Emulsified feedstock for hydrocarbon process units that incorporate spray atomization

The present invention is directed to a method for producing an emulsified aqueous hydrocarbon solution comprising, providing a liquid hydrocarbon stream at a particular temperature and a separate water stream, mixing the water stream with a surfactant at a predetermined ratio, raising the pressure of the hydrocarbon stream to a pressure greater than the vapor pressure of steam at the temperature, spraying the water into the hydrocarbon stream at a pressure greater than that of the hydrocarbon stream in a pre-mix chamber; and passing the pressurized hydrocarbon-water mixture through a static mixing chamber.