초록 ▼

The disclosed invention relates to a process for making a multiphase mixture, comprising: flowing a first fluid stream through a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second

The disclosed invention relates to a process for making a multiphase mixture, comprising: flowing a first fluid stream through a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase.

대표청구항 ▼

The invention claimed is: 1. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an entrance for flowing the first fluid stream i

The invention claimed is: 1. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an entrance for flowing the first fluid stream into the process microchannel, an outlet for flowing the multiphase mixture out of the process microchannel, a sidewall extending between the entrance and the outlet, and an apertured section in the sidewall; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase. 2. The process of claim 1 wherein the second fluid stream flows from a second fluid stream channel through the apertured section. 3. The process of claim 2 wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the second fluid stream channel and a heat source and/or heat sink, or both the process microchannel and the second fluid stream channel and a heat source and/or heat sink. 4. The process of claim 3 wherein the first fluid stream and the second fluid stream contact each other in a mixing zone in the process microchannel, and heat is exchanged between a heat source and/or heat sink and at least part of the process microchannel in the mixing zone. 5. The process of claim 3 wherein the first fluid stream and the second fluid stream contact each other in a mixing zone in the process microchannel, and heat is exchanged between a heat source and/or heat sink and at least part of the process microchannel upstream of the mixing zone. 6. The process of claim 3 wherein the first fluid stream and the second fluid stream contact each other in a mixing zone in the process microchannel, and heat is exchanged between a heat source and/or heat sink and at least part of the process microchannel downstream of the mixing zone. 7. The process of claim 2 wherein the second fluid stream channel has an internal dimension perpendicular to the flow of the second fluid stream through the second fluid stream channel of up to about 100 cm. 8. The process of claim 2 wherein the second fluid stream channel has an internal dimension perpendicular to the flow of the second fluid stream through the second fluid stream channel of up to about 10 mm. 9. The process of claim 2 wherein the second fluid stream channel has an internal dimension perpendicular to the flow of the second fluid stream through the second fluid stream channel of up to about 2 mm. 10. The process of claim 2 wherein the second fluid stream 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. 11. The process of claim 1 wherein the second fluid stream comprises a microbody forming material. 12. The process of claim 11 wherein the microbody forming material comprises a glass microbody forming material or a polymeric microbody forming material. 13. The process of claim 12 wherein the polymeric microbody forming material comprises one or more acrylic resins, silicon resins, urethane resins, vinyl acetate resins, teflon resins, polyamide resins, vinyl chloride resins, styrenic resins, phenol resins, epoxy resins, styrene-butadiene-styrene block copolymer resins, styrene-ethylene-butylene-styrene block copolymer resins, styrene-isoprene-styrene block copolymer resins, n-butyl rubber, chloroprene rubber, natural rubber, or a combination of two or more thereof. 14. 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 fluid stream manifold, the first fluid stream flowing through the at least one first fluid stream manifold to the process microchannels. 15. The process of claim 14 wherein second fluid stream channels are adjacent to the process microchannels, the microchannel mixer further comprising at least one second fluid stream manifold connected to the second fluid stream channels, the second fluid stream flowing through the at least one second fluid stream manifold to the second fluid stream channels. 16. The process of claim 15 wherein the microchannel mixer further comprises heat exchange channels adjacent to the process microchannels and/or second fluid stream 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. 17. The process of claim 1 wherein the process microchannel further comprises surface features formed in and/or on one or more interior walls of the process microchannel for modifying flow within the process microchannel. 18. The process of claim 17 wherein the surface features are in the form of at least two surface feature regions wherein mixing of the first fluid and second fluid is conducted in a first surface feature region followed by flow in a second surface feature region wherein the flow pattern in the second surface feature region is different than the flow pattern in the first surface feature region. 19. The process of claim 18 wherein the flow in the second surface feature region is used to separate the first fluid and second fluid. 20. The process of claim 17 wherein the surface features are in the form of depressions in and/or projections from one or more of the microchannel interior walls that are oriented at oblique angles relative to the direction of flow of fluid through the process microchannel. 21. The process of claim 17 wherein the surface features comprise two or more layers stacked on top of each other and/or intertwined in a three-dimensional pattern. 22. The process of claim 17 wherein the surface features are in the form of circles, oblongs, squares, rectangles, checks, chevrons, wavy shapes, or combinations thereof. 23. The process of claim 17 wherein the surface features comprise major walls and sub-features where the major walls of the surface features further contain smaller surface features in the form of notches, waves, indents, holes, burrs, checks, scallops, or combinations thereof. 