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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

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.

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The invention claimed is: 1. A process for making an emulsion, comprising: flowing a first liquid through at least one first liquid manifold into a plurality of process microchannels, each process microchannel having at least one wall with at least one apertured section; flowing a second liquid thr

The invention claimed is: 1. A process for making an emulsion, comprising: flowing a first liquid through at least one first liquid manifold into a plurality of process microchannels, each process microchannel having at least one wall with at least one apertured section; flowing a second liquid through at least one second liquid manifold into a plurality of liquid channels adjacent to the process microchannels and through the apertured sections into the process microchannels in contact with the first liquid to form the emulsion, the process microchannels and liquid channels being aligned side by side or stacked one above another, 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 2 wherein the heat exchanger comprises at least one heat exchange channel. 4. The process of claim 3 wherein the process microchannel exchanges heat with a heat exchange fluid flowing through the heat exchange channel. 5. The process of claim 4 wherein the heat exchange fluid undergoes a phase change as it flows through the heat exchange channel. 6. The process of claim 4 wherein an endothermic process is conducted in the heat exchange channel. 7. The process of claim 4 wherein an exothermic process is conducted in the heat exchange channel. 8. The process of claim 4 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. 9. The process of claim 4 wherein the heat exchange fluid comprises the first liquid, the second liquid, or a mixture of the first liquid and the second liquid. 10. The process of claim 3 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. 11. The process of claim 3 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. 12. The process of claim 3 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. 13. The process of claim 3 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. 14. The process of claim 1 wherein the second liquid flows from a liquid channel through the apertured section. 15. The process of claim 14 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. 16. The process of claim 15 wherein the heat exchanger comprises an electric heating element, resistance heater and/or non-fluid cooling element. 17. The process of claim 16 wherein the electric heating element, resistance heater and/or non-fluid cooling element is adjacent to the process microchannel and/or liquid channel. 18. The process of claim 16 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. 19. The process of claim 16 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. 20. The process of claim 15 wherein the heat exchanger is adjacent to the process microchannel and/or liquid channel. 21. The process of claim 15 wherein the heat exchanger is remote from the process microchannel and/or liquid channel. 22. The process of claim 14 wherein the liquid channel has an internal dimension perpendicular to the flow of liquid through the liquid channel of up to about 100 cm. 23. The process of claim 14 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. 24. The process of claim 14 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. 25. The process of claim 14 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. 26. 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. 27. The process of claim 26 wherein the third liquid flows from another liquid channel through the another apertured section. 28. The process of claim 27 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. 29. The process of claim 27 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. 30. The process of claim 27 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. 31. The process of claim 27 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. 32. The process of claim 26 wherein the liquid mixture is dispersed as a discontinuous phase in the first liquid. 33. The process of claim 26 wherein the liquid mixture comprises another emulsion. 34. The process of claim 26 wherein the third liquid is dispersed in the second liquid. 35. The process of claim 26 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. 36. The process of claim 26 wherein the third liquid comprises water. 37. The process of claim 26 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. 38. The process of claim 26 wherein the emulsion comprises a water-in-oil-in-water emulsion. 39. 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. 40. The process of claim 39 wherein the separate second liquids flowing through each of the apertured sections have different compositions. 41. The process of claim 40 with a coating overlying at least part of the sheet or plate and filling part of the apertures. 42. The process of claim 40 wherein the sheet or plate is heat treated. 43. The process of claim 39 wherein the separate second liquids flowing through each of the apertured sections have different properties. 44. The process of claim 1 wherein the first liquid and the second liquid contact each other in a mixing zone in the process microchannel. 45. The process of claim 44 wherein heat is exchanged between a heat exchanger and at least part of the process microchannel in the mixing zone. 46. The process of claim 44 wherein heat is exchanged between a heat exchanger and at least part of the process microchannel upstream of the mixing zone. 47. The process of claim 44 wherein heat is exchanged between a heat exchanger and at least part of the process microchannel downstream of the mixing zone. 48. The process of claim 44 wherein the emulsion is quenched in the process microchannel downstream of the mixing zone. 49. The process of claim 44 wherein the process microchannel has a restricted cross section in the mixing zone. 50. 