Modeling the Gradual Evaporation of the Aqueous Phase from Highly Stable Water–Hydrocarbon Emulsions in a Batch Reactor for Thermomechanical Dehydration: A Comparison of Average and Extreme Vapor Formation Rates

In various sectors of the petrochemical and metallurgical industries, significant volumes of waste in the form of highly stable water–hydrocarbon emulsions are generated and stored. The presence of an aqueous phase limits their further use. To utilize this waste and obtain valuable commercial products, a thermomechanical dewatering method based on the evaporation of the aqueous phase under turbulent emulsion flow conditions has been proposed and tested. However, the dynamics of aqueous phase evaporation and vapor phase formation within this method remain poorly understood. This understanding is crucial, as it directly influences the optimal selection of necessary auxiliary equipment. To address this gap, the dynamics of vapor formation during the boiling off of the aqueous phase from highly stable water–hydrocarbon emulsions in a batch thermomechanical dewatering reactor were simulated. To identify general patterns, the gradual evaporation process was calculated as a set of multiple single-effect evaporation steps with a two-degree increment. Initially, modeling results showed that to obtain a commercial product with a water content of less than 1%, temperatures must be maintained at up to 150 °C. This finding was in complete agreement with experimental data, thereby confirming the accuracy of the calculations. Subsequently, extreme vaporization rates were identified, which significantly (1.7–9 times) exceeded the average vapor formation rates in a batch reactor. Maximum vapor formation rates were observed in the temperature range of 100–120 °C. Furthermore, increasing the feedstock water content above 10% was found to significantly prolong the processing time and elevate the maximum vapor formation rate. The patterns presented in this article facilitate the optimization of operating modes for commercial thermomechanical dewatering units, enable the informed selection of necessary auxiliary equipment, and help maintain both the safety and efficiency of the industrial process.