24. The process of claim 1 wherein heat is exchanged between the process microchannel and a heat source and/or heat sink. 25. The process of claim 24 wherein the heat source and/or heat sink is adjacent to the process microchannel. 26. The process of claim 24 wherein the heat source and/or heat sink is remote from the process microchannel. 27. 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 fluid stream flowing through each of apertured sections into the process microchannel. 28. The process of claim 27 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. 29. The process of claim 27 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. 30. The process of claim 1 wherein the process microchannel is formed from parallel spaced sheets and/or plates. 31. The process of claim 30 wherein the second fluid stream flows from a second fluid stream channel through the apertured section into the process microchannel, the second fluid stream channel being formed from parallel spaced sheets and/or plates, the second fluid stream channel being adjacent to the process microchannel. 32. The process of claim 1 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels and second fluid stream channels, each process microchannel having a wall with apertured section and an adjacent second fluid stream channel, the second fluid stream flowing from the second fluid stream channel through the apertured section into the process microchannel in contact with the first fluid stream, the process microchannels and second fluid stream channels being formed from parallel spaced sheets and/or plates, the process microchannels and second fluid stream channels being adjacent to each other and aligned in interleaved side-by-side planes or interleaved planes stacked one above another. 33. The process of claim 32 wherein the microchannel mixer further comprises a plurality of heat exchange channels formed from parallel spaced sheets and/or plates, the heat exchange channels being adjacent to the process microchannels, the second fluid stream channels, or both the process microchannels and the second fluid stream channels. 34. The process of claim 1 wherein the multiphase mixture comprises microbodies. 35. The process of claim 34 wherein the microbodies are solid. 36. The process of claim 34 wherein the microbodies comprise polymeric microspheres. 37. The process of claim 1 wherein the multiphase mixture comprises at least one emulsifier and/or surfactant. 38. The process of claim 37 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. 39. The process of claim 37 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. 40. The process of claim 1 wherein the second fluid mixes with the first fluid in the process microchannel. 41. The process of claim 1 wherein the multiphase mixture further comprises solid particles dispersed in the first fluid stream. 42. The process of claim 1 wherein the apertured section extends along at least part of the axial length of the process microchannel. 43. The process of claim 1 wherein the first fluid stream and the second fluid stream contact each other in a mixing zone in the process microchannel, the process microchannel having a restricted cross section in the mixing zone. 44. The process of claim 1 wherein the process microchannel is in a multiphase mixture forming unit comprising a first process microchannel, a second process microchannel, and a second fluid stream channel positioned between the first process microchannel and the second process microchannel, each process microchannel having a wall with an apertured section, the first fluid stream flowing through the first process microchannel and the second process microchannel, the second fluid stream flowing from the second fluid stream channel through the apertured section in the first process microchannel in contact with the first fluid stream and through the apertured section in the second process microchannel in contact with the first fluid stream. 45. 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 process microchannel entrance to the mixing zone. 46. The process of claim 1 wherein the apertured section comprises a sheet and/or plate with a plurality of apertures in the sheet and/or plate. 47. The process of claim 1 wherein the apertured section has a wall thickness and a length along the flow path of the first fluid stream 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 100. 48. The process of claim 1 wherein the first fluid stream comprises water. 49. The process of claim 1 wherein the process microchannel has an internal dimension perpendicular to the flow of the first fluid stream through the process microchannel of up to about 50 mm. 50. The process of claim 1 wherein the process microchannel has an internal dimension perpendicular to the flow of the first fluid stream through the process microchannel of up to about 10 mm. 51. The process of claim 1 wherein the process microchannel has an internal dimension perpendicular to the flow of the first fluid stream through the process microchannel of up to about 2 mm. 52. 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. 53. The process of claim 1 wherein the multiphase mixture comprises water. 54. The process of claim 1 wherein the multiphase mixture comprises at least one organic liquid. 55. The process of claim 1 wherein the multiphase mixture comprises at least one fatty alcohol, fatty acid ester, or a mixture thereof. 56. The process of claim 1 wherein the multiphase mixture 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. 57. The process of claim 1 wherein solids are dispersed in the multiphase mixture. 58. The process of claim 1 wherein the first fluid stream comprises a gas or liquid and the second fluid stream comprises a microbody-forming material. 59. The process of claim 1 wherein the process produces at least 1 liter of multiphase mixture per minute. 60. 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. 