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. 51. The process of claim 50 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. 52. The process of claim 50 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. 53. 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. 54. The process of claim 53 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. 55. The process of claim 1 wherein the process microchannel is formed from parallel spaced sheets, plates or a combination of such sheets and plates. 56. The process of claim 55 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. 57. The process of claim 55 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. 58. 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. 59. The process of claim 58 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. 60. 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. 61. The process of claim 60 wherein the process microchannel is in an annular space and the liquid channel is in the center space or an adjacent annular space. 62. The process of claim 60 wherein the process microchannel is in the center space and the liquid channel is in an adjacent annular space. 63. 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. 64. The process of claim 63 wherein the emulsions formed in at least two of the process microchannels are different in composition. 65. The process of claim 63 wherein the emulsions formed in at least two of the process microchannels have one or more different physical properties. 66. The process of claim 1 wherein the apertured section is made from a porous material. 67. The process of claim 66 wherein the porous material is metallic. 68. The process of claim 1 wherein the emulsion comprises at least one emulsifier and/or surfactant. 69. The process of claim 68 wherein the emulsifier and/or surfactant comprises an alkanolamine, 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. 70. 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. 71. 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. 72. The process of claim 1 wherein the apertured section comprises a sheet or plate with a plurality of apertures in the sheet or plate. 73. 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. 74. 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. 75. 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. 76. 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 200 microns. 77. 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. 78. The process of claim 1 wherein the first liquid comprises water. 79. The process of claim 1 wherein the second liquid comprises an organic liquid. 80. 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. 81. 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. 82. 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. 83. 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. 84. The process of claim 1 wherein the second liquid flows from a liquid channel through the apertured section. 85. The process of claim 1 wherein the emulsion is cooled to room temperature within a time period of up to about 10 minutes. 86. The process of claim 1 wherein the emulsion is filtered. 87. The process of claim 1 wherein the emulsion comprises an oil-in-water emulsion. 88. The process of claim 1 wherein the emulsion comprises at least one organic liquid. 89. The process of claim 1 wherein the emulsion comprises at least one liquid hydrocarbon. 90. The process of claim 1 wherein the emulsion comprises at least one natural oil, synthetic oil, or mixture thereof. 91. The process of claim 1 wherein the emulsion comprises at least one liquid derived from a vegetable source, a mineral source, or mixture thereof. 92. The process of claim 1 wherein the emulsion comprises at least one normally liquid hydrocarbon fuel. 93. The process of claim 1 wherein the emulsion comprises at least one fatty alcohol, fatty acid ester, or a mixture thereof. 94. 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. 95. 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. 96. The process of claim 1 wherein solids are dispersed in the emulsion. 97. The process of claim 1 wherein pigment is dispersed in the emulsion. 98. The process of claim 1 wherein a catalyst is dispersed in the emulsion. 99. The process of claim 1 wherein optical or thermal-optical features of the emulsion are adjusted in the process microchannel. 100. The process of claim 1 wherein the process produces at least 1 liter of emulsion per minute. 101. The process of claim 1 wherein the process produces at least 1 liter of emulsion per second. 102. 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. 103. 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. 104. 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. 105. 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. 106. The process of claim 1 wherein heat exchange channels are adjacent to the process microchannels and/or liquid channels, and at least one heat exchange manifold is connected to the heat exchange channels, a heat exchange fluid flowing through the at least one heat exchange manifold to the heat exchange channels. 107. 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. 108. The process of claim 107 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. 109. The process of claim 108 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. 110. The process of claim 107 wherein the first liquid flows through a header into the process microchannel. 111. The process of claim 107 wherein the second liquid flows through a header into the liquid channel. 112. The process of claim 107 wherein the emulsion flows out of the process microchannel through a footer.