition through 12 or more baffle elements of a static mixer.

Claim 39

The process of claim 36 additionally comprising adding xanthan biopolymer.

Claim 40

The process of claim 29 wherein said agitating comprises (a) positioning a portion of a mixture comprising said hydrocarbon and said emulsifying composition in a first shearing and mixing means having a first predetermined shear rate to produce a first oil-in aqueous phase emulsion having a first viscosity, leaving a remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition that is not positioned in the first shearing and mixing means; (b) positioning said remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition in a second shearing and mixing means having a second predetermined shear rate which is different from said first shear rate to produce a second oil-in-aqueous phase emulsion having a second viscosity; and (c) mixing the first oil-in-aqueous phase emulsion with the second oil-in-phase emulsion to form said oil-in-aqueous phase emulsion that has a viscosity lower than the first viscosity and lower than the second viscosity.

Claim 41

The process of claim 38 wherein said first shearing and mixing means is a dynamic mixer, and said second shearing and mixing means is a static mixer.

Claim 42

The process of claim 38 wherein said first shearing and mixing means is a static mixer, and said second shearing and mixing means is a dynamic mixer.

Claim 43

The process of claim 38 wherein said first shearing and mixing means is a first dynamic mixer, and said second shearing and mixing means is a second dynamic mixer.

Claim 44

The process of claim 38 wherein said first shearing and mixing means is a first static mixer, and said second shearing and mixing means is a second static mixer.

Claim 45

The process of claim 29 additionally comprising transporting said formed oil-in-aqueous phase emulsion through a pipeline to a combustion chamber; and adding additional emulsifying agent to the formed oil-in-aqueous phase emulsion as it is being transported through the pipeline.

Claim 46

The process of claim 29 additionally comprising separating thereafter a substantial portion of the hydrocarbon from the formed oil-in-aqueous phase emulsion.

Claim 47

The process of claim 29 additionally comprising transporting said formed oil-in-aqueous phase emulsion through a pipeline to a combustion chamber; and for burning said formed oil-in-aqueous phase emulsion.

Claim 48

The process of claim 29 additionally comprising transporting said oil-in-aqueous phase emulsion to a combustion chamber.

Claim 49

The process of claim 29 wherein said agitating comprises passing said hydrocarbon and said emulsifying composition through a static mixer at varying flow and shear rates to form a multimodal oil-in-aqueous phase emulsion.

Claim 50

The process of claim 29 wherein said hydrocarbon comprises a hydrocarbon having a TBP of about 650° F. or above.

Claim 51

A process for preparing an oil-in-aqueous phase emulsion comprising; shearing and mixing statically, without any dynamic shearing and mixing preceding or following said shearing and mixing statically, a hydrocarbon with an emulsifying composition at a temperature to form an oil-in-aqueous phase emulsion, wherein said emulsifying composition comprises an aqueous phase and a minor amount of an emulsifying agent and said temperature is above 200° F., wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 15% to about 60% by weight, and wherein the emulsifying agent is used in an amount sufficient to assist in the formation of the oil-in-aqueous phase emulsion that is sufficiently stable for pipeline transmission; and wherein said emulsifying agent comprises about 50 percent by weight of an ethoxylated nonyl phenol compound having the formula: ##STR53## wherein y 1 is equal to 40 and is the average number of ethylene oxide units in the formula, and about 50 percent by weight of an ethoxylated nonyl phenol compound having the formula: ##STR54## wherein y 2 is equal to 100 and is the average number of ethylene oxide units in the formula.

Claim 52

A process for preparing an oil-in-aqueous phase emulsion comprising; shearing and mixing statically, without any dynamic shearing and mixing preceding or following said shearing and mixing statically, a hydrocarbon with an emulsifying composition at a temperature to form an oil-in-aqueous phase emulsion, wherein said emulsifying composition comprises an aqueous phase and a minor amount of an emulsifying agent and said temperature is above 200° F., wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 15% to about 60% by weight, and wherein the emulsifying agent is used in an amount sufficient to assist in the formation of the oil-in-aqueous phase emulsion that is sufficiently stable for pipeline transmission; and wherein said emulsifying agent comprises about 50 percent by weight of an ethoxylated nonyl phenol compound having the formula: ##STR53## wherein y 1 is equal to 40 and is the average number of ethylene oxide units in the formula, and about 50 percent by weight of an ethoxylated nonyl phenol compound having the formula: ##STR54## wherein y 2 is equal to 100 and is the average number of ethylene oxide units in the formula.