61. 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. 62. 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. 63. The process of claim 1 wherein the apertured section comprises an interior portion that forms part of one or more of the interior walls of the process microchannel and a surface feature sheet that overlies the interior portion of the apertured section, surface features being in and/or on the surface feature sheet. 64. The process of claim 1 wherein the multiphase mixture comprises solid particles dispersed in the first and/or second fluid stream and is in the form of a fluidized bed, the process microchannel comprising surface features formed in and/or on one or more of its interior walls for modifying flow within the process microchannel. 65. The process of claim 1 wherein the multiphase mixture is in the form of a foam. 66. The process of claim 1 wherein the first fluid stream and the second fluid stream contact each other in a mixing zone in the process microchannel. 67. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having one or more interior walls with surface features formed in and/or on one or more of the interior walls for modifying flow within the process microchannel; contacting the first fluid stream with a second fluid stream within the process microchannel to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase, the multiphase mixture flowing in the process microchannel and contacting the surface features, the flow of the multiphase mixture within the process microchannel being modified by contacting the surface features. 68. The process of claim 67 wherein heat is exchanged between the process microchannel and a heat source and/or heat sink. 69. The process of claim 68 wherein the heat source and/or heat sink comprises at least one heat exchange channel. 70. The process of claim 69 wherein a heat exchange fluid undergoes a phase change in the heat exchange channel. 71. The process of claim 69 wherein an endothermic process is conducted in the heat exchange channel. 72. The process of claim 69 wherein an exothermic process is conducted in the heat exchange channel. 73. The process of claim 69 wherein a heat exchange fluid is in the heat exchange channel, the heat exchange fluid comprising air, steam, liquid water, carbon monoxide, carbon dioxide, gaseous nitrogen, liquid nitrogen, at least one gaseous hydrocarbon, at least one liquid hydrocarbon, or a combination of two or more thereof. 74. The process of claim 69 wherein a heat exchange fluid is in the heat exchange channel, the heat exchange fluid comprising the first fluid stream, the second fluid stream, or a mixture of the first fluid stream and the second fluid stream. 75. The process of claim 69 wherein the heat exchange channel comprises surface features formed in and/or on one or more interior walls for modifying flow within the heat exchange channel. 76. The process of claim 67 wherein the surface features are in the form of at least two surface feature regions wherein mixing of the first fluid and second fluid is conducted in a first surface feature region followed by flow in a second surface feature region wherein the flow pattern in the second surface feature region is different than the flow pattern in the first surface feature region. 77. The process of claim 76 wherein the flow in the second surface feature region is used to separate the first fluid and second fluid. 78. The process of claim 67 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels wherein separate multiphase mixtures are formed in each of the process microchannels, the multiphase mixtures formed in at least two of the process microchannels being different from each other. 79. The process of claim 67 wherein the multiphase mixture comprises water. 80. The process of claim 67 wherein the multiphase mixture comprises at least one organic liquid. 81. The process of claim 67 wherein the multiphase mixture comprises at least one liquid hydrocarbon. 82. The process of claim 67 wherein the multiphase mixture comprises at least one emulsifier and/or surfactant. 83. The process of claim 67 wherein solids are dispersed in the multiphase mixture. 84. The process of claim 67 wherein the surface features are in the form of depressions in and/or projections from one or more of the microchannel interior walls that are oriented at oblique angles relative to the direction of flow of fluid through the process microchannel. 85. The process of claim 67 wherein the multiphase mixture comprises solid particles dispersed in the first and/or second fluid stream and is in the form of a fluidized bed. 86. The process of claim 67 wherein the surface features comprise two or more layers stacked on top of each other and/or intertwined in a three-dimensional pattern. 87. The process of claim 67 wherein the surface features are in the form of circles, oblongs, squares, rectangles, checks, chevrons, wavy shapes, or combinations thereof. 88. The process of claim 67 wherein the surface features comprise sub-features where the major walls of the surface features further contain smaller surface features in the form of notches, waves, indents, holes, burrs, checks, scallops, or combinations thereof. 89. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; and wherein the second fluid dissolves in the first fluid. 90. The process of claim 89 wherein the second fluid dissolves in the first fluid in the process microchannel. 91. The process of claim 89 wherein the second fluid dissolves in the first fluid after the multiphase mixture exits the process microchannel. 92. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein a third fluid stream flows in a third fluid stream channel, the third fluid stream channel having another wall with another apertured section, the process further comprising: flowing the second fluid stream through the another apertured section in contact with the third fluid stream to form another multiphase mixture; and flowing the another multiphase mixture through the apertured section into the process microchannel in contact with the first fluid stream. 