Continuous process for making an aqueous hydrocarbon fuel emulsion

A process to produce aqueous hydrocarbon fuel comprising emulsifying components comprising:

• (A) a liquid hydrocarbon fuel;
• (B) at least one emulsifier, wherein the emulsifier comprises:
• (i) at least one fuel-soluble product made by reacting at least one hydrocarbyl-substituted carboxylic acid acylating agent with ammonia or an amine, the hydrocarbyl substituent of said acylating agent having about 50 to about 500 carbon atoms;
• (ii) at least one of an ionic or a nonionic compound having a hydrophilic-lipophilic balance (HLB) of about 1 to about 40;
• (iii) a mixture of (ii) with (i);
• (iv) a water-soluble compound selected from the group consisting of amine salts, ammonium salts, azide compounds, nitrate esters, nitramine, nitrocompounds, alkali metal salts, alkaline earth metal salts, in combination with (i), (ii), (iii), (v), (vii) or combinations thereof;
• (v) the reaction product of polyacidic polymer with at least one fuel soluble product made by reacting at least one hydrocarbyl-substituted carboxylic acid acylating agent with ammonia, an amine, a polyamine, or hydroxy alkyl amines;
• (vi) an amino alkylphenol which is made by reacting an alkylphenol, an aldehyde and an amine, resulting in an amino alkylphenol;
• or
• (vii) the combination of (vi) with (i), (ii), (iii), (iv), (v) or combinations thereof;
• (C) a reactant emulsion comprising a water in oil emulsion of a liquid hydrocarbon and at least one emulsifier wherein the liquid hydrocarbon fuel and at least one emulsifier are selected from the group of the same, similar, or different liquid hydrocarbon fuel than the one used in step (A) and at least one emulsifier disclosed in step B;
• and
• (D) a water mixture selected from the group comprising water, water antifreeze, water ammonium salt, water antifreeze ammonium nitrate mixture, and combinations thereof,
• under emulsification conditions wherein the ratio of hydrocarbon fuel, emulsifier and water to reactant emulsion is in the range of about 1% to about 99% by weight hydrocarbon fuel, emulsifier and water to about 99% to about 1% by weight reactant emulsifier and wherein the emulsification shear rate results in an emulsion having a particle size having a mean diameter of less than 1.0 micron.