Claim 53

A process for preparing an oil-in-aqueous phase emulsion comprising: (a) agitating a hydrocarbon with a first emulsifying composition to disperse the first emulsifying composition in the hydrocarbon to form an aqueous phase-in-oil emulsion, wherein said first emulsion emulsifying composition comprises an aqueous phase and a minor amount of a first emulsifying agent and the amount of aqueous phase in said aqueous phase-in-oil emulsion is from about 1% to bout 10% by weight, wherein the first emulsifying agent is used in an amount sufficient to assist in the formation of said aqueous phase-in-oil emulsion, and wherein said first emulsifying agent has a general formula selected from the group consisting of: ##STR55## where n is from about 7 to about 20, and y is an integer that represents the average number of ethylene oxide units or segments in the emulsifying agent(s), which is the mean of a normal Gaussian distribution curve and is from about 2 to about 15; ##STR56## wherein n 1 is from about 7 to about 18, n 2 is from about 7 to about 18, and y 1 is an integer that represents the average number of ethylene oxide units or segments in the emulsifying agent(s), which is the mean of a normal Gaussian distribution curve and is from about 2 to about 15, and mixtures thereof; (b) agitating the formed aqueous phase-in-oil emulsion of step (a) with a second emulsifying composition to form an oil-in-aqueous phase emulsion, wherein said second emulsifying composition comprises an aqueous phase and a minor amount of a second emulsifying agent, wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 20% to about 29% by weight, wherein the second emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said second emulsifying agent comprises at least one ethoxylated alkylphenol compound having the general formula: ##STR57## wherein n 3 is an integer having a value of from about 7 to about 20, and y 2 is an integer having a value of from about 4 to about 1000; and said at least one ethoxylated alkylphenol compound has a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about 1966 to about 9188; and wherein at least about 50% by weight of the second emulsifying agent comprises said at least one ethoxylated alkylphenol compound having a molecular weight of from about 1966 to about 9188.

Claim 54

A process for preparing an oil-in-aqueous phase emulsion comprising: (a) agitating a hydrocarbon with a first emulsifying composition to disperse the first emulsifying composition in the hydrocarbon to form an aqueous phase-in-oil emulsion, wherein said first emulsion emulsifying composition comprises an aqueous phase and a minor amount of a first emulsifying agent and the amount of aqueous phase in said aqueous phase-in-oil emulsion is from about 1% to bout 10% by weight, wherein the first emulsifying agent is used in an amount sufficient to assist in the formation of said aqueous phase-in-oil emulsion, and wherein said first emulsifying agent has a general formula selected from the group consisting of: ##STR55## where n is from about 7 to about 20, and y is an integer that represents the average number of ethylene oxide units or segments in the emulsifying agent(s), which is the mean of a normal Gaussian distribution curve and is from about 2 to about 15; ##STR56## wherein n 1 is from about 7 to about 18, n 2 is from about 7 to about 18, and y 1 is an integer that represents the average number of ethylene oxide units or segments in the emulsifying agent(s), which is the mean of a normal Gaussian distribution curve and is from about 2 to about 15, and mixtures thereof; (b) agitating the formed aqueous phase-in-oil emulsion of step (a) with a second emulsifying composition to form an oil-in-aqueous phase emulsion, wherein said second emulsifying composition comprises an aqueous phase and a minor amount of a second emulsifying agent, wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 20% to about 29% by weight, wherein the second emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said second emulsifying agent comprises at least one ethoxylated alkylphenol compound having the general formula: ##STR57## wherein n 3 is an integer having a value of from about 7 to about 20, and y 2 is an integer having a value of from about 4 to about 1000; and said at least one ethoxylated alkylphenol compound has a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about 1966 to about 9188; and wherein at least about 50% by weight of the second emulsifying agent comprises said at least one ethoxylated alkylphenol compound having a molecular weight of from about 1966 to about 9188.

Claim 55

The process of claim 50 wherein from 1% by weight to 90% by weight of the second emulsifying agent comprises said at least one ethoxylated alkylphenol compound wherein y 2 had a value greater than 100.

Claim 56

The process of claim 50 wherein said aqueous phase-in-oil emulsion of step (a) is formed at a temperature above 200° F.; and said oil-in-aqueous phase emulsion is formed at a temperature above 200° F.; and said hydrocarbon has a TBP of about 650° F. or above.