93. The process of claim 92 wherein the another multiphase mixture is dispersed as a discontinuous phase in the first fluid stream. 94. The process of claim 92 wherein at least part of the third fluid stream is in the form of droplets dispersed in the first fluid stream, and at least part of the second fluid stream is in the form of bubbles positioned within the droplets of the third fluid stream. 95. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the process microchannel is formed from parallel spaced sheets and/or plates; wherein the second fluid stream flows from a second fluid stream channel through the apertured section into the process microchannel, the second fluid stream channel being formed from parallel spaced sheets and/or plates, the second fluid stream channel being adjacent to the process microchannel; and wherein the process microchannel and the second fluid stream channel exchange heat with a heat exchange channel, the heat exchange channel being formed from parallel spaced sheets and/or plates, the heat exchange channel being adjacent to the process microchannel, the second fluid stream channel, or both the process microchannel and the second fluid stream channel. 96. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; and wherein the second fluid stream flows from a second fluid stream channel through the apertured section into the process microchannel, the process microchannel and the second fluid stream channel comprising circular tubes aligned concentrically. 97. The process of claim 96 wherein the process microchannel is in an annular space and the second fluid stream channel is in the center space or an adjacent annular space. 98. The process of claim 96 wherein the process microchannel is in the center space and the second fluid stream channel is in an adjacent annular space. 99. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; and wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels wherein separate multiphase mixtures are formed in each of the process microchannels, the multiphase mixtures formed in at least two of the process microchannels being different from each other. 100. The process of claim 99 wherein the multiphase mixtures formed in at least two of the process microchannels are different in composition. 101. The process of claim 99 wherein the multiphase mixtures formed in at least two of the process microchannels have one or more different physical properties. 102. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the process microchannel comprises two or more apertured sections and separate second fluid streams flow through each of the apertured sections. 103. The process of claim 102 wherein the separate second fluid streams flowing through each of the apertured sections have different compositions. 104. The process of claim 102 wherein the separate second fluid streams flowing through each of the apertured sections have one or more different properties. 105. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; 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 gas to flow from the relatively large apertures through the relatively small apertures. 106. The process of claim 105 with a coating overlying at least part of the sheet and/or plate and filling part of the apertures. 107. The process of claim 105 wherein the sheet and/or plate is heat treated. 108. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section, wherein the apertured section is made from a porous material; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase. 109. The process of claim 108 wherein the porous material is metallic. 110. The process of claim 108 wherein the porous material is nonmetallic. 111. The process of claim 108 wherein the porous material is oxidized. 112. The process of claim 108 wherein the porous material is coated with alumina, nickel, or a combination thereof. 113. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; 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. 114. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the discontinuous phase is in the form of gas bubbles having a volume-based mean diameter in the range of up to about 25 microns, and a span in the range from about 1.9 to about 2.5. 115. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the discontinuous phase comprises microbody having a volume-based mean diameter in the range up to about 5 microns, and a span in the range from about 1.8 to about 2.5. 116. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the first fluid stream comprises an organic liquid. 117. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the first fluid stream comprises at least one gas. 118. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the second fluid stream comprises at least one gas. 119. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the second fluid stream comprises air, hydrogen, nitrogen, carbon dioxide, or a mixture of two or more thereof. 120. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the second fluid stream comprises a microbody forming material, the polymeric microbody forming material comprising a (meth)acrylate ester of an alcohol of 1 to about 14 carbon atoms. 121. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the second fluid stream comprises a microbody forming material, the polymeric microbody forming material comprising at least one alkyl (meth)acrylate. 122. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the heat source and/or heat sink comprising at least one heat exchange channel. 123. The process of claim 122 wherein a heat exchange fluid is in the heat exchange channel. 124. The process of claim 123 wherein the heat exchange fluid undergoes a phase change in the heat exchange channel. 125. The process of claim 123 wherein the heat exchange fluid comprises air, steam, liquid water, carbon monoxide, carbon dioxide, gaseous nitrogen, liquid nitrogen, at least one gaseous hydrocarbon, at least one liquid hydrocarbon, or a combination of two or more thereof. 