Coiled tube emulsification methods

Abstract

Embodiments of the present technology may include a method of forming an emulsion. The method may include flowing an oil stream and an aqueous stream into a coiled tube to form a mixture of an oil phase and an aqueous phase in the coiled tube. The method may also include flowing the mixture in the coiled tube against gravity and under laminar conditions. A plurality of beads may be disposed within the coiled tube. The method may further include mixing the oil phase and the aqueous phase in the coiled tube until the emulsion is formed.

What is claimed is: 
     
         1 . A method of forming an emulsion, the method comprising:
 flowing an oil stream and an aqueous stream into a coiled tube to form a mixture of an oil phase and an aqueous phase in the coiled tube;   flowing the mixture in the coiled tube against gravity and under laminar conditions, wherein a plurality of beads are disposed within the coiled tube; and   mixing the oil phase and the aqueous phase in the coiled tube until the emulsion is formed.   
     
     
         2 . The method of  claim 1 , wherein:
 the oil stream comprises a biodegradable polymer, and the method further comprising:   diluting the emulsion with additional water, and   forming microparticles from the emulsion.   
     
     
         3 . The method of  claim 2 , wherein:
 the oil stream comprises a physiologically active substance, and   the microparticles comprise the physiologically active substance.   
     
     
         4 . The method of  claim 2 , wherein:
 the oil stream comprises a protein or peptide compound, and   the microparticles comprise the protein or peptide compound.   
     
     
         5 . The method of  claim 4 , wherein the protein or peptide compound comprises insulin, human growth hormone, glucagon-like peptide-1, parathyroid hormone, a fragment of parathyroid hormone, enfuvirtide, or octreotide. 
     
     
         6 . The method of  claim 4 , wherein the protein or peptide compound comprises a protein-PEG conjugate. 
     
     
         7 . The method of  claim 2 , wherein:
 the aqueous stream comprises a physiologically active substance, and   the microparticles comprise the physiologically active substance.   
     
     
         8 . The method of  claim 2 , wherein:
 forming microparticles comprises removing water and solvent from the emulsion.   
     
     
         9 . The method of  claim 1 , further comprising flowing a plurality of oil streams and a plurality of aqueous streams into a plurality of coiled tubes. 
     
     
         10 . The method of  claim 2 , wherein:
 the microparticles comprise a median diameter in a range from 30 to 50 μm.   
     
     
         11 . The method of  claim 1 , wherein:
 flowing the oil stream is at a flow rate in a range from 20 to 100 ml/min, and   flowing the aqueous stream is a flow rate in a range from 100 to 200 ml/min.   
     
     
         12 . The method of  claim 1 , wherein the flowing the mixture in the coiled tube is at a Reynolds number ranging from 0.1 to 10,000. 
     
     
         13 . The method of  claim 1 , wherein:
 the oil stream is a first oil stream,   the aqueous stream is a first aqueous stream,   the coiled tube is a first coiled tube,   the mixture is a first mixture,   the oil phase is a first oil phase,   the aqueous phase is a first aqueous phase,   the plurality of beads is a first plurality of beads, and   the emulsion is a first emulsion, further comprising:   flowing a second oil stream and a second aqueous stream into a second coiled tube to form a second mixture of a second oil phase and a second aqueous phase in the second coiled tube,   flowing the second mixture in the second coiled tube against gravity and under laminar conditions, wherein a second plurality of beads are disposed within the second coiled tube,   mixing the second oil phase and the second aqueous phase in the second coiled tube until a second emulsion is formed, and   mixing the first emulsion and the second emulsion to form a third emulsion.   
     
     
         14 . The method of  claim 13 , wherein:
 the first emulsion comprises a first physiologically active substance,   the second emulsion comprises a second physiologically active substance, and   the first physiologically active substance is different from the second physiologically active substance.   
     
     
         15 . The method of  claim 13 , wherein:
 the first emulsion comprises a physiologically active substance at a first concentration,   the second emulsion comprises the physiologically active substance at a second concentration, and   the first concentration is different from the second concentration.   
     
     
         16 . The method of  claim 13 , further comprising:
 flowing a third oil stream and a third aqueous stream into a third coiled tube to form a third mixture of a third oil phase and a third aqueous phase in the third coiled tube,   flowing the third mixture in the third coiled tube against gravity and under laminar conditions, wherein a third plurality of beads are disposed within the third coiled tube,   mixing the third oil phase and the third aqueous phase in the third coiled tube until a fourth emulsion is formed, and   mixing the fourth emulsion with the first emulsion and the second emulsion to form the third emulsion.   
     
     
         17 . The method of  claim 1 , wherein:
 the mixture is a first mixture, further comprising:   mixing the emulsion with an aqueous solution comprising an emulsifier to form a second mixture, and   evaporating water from the second mixture to form microparticles.   
     
     
         18 . The method of  claim 16 , further comprising:
 removing wastewater, fines, or aggregates from the second mixture using a plurality of screens.   
     
     
         19 . The method of  claim 1 , wherein:
 the coiled tube is coiled around a longitudinal axis, and   the longitudinal axis is vertical.   
     
     
         20 . The method of  claim 1 , wherein the emulsion is characterized by particles having a unimodal particle size distribution profile.