Claim 57

The process of claim 50 wherein said second emulsifying agent further comprises at least one ethoxylated dialkylphenol compound having the general formula: ##STR58## wherein n 1 is an integer having the value of from about 7 to 18, and n 2 is an integer having a value of from about 7 to about 18, and y 1 is an integer having a value of about 4 to about 1000; and said at least one ethoxylated dialkylphenol compound has a molecular weight distribution with a dispersity of from about 1.0 to about 5.0 and with a weight average molecular weight of from about 2519 to about 11,627; and wherein at least about 50% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound having a molecular weight of from about 2519 to about 11,627; and from 1% by weight to 90% by weight of the emulsifying agent comprises said at least one ethoxylated dialkylphenol compound wherein y 1 is greater than 100; or a mixture of the ethoxylated alkylphenol compound and the ethoxylated dialkylphenol compound.

Claim 58

A process for preparing an oil-in-aqueous phase emulsion comprising: (a) agitating a hydrocarbon having a TBP of about 950° F. or above with an emulsifying composition at a temperature ranging from about 200° F. to about 280° F. to form an oil-in-aqueous phase emulsion, said emulsifying composition including an emulsifying agent selected from the group consisting of ethoxylated alkylphenol compounds, ethoxylated dialkylphenol compounds, and mixtures thereof; (b) subsequently cooling to a temperature below about 175° F. the formed oil-in-aqueous phase emulsion of step (a), within a time period, after formation of the oil-in-aqueous phase emulsion in step (a), ranging from about one (1) sec. to about five (5) minutes to produce and form an oil-in-aqueous phase emulsion containing an oil droplet phase dispersed in an aqueous continuous phase; (c) transporting the formed oil-in-aqueous phase emulsion of step (b) until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase and a residual oil-in-aqueous phase emulsion without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion; and (d) reformulating said oil-in-aqueous phase emulsion containing said oil droplet phase dispersed in said aqueous continuous phase.

Claim 59

A process for preparing an oil-in-aqueous phase emulsion comprising: (a) agitating a hydrocarbon having a TBP of about 950° F. or above with an emulsifying composition at a temperature ranging from about 200° F. to about 280° F. to form an oil-in-aqueous phase emulsion, said emulsifying composition including an emulsifying agent selected from the group consisting of ethoxylated alkylphenol compounds, ethoxylated dialkylphenol compounds, and mixtures thereof; (b) subsequently cooling to a temperature below about 175° F. the formed oil-in-aqueous phase emulsion of step (a), within a time period, after formation of the oil-in-aqueous phase emulsion in step (a), ranging from about one (1) sec. to about five (5) minutes to produce and form an oil-in-aqueous phase emulsion containing an oil droplet phase dispersed in an aqueous continuous phase; (c) transporting the formed oil-in-aqueous phase emulsion of step (b) until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase and a residual oil-in-aqueous phase emulsion without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion; and (d) reformulating said oil-in-aqueous phase emulsion containing said oil droplet phase dispersed in said aqueous continuous phase.

Claim 60

The process of claim 54 wherein said subsequently cooling step (b) is within a time period after formation of the oil-in-aqueous phase emulsion in step (a) ranging from about one (1) sec. to about three (3) minutes.

Claim 61

The process of claim 54 additionally comprising transporting the reformulated oil-in-aqueous phase of step (d) for combustion purposes with a limited aqueous phase.

Claim 62

The process of claim 54 wherein said partially coalesced oil droplet phase includes a viscosity higher than the viscosity of the formed oil-in-aqueous phase emulsion of step (b), and said mixture of step (c) comprises said coalesced oil droplet phase and said residual oil-in-aqueous phase emulsion has a viscosity lower than or equal to the viscosity of the formed oil-in-aqueous phase emulsion of step (b).

Claim 63

The process of claim 54 wherein said agitating step comprises passing the hydrocarbon and the emulsifying composition through a static mixer having from 16 to 32 baffle elements.

Claim 64

The process of claim 54 wherein said agitating step (a) comprises passing the hydrocarbon and the emulsifying composition through static mixer at a superficial fluid velocity ranging from 20 to 140 inches per minute.

Claim 65

The process of claim 54 wherein said agitating step (a) comprises passing the hydrocarbon and the emulsifying composition through a static mixer at a pressure differential ranging from 150 to 325 psi.

Claim 66

The process of claim 54 wherein said oil droplet phase comprises less than 5% by wt. of oil droplets having a particle size larger than 100 microns.

