Conventionally, emulsification has been carried out using both high and low-energy methods. In this work, we developed a novel emulsification method based on steam condensation, which is simple, scalable, and energy efficient. Super-heated steam loses its heat to the organic phase, forming tiny water droplets in the oil phase. We investigated the effects of surfactant and particle stabilizations and applied this method to liquid-liquid extraction and interfacial reactions.

We first discuss continuous production of surfactant-stabilized water in oil emulsions via steam condensation for potential use as a superior fuel in internal combustion engines. The focus then shifted to using shape-anisotropic particles to stabilize emulsions. Hematite particles, made hydrophobic with oleic acid, were found to be effective emulsifiers. An application of this method to liquid-liquid extraction in a helical tube using the steam condensation method, and its comparison to classical extraction method is then analysed. Finally, we show how this method can be used to synthesize polyurea capsules through interfacial polymerization. These capsules have various applications, including targeted drug delivery and cosmetics.