126. The process of claim 123 wherein the heat exchange fluid comprises the first fluid stream, the second fluid stream, or a mixture of the first fluid stream and the second fluid stream. 127. The process of claim 122 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. 128. The process of claim 122 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. 129. The process of claim 122 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. 130. The process of claim 122 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. 131. The process of claim 122 wherein an endothermic process is conducted in the heat exchange channel. 132. The process of claim 122 wherein an exothermic process is conducted in the heat exchange channel. 133. The process of claim 122 wherein the heat exchange channel comprises surface features formed in and/or on one or more interior walls for modifying flow within the heat exchange channel. 134. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the heat source and/or heat sink comprising an electric heating element and/or resistance heater. 135. The process of claim 134 wherein the electric heating element and/or resistance heater are in one or more walls of the process microchannel. 136. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the heat source and/or heat sink comprising a non-fluid cooling element. 137. The process of claim 136 wherein the non-fluid cooling element is in one or more walls of the process microchannel. 138. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture comprises at least one liquid hydrocarbon. 139. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture comprises at least one natural oil, synthetic oil, or mixture thereof. 140. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture comprises at least one liquid derived from a vegetable source, a mineral source, or mixture thereof. 141. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture comprises microbodies, the microbodies being hollow. 142. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture comprises microbodies, the microbodies comprising glass microspheres. 143. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein pigment is dispersed in the multiphase mixture. 144. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein a catalyst is dispersed in the multiphase mixture. 145. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein optical or thermal-optical features of the multiphase mixture are adjusted in the process microchannel. 146. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the first fluid stream comprises a liquid stream and the second fluid stream comprises one or more of air, oxygen, nitrogen, carbon dioxide, hydrogen, ammonia, chlorine gas, ozone, one or more gaseous hydrocarbons, or a combination of two or more thereof; or wherein the first fluid stream comprises a liquid waste stream and the second fluid stream comprises air; or wherein the first fluid stream comprises a hazardous waste stream and the second fluid stream comprises air; or wherein the first fluid stream comprises salad dressing or mustard and the second fluid stream comprises nitrogen; or wherein the first fluid stream comprises a liquid beverage or beer and the second fluid stream comprises carbon dioxide; or wherein the first fluid stream comprises a bleaching pulp and the second fluid stream comprises chlorine; or wherein the first fluid stream comprises a dispersion of coal in water and the second fluid stream comprises air; or wherein the first fluid stream comprises motor oil containing entrained water and the second fluid stream comprises nitrogen; or wherein the first fluid stream comprises cells for a fermentation reaction and the second fluid stream comprises oxygen or air; or wherein the first fluid stream comprises a liquid reaction medium and the second fluid stream comprises air or oxygen; or wherein the first fluid stream comprises a reaction medium for conducting a hydrogenation reaction and the second fluid stream comprises hydrogen; or wherein the first fluid stream comprises a mixture of oil and water and the second fluid stream comprises air or natural gas; or wherein the first fluid stream comprises a bleaching pulp and the second stream comprises oxygen; or wherein the first fluid stream comprises an edible oil, wine or juice and the second fluid stream comprises nitrogen; or wherein the first fluid stream comprises water for use in fish farming and the second fluid stream comprises oxygen; or wherein the first fluid stream comprises water and the second fluid stream comprises ozone; or wherein the first fluid stream comprises a waste or process stream and the second fluid stream comprises carbon dioxide or ammonia; or wherein the first fluid stream comprises air and the second fluid stream comprises steam; or wherein the first fluid stream comprises a waste stream containing volatile organic compounds and the second fluid stream comprises air. 147. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the second fluid stream flows from a second fluid stream channel through the apertured section, the second fluid stream channel comprising surface features formed in and/or on one or more interior walls for modifying flow within the second fluid stream channel. 148. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture comprises solid particles dispersed in the first and/or second fluid stream and is in the form of a fluidized bed, the process microchannel comprising surface features formed in and/or on one or more of its interior walls of the process microchannel for modifying flow within the process microchannel. 149. A process for making a multiphase mixture, comprising: flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section; flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase; wherein the multiphase mixture is in the form of a foam.