Claim 67

The process of claim 61 wherein less than 1% by wt. of the oil droplets have a particle size larger than 100 microns.

Claim 68

The process of claim 54 wherein said agitating comprises (a) positioning a portion of a mixture comprising said hydrocarbon and said emulsifying composition in a first shearing and mixing means having a first predetermined shear rate to produce a first oil-in aqueous phase emulsion having a first viscosity, leaving a remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition that is not positioned in the first shearing and mixing means; (b) positioning said remaining portion of said mixture comprising the hydrocarbon and the emulsifying composition in a second shearing and mixing means having a second predetermined shear rate which is different from said first shear rate to produce a second oil-in-aqueous phase emulsion having a second viscosity; and (c) mixing the first oil-in-aqueous phase emulsion with the second oil-in-phase emulsion to form said oil-in-aqueous phase emulsion that has a viscosity lower than the first viscosity and lower than the second viscosity.

Claim 69

The process of claim 54 wherein said formed oil-in-aqueous emulsion is formed with a layer of skim that comprises up to about 3% by wt. of the formed oil-in-aqueous phase emulsion; and said layer of skim is removed and admixed with said hydrocarbon and/or said emulsifying composition for forming a second oil-in-aqueous phase emulsion.

Claim 70

The process of claim 54 wherein said reformulating step (d) comprises passing said oil-in-aqueous phase emulsion, containing said oil droplet phase dispersed in said aqueous continuous phase, through a homogenizer to substantially eliminate in said oil droplet phase oil droplets having a particle size larger than 100 microns.

Claim 71

The process of claim 65 wherein less than 1% by wt. of the oil droplets have a particle size larger than 100 microns.

Claim 72

The process of claim 66 wherein said subsequently cooling step (c) is within a time period after formation of the oil-in-aqueous phase emulsion in step (b) ranging from about one (1) sec. to about three (3) minutes.

Claim 73

The process of claim 66 additionally comprising transporting the reformulated oil-in-aqueous phase of step (e) for combustion purposes with a limited aqueous phase.

Claim 74

The process of claim 54 wherein said formed oil-in-aqueous phase emulsion has a d 50 as being from about 10 to about 20.

Claim 75

The process of claim 54 wherein no more than 3% by wt. of the oil droplet phase of any given volume of the formulated oil-in-aqueous phase emulsion has a particle size larger than 100 microns.

Claim 76

The process of claim 54 wherein oil-in-aqueous phase emulsion comprises from about 20 to 40% by wt. of water.

Claim 77

The process of claim 54 wherein about 1% by wt. or less of the formed oil-in-aqueous phase emulsion is asphalt-foam skim.

Claim 78

The process of claim 54 wherein at least 1% by weight of the emulsifying agent comprises more than 100 ethylene oxide repeat units.

Claim 79

The process of claim 54 wherein said hydrocarbon has a TBP of from about 950° F. to about 1100° F.

Claim 80

The process of claim 74 wherein said agitating step (a) is performed at a pressure ranging from about 75 p.s.i. to about 625 p.s.i.

Claim 81

The process of claim 54 wherein said agitating step (a) is performed at a pressure ranging from about 75 p.s.i. to about 625 p.s.i.

Claim 82

A process for preparing an oil-in-aqueous phase emulsion comprising: (a) agitating a hydrocarbon having a TBP of about 950° F. or above with a first emulsifying composition at a temperature ranging from about 200° F. to about 280° F. and at a pressure ranging from about 100 p.s.i. to about 500 p.s.i. to disperse the first emulsifying composition in the hydrocarbon to form an aqueous phase-in-oil emulsion, wherein said first emulsion emulsifying composition comprises an aqueous phase and a minor amount of a first emulsifying agent and the amount of aqueous phase in said aqueous phase-in-oil emulsion is from about 1% to about 10% by weight, wherein the first emulsifying agent is used in an amount sufficient to assist in the formation of said aqueous phase-in-oil emulsion, and wherein said first emulsifying agent is selected from the group consisting of ethoxylated alkylphenol compounds, ethoxylated dialkylphenol compounds, and mixtures thereof; (b) agitating the formed aqueous phase-in-oil emulsion of step (a) with a second emulsifying composition at a temperature ranging from about 200° F. to about 280° F. and at a pressure ranging from about 100 p.s.i. to about 500 p.s.i. to form an oil-in-aqueous phase emulsion, wherein said second emulsifying composition comprises an aqueous phase and a minor amount of a second emulsifying agent, wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 20% to about 29% by weight, wherein the second emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said second emulsifying agent is selected from the group consisting of ethoxylated alkylphenol compounds, ethoxylated dialkylphenol compounds, and mixtures thereof; (c) subsequently cooling to a temperature below about 175° F. the formed oil-in-aqueous phase emulsion of step (b), within a time period, after formation of the oil-in-aqueous phase emulsion in step (b), ranging from about one (1) sec. to about five (5) minutes to produce and form an oil-in-aqueous phase emulsion containing an oil droplet phase dispersed in an aqueous continuous phase; (d) transporting the formed oil-in-aqueous phase emulsion of step (c) until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase and a residual oil-in-aqueous phase emulsion without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion; and (e) reformulating said oil-in-aqueous phase emulsion containing said oil droplet phase dispersed in said aqueous continuous phase.

Claim 83

A process for preparing an oil-in-aqueous phase emulsion comprising: (a) agitating a hydrocarbon having a TBP of about 950° F. or above with a first emulsifying composition at a temperature ranging from about 200° F. to about 280° F. and at a pressure ranging from about 100 p.s.i. to about 500 p.s.i. to disperse the first emulsifying composition in the hydrocarbon to form an aqueous phase-in-oil emulsion, wherein said first emulsion emulsifying composition comprises an aqueous phase and a minor amount of a first emulsifying agent and the amount of aqueous phase in said aqueous phase-in-oil emulsion is from about 1% to about 10% by weight, wherein the first emulsifying agent is used in an amount sufficient to assist in the formation of said aqueous phase-in-oil emulsion, and wherein said first emulsifying agent is selected from the group consisting of ethoxylated alkylphenol compounds, ethoxylated dialkylphenol compounds, and mixtures thereof; (b) agitating the formed aqueous phase-in-oil emulsion of step (a) with a second emulsifying composition at a temperature ranging from about 200° F. to about 280° F. and at a pressure ranging from about 100 p.s.i. to about 500 p.s.i. to form an oil-in-aqueous phase emulsion, wherein said second emulsifying composition comprises an aqueous phase and a minor amount of a second emulsifying agent, wherein the amount of aqueous phase in said oil-in-aqueous phase emulsion is from about 20% to about 29% by weight, wherein the second emulsifying agent is used in an amount sufficient to assist in the formation of said oil-in-aqueous phase emulsion, and wherein said second emulsifying agent is selected from the group consisting of ethoxylated alkylphenol compounds, ethoxylated dialkylphenol compounds, and mixtures thereof; (c) subsequently cooling to a temperature below about 175° F. the formed oil-in-aqueous phase emulsion of step (b), within a time period, after formation of the oil-in-aqueous phase emulsion in step (b), ranging from about one (1) sec. to about five (5) minutes to produce and form an oil-in-aqueous phase emulsion containing an oil droplet phase dispersed in an aqueous continuous phase; (d) transporting the formed oil-in-aqueous phase emulsion of step (c) until a portion of the dispersed oil droplet phase coalesces in the aqueous continuous phase to produce a mixture comprising a partially coalesced oil droplet phase and a residual oil-in-aqueous phase emulsion without a substantial portion of said oil-in-aqueous phase emulsion being inverted into an aqueous phase-in-oil emulsion; and (e) reformulating said oil-in-aqueous phase emulsion containing said oil droplet phase dispersed in said aqueous continuous phase.

Claim 84

The process of claim 54 wherein said formed oil-in-aqueous phase emulsion has a d 50 as being from about 10 to about 20.

Claim 85

The process of claim 77 wherein said aqueous phase-in-oil emulsion comprises said aqueous phase in the hydrocarbon having a mean aqueous droplet size distribution ranging from 1 micron to 100 micron.

Claim 86

The process of claim 77 wherein said about 1% to about 10% by weight of said aqueous phase in said aqueous phase-in-oil emulsion of step (a) has a mean aqueous droplet size ranging from about 1 micron to about 50 microns; and said oil droplet phase in said aqueous continuous phase in step (c) has a mean oil droplet size ranging from about 1 to 100 microns.

Claim 87

The process of claim 77 wherein at least 1% by weight of the second emulsifying agent comprises more than 100 ethylene oxide repeat units.

Claim 88

The process of claim 77 wherein said hydrocarbon has a TBP of from about 950° F. to about 1100° F.