Two-phase separator device incorporating inertial separation and porous media extraction

Abstract

Disclosed herein are phase separator devices and related methods of manufacture and use. The present disclosure provides improved phase separator devices for phase separation of an input feed, as well as systems / methods for utilizing and manufacturing the devices. The present disclosure provides phase separator devices that utilize inertial separation and porous media extraction for phase separation of a two-phase input feed (e.g., to separate a two-phase mixture input feed into a first phase output (e.g., a liquid output stream) and a second phase output (e.g., a gas output stream)). The devices can separate both liquid and gas mixed fluid streams. The liquid and gas can include liquid and vapor phases of the same chemical / component (e.g., ammonia) or can include liquid and gas phases of two different components (e.g., liquid water and air). The phase separator devices can be utilized in standard, micro, and zero gravity environments.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to (i) a provisional application having assigned serial number 62 / 928,912, filed October 31, 2019, and (ii) a provisional application having assigned serial number 63 / 010,299, filed April 15, 2020. The entire contents of both of the foregoing provisional applications are incorporated herein by reference.

[0002] The present disclosure relates to phase separator devices for phase separation of an input feed and systems / methods for utilizing and manufacturing phase separator devices, and more particularly to phase separator devices that utilize inertial separation and porous media extraction for phase separation of a two-phase input feed (e.g., to separate the input feed of a two-phase mixture into a first phase output (e.g., into a liquid output stream) and a second phase output (e.g., into a gas output stream)). [Background technology]

[0003] In general, there are numerous applications for structures and assemblies for phase separation of input feeds.

[0004] There is interest in improved systems and methods for phase separation of input feeds.

[0005] These and other inefficiencies and opportunities for improvement are addressed and / or overcome by the systems, methods and devices of the present disclosure. Summary of the Invention

[0006] The present disclosure provides advantageous phase separator devices for phase separation of an input feed, as well as improved systems / methods for utilizing and manufacturing the phase separator devices. More specifically, the present disclosure relates to phase separator devices that utilize inertial separation and porous media extraction for phase separation of a two-phase input feed (e.g., to separate the input feed of a two-phase mixture into a first phase output (e.g., into a liquid output stream) and a second phase output (e.g., into a gas output stream)). The phase separator devices can be utilized in standard gravity, microgravity, and zero gravity environments.

[0007] The present disclosure provides a phase separator device including: a housing extending from a first end to a second end, the housing having one or more first openings through which a first phase output exits and one or more second openings through which a second phase output exits; and one or more guide vanes disposed in the housing, the housing including an axial cyclone separating section and a porous media section, the axial cyclone separating section and the porous media section configured and dimensioned to separate an input feed introduced into the housing into a first phase output and a second phase output.

[0008] The present disclosure provides a phase separator device comprising one or more extractor elements disposed in a housing, the housing having an inlet for an input feed, a first outlet for a first phase output, and a second outlet for a second phase output, each extractor element comprising a threaded rod housed in a porous media tube, the one or more extractor elements configured and dimensioned to separate an input feed introduced at the inlet into the first phase output and the second phase output.

[0009] The present disclosure provides a phase separator device including: a housing extending from a first end to a second end, the housing having one or more first openings through which a first phase output exits and one or more second openings through which a second phase output exits; and one or more guide vanes disposed in the housing, the housing including a counter-flow cyclone separating section and a porous media section, the counter-flow cyclone separating section and the porous media section configured and dimensioned to separate an input feed introduced into the housing into a first phase output and a second phase output.

[0010] The above-described and other features are illustrated by the following drawings and detailed description.

[0011] Any combination or permutation of embodiments is contemplated. Additional advantageous features, functions, and applications of the disclosed systems, methods, and devices of the present disclosure will become apparent from the following description, particularly when read in conjunction with the accompanying drawings. All references cited in this disclosure are incorporated herein by reference in their entirety.

[0012] The following figures are exemplary embodiments in which like elements are similarly numbered.

[0013] Features and aspects of the embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily drawn to scale.

