Abstract: A process for preparing a solution of a liquid additive in a liquid base wherein the liquid additive tends to gel when mixed with the liquid base at temperatures less than a gelling temperature TG includes the steps of providing a stream of the liquid base at a temperature TC which is greater than ambient temperature and less than the gelling temperature TG; feeding the stream to a mixer having a mixer inlet so as to impart energy to the stream; and adding the liquid additive to the stream downstream of the inlet, whereby the liquid additive mixes with the liquid base and the energy inhibits gelling of the liquid additive.

Abstract: A process for preparing a bimodal emulsion of viscous hydrocarbon in water includes providing a stream of water at ambient temperature; providing a liquid additive that tends to gel when mixed with water at temperatures less than a gelling temperature TG; heating the stream to provide a heated stream at a temperature TC which is greater than ambient temperature and less than the gelling temperature TG; feeding the heated stream to a mixer having a mixer inlet so as to impart energy to the heated stream; adding the liquid additive to the heated stream downstream of the mixer inlet, whereby the liquid additive mixes with the stream and the energy inhibits gelling of the liquid additive to provide a substantially homogeneous solution of additive in water. The solution is then divided and used to make two different droplet sized emulsions which are mixed to form the bimodal emulsion.

Abstract: A process for preparing a hydrocarbon in water emulsion, comprising the steps of providing a liquid additive that tends to gel when mixed with water at temperatures less than a gelling temperature TG; providing a stream of water at a temperature TC less than the gelling temperature TG; feeding said stream to a mixer having a mixer inlet so as to impart energy to the stream; adding the liquid additive to the stream downstream of the mixer inlet, whereby the liquid additive mixes with the stream and the energy inhibits gelling of the liquid additive so as to provide a substantially homogeneous solution of the liquid additive in the water; and mixing the solution with a hydrocarbon in a mixer so as to form a hydrocarbon-in-water emulsion. In further accordance with the invention, different emulsions can be formed and combined so as to provide a combined emulsion having desired properties.