Modeling the Conditions for Stabilizing Aqueous Phase Evaporation in Highly Stable Water-Hydrocarbon Emulsions Under Mechanical Turbulence to Suppress Unstable Phase Transfer and Reduce Accident Risks

Vast quantities of liquid hydrocarbon and oil-containing wastes are generated and accumulate annually. Dewatering such sludges presents a significant technological challenge due to the high content of emulsified and chemically bound water. Consequently, the development of integrated approaches, particularly thermomechanical methods, have emerged as a promising strategy. These methods aim to disrupt the emulsion stability and enhance water evaporation efficiency. This study provides a theoretical basis for stabilizing the evaporation of the aqueous phase through mechanical agitation within boiling emulsions. A quantitative mathematical model is developed to identify critical conditions that prevent explosive boiling. Under intensive mixing, water globule diameters decrease by 80–85% within the first 5 s, while their settling time exceeds the dispersion time by hundreds of times—effectively inhibiting the accumulation of a critical aqueous-phase mass. Energy analysis reveals that, at a superheat temperature of 110 °C, the maximum permissible droplet diameter is approximately 0.5 mm; at 150 °C, it must not exceed 0.25 mm to avoid explosive boiling. To ensure safe operation, mixer rotational speeds of at least 100–200 rpm are required, with higher speeds (>200 rpm) necessary near 150 °C. The mechanical agitation modes proposed herein enable controlled, non-explosive evaporation of water from complex emulsions. Collectively, these findings lay a theoretical foundation for the industrial-scale deployment of thermomechanical dewatering technologies—offering a safer, more efficient pathway for managing challenging sludge streams.