[0014] Exemplary embodiments of the present disclosure are further described with reference to the accompanying drawings. It should be noted that the various features, steps, and combinations of features / steps described below and illustrated in the drawings can be arranged and organized differently to result in embodiments that are still within the scope of the present disclosure. Reference is made to the accompanying drawings to assist those skilled in the art in making and using the disclosed systems, methods, and devices. [Brief explanation of the drawings]

[0015] [Figure 1] 1 illustrates inertial separation for cyclone separation of a denser phase from a lighter gas phase. [Figure 2] FIG. 1 is a diagram of an axial flow separator. [Figure 3] FIG. 1 is a diagram of one stage of a five-stage cascade axial cyclone. [Figure 4] Component images for one stage of a five-stage cascade axial cyclone. [Figure 5] Particle separation (collection efficiency) is shown as a function of particle size for each stage of a five-stage cascade axial cyclone. [Figure 6] FIG. 1 is a diagram of an exemplary phase separator device (e.g., a two-phase axial flow cyclone separator device with an axial inlet for the input feed) according to the present disclosure. [Figure 7] FIG. 7 is another view of the phase separator device of FIG. 6. [Figure 8] FIG. 2 is a diagram of another exemplary phase separator device (e.g., a two-phase axial flow cyclone separator device with a tangential inlet for the input feed) according to the present disclosure. [Figure 9] FIG. 2 is a diagram of another exemplary phase separator device (e.g., a two-phase counter-flow cyclone separator device with a tangential inlet for the input feed) according to the present disclosure. [Figure 10] FIG. 2 is a diagram of another exemplary phase separator device (e.g., a two-phase counter-flow cyclone separator device with an axial inlet for the input feed) according to the present disclosure. [Figure 11] FIG. 11 is another view of the phase separator device of FIG. [Figure 12] A radial / spiral flow path element designed to separate and extract one phase (e.g., liquid) from a two-phase input feed (e.g., a two-phase fluid input feed such as liquid and vapor). [Figure 13] FIG. 1 is another exemplary phase separator device of the present disclosure, showing a cross-sectional view showing a two-phase inlet on the left, a first phase outlet (e.g., vapor phase outlet) on the right, and a second phase outlet (e.g., liquid phase outlet) on the top, where a central housing contains multiple (e.g., 31) parallel flow paths for fluid flow and separation. [Figure 14A] 14A-14C are additional drawings showing other views of the exemplary phase separator device of FIG. 13 utilizing multiple (e.g., 31) parallel flow separator elements within the separator main housing; and FIG. 14B are views of a phase separator device utilizing a radial / swirl liquid extractor. [Figure 14B] 14A-14C are additional drawings showing other views of the exemplary phase separator device of FIG. 13 utilizing multiple (e.g., 31) parallel flow separator elements within the separator main housing; and FIG. 14B are views of a phase separator device utilizing a radial / swirl liquid extractor. [Figure 14C] 14A-14C are additional drawings showing other views of the exemplary phase separator device of FIG. 13 utilizing multiple (e.g., 31) parallel flow separator elements within the separator main housing; and FIG. 14B are views of a phase separator device utilizing a radial / swirl liquid extractor. [Figure 14D] 14A-14C are additional drawings showing other views of the exemplary phase separator device of FIG. 13 utilizing multiple (e.g., 31) parallel flow separator elements within the separator main housing; and FIG. 14B are views of a phase separator device utilizing a radial / swirl liquid extractor. [Figure 14E] 14A-14C are additional drawings showing other views of the exemplary phase separator device of FIG. 13 utilizing multiple (e.g., 31) parallel flow separator elements within the separator main housing; and FIG. 14B are views of a phase separator device utilizing a radial / swirl liquid extractor. [Figure 15] FIG. 14 shows an isometric view of the phase separator device of FIG. 13. [Figure 16] 1 is another exemplary phase separator device according to the present disclosure. [Figure 17] 1 shows a porous medium within a spiral cavity of a phase separator device according to the present disclosure. [Figure 18] 1 illustrates a spiral passage of a phase separator device according to the present disclosure. [Figure 19] 1 illustrates the orientation of the inlet and outlet of a phase separator device according to the present disclosure. [Figure 20] 1 shows a schematic diagram of an exemplary custom test stand. [Figure 21]10 is a graph showing predicted gas phase pressure drop versus quality calculated using analytical model and experimentally measured values ​​for Design A. [Figure 22] 1 is a graph showing predicted liquid phase pressure drop versus quality calculated using analytical model and experimentally measured values ​​for Design A. [Figure 23] 10 is a graph showing predicted gas phase pressure drop versus quality calculated using analytical model and experimentally measured values ​​for Design C. [Figure 24] 1 is a graph showing predicted liquid phase pressure drop versus quality calculated using an analytical model and experimentally measured values. DETAILED DESCRIPTION OF THE INVENTION

[0016] The exemplary embodiments disclosed herein illustrate advantageous phase separator devices and systems, and methods / techniques thereof, of the present disclosure. However, it should be understood that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Therefore, the details disclosed herein with reference to exemplary phase separator devices and related processes / techniques of assembly and application are not intended to be limiting and should be construed merely as a basis for teaching those skilled in the art how to make and use advantageous phase separator devices and / or alternative phase separator devices of the present disclosure.

[0017] The present disclosure provides advantageous phase separator devices for phase separation of input feeds, as well as improved systems / methods for utilizing and manufacturing the phase separator devices.

[0018] More specifically, the present disclosure relates to a phase separator device that utilizes inertial separation and porous media extraction for phase separation of a two-phase input feed (e.g., to separate the input feed of a two-phase mixture into a first phase output (e.g., into a liquid output stream) and a second phase output (e.g., into a gas output stream)). The phase separator device can be utilized in standard gravity, microgravity, and zero gravity environments.

[0019] An exemplary phase separator device (e.g., a two-phase flow separator device) of the present disclosure incorporates inertial separation and porous media extraction. The device separates a two-phase input feed (e.g., a two-phase fluid stream) into a first phase output and a second phase output (e.g., a fluid output stream for each phase). In certain embodiments, the device can separate mixed fluid streams of both liquid and gas. The liquid and gas may comprise liquid and vapor phases of the same chemical / component (e.g., ammonia) or may comprise liquid and gas phases of two different components (e.g., liquid water and air).

[0020] The two-phase input feed (eg, the two-phase input stream) may be at room temperature (eg, about 20-25 degrees Celsius) or may be at some other operating temperature.

[0021] The two-phase input feed / stream can be at atmospheric pressure (e.g., nominally 1 atmosphere), or can be at a higher or lower pressure. For example, the exemplary phase separator device may be utilized for the separation of a two-phase input / stream / mixture flowing or input as a compressed fluid in a partial or fully closed loop system.

[0022] The two-phase flow / input can be in standard gravity, microgravity, or zero gravity environments. Note that separation, capture, and extraction of the liquid (or solid) phase can be much more complicated in microgravity to zero gravity environments, as gravity (the force of Earth's gravitational pull) typically cannot be used in such separation, capture, and extraction processes.

[0023] In an exemplary embodiment, the role of the phase separator device is to achieve separation of the first and second phases (e.g., liquid and gas phases) by utilizing the only difference between the properties of the first phase output (e.g., liquid output) and the second phase output (e.g., gas component) in a two-phase input / mixture, particularly by employing, for example, differences in density and / or capillary forces.

[0024] In certain embodiments, of interest is the separation and capture of the liquid phase. There are several approaches / techniques that can be employed to separate the liquid, including (i) cooling the two-phase mixture to condense the fluids, (ii) using demisters, (iii) using inertial separators such as cyclones or impactors, and (iv) using wicks to extract the liquid phase.

[0025] With respect to inertial separation, it is noted that separation of a second phase (e.g., a gas phase) from a first phase (e.g., a liquid phase and / or a solid phase) can be achieved via inertial properties to separate a denser phase (e.g., a liquid phase and / or a solid phase) from a lighter phase (e.g., a gas phase) in an incoming input feed (e.g., an incoming two-phase fluid stream).

[0026] The effectiveness of inertial separation increases with increasing mass (density) of the denser phase (e.g., liquid droplets or solid particles) relative to the lighter phase (e.g., gas density). This effectiveness also increases with decreasing gas viscosity. Inertial separation techniques can be utilized in devices such as cyclones, centrifuges, impactors, and particle collectors.

[0027] Referring now to the drawings, wherein like parts are respectively designated with the same reference numerals throughout the specification and drawings, the drawings are not necessarily to scale and in certain drawings parts may be exaggerated for purposes of clarity.

[0028] As shown in Figure 1, separation effectiveness is increased by increasing the inertia of the denser phase (e.g., liquid or solid particles) in the separation device by increasing its velocity. Furthermore, separation is also increased in cyclone separation by decreasing the radius of curvature in the fluid passage (e.g., decreasing the radius of the separator housing).

[0029] With respect to axial flow separators (e.g., axial flow cyclones), it is noted that an axial flow cyclone design is illustrated in FIG. 2. The function of an axial flow cyclone is to separate a denser phase (e.g., liquid or solid particles such as dust) present in an incoming input feed (e.g., incoming gas stream) from the feed, provide a cleaned lighter output phase (e.g., gas stream or clean gas), and provide a denser output (e.g., liquid or solid particle stream). In an axial flow cyclone, the incoming input feed (e.g., gas stream) and the cleaned lighter phase output (cleaned gas stream) can be on the same axis, with the gas stream entering and exiting in the same direction. Some major components of an axial flow cyclone are a cylindrical housing, one or more guide vanes, and an outlet passage (opening) for the cleaned gas and separated liquid or solid particles.

[0030] Axial cyclone technology is primarily employed in products for the separation of particles (solid or liquid) from gas streams in industrial applications, or air intakes for engines and buildings. Axial cyclones remove larger particles in the incoming gas stream for subsequent collection and application. In other applications, axial cyclones remove a portion of the particles in the gas stream and act as a pre-cleaner for further particle collection (e.g., a filter), thereby extending the life of the filter.

[0031] Figures 3 and 4 show the design of one stage of a five-stage cascade axial cyclone used to collect solid particles (e.g., dust) for subsequent use in particle size fractionation samples. Figure 5 shows particle separation (collection efficiency) as a function of particle size for each stage of the five-stage cascade axial cyclone. In this example, the five stages were able to achieve separation and collection of particles as small as 1 micrometer. The collection efficiency for each stage was achieved by varying the guide vane pitch angle and the inner and outer diameters of the guide vanes and cyclone housing.

[0032] 6 illustrates an exemplary design and configuration of an embodiment of a phase separator device 10 (e.g., a two-phase axial flow cyclone separator device 10) for an input feed 11 (e.g., for a liquid / gas mixture input feed 11). As shown in FIG. 6, the device 10 takes the form of a two-phase axial flow cyclone separator device 10 with an axial inlet 13 for the input feed 11. Thus, the phase separator device 10 is configured and dimensioned to be utilized for phase separation of the input feed 11 (two-phase mixture 11) into a first phase output 12 (e.g., into a liquid output stream 12) and a second phase output 14 (e.g., into a gas output stream 14).

[0033] More specifically, the phase separator device 10, discussed further below, includes a housing 16 extending from a first end to a second end, the housing 16 having one or more first openings through which the first phase output 12 exits and one or more second openings through which the second phase output 14 exits. One or more guide vanes 24 are disposed within the housing 16 of the phase separator device 10. As noted above, the device 10 includes an axial inlet 13 for the input feed 11. FIG. 7 shows another depiction of the phase separator device 10 of FIG. 6 (e.g., a two-phase axial flow cyclone separator device 10 with an axial inlet 13 for the input feed 11).

[0034] In general, phase separator device 10 is configured and dimensioned to separate a darker phase (e.g., a liquid phase) present in input feed 11 from incoming input feed 11 and provide a cleaned lighter phase output 14 (e.g., second phase output 14) and a darker output 12 (e.g., a liquid stream in first phase output 12). Incoming input feed 11 and outgoing cleaned second phase output 14 may be coaxial with the incoming and outgoing gas streams / input feed 11 in the same traveling direction.

[0035] The design of the exemplary phase separator device 10 can utilize two distinct sections, and may utilize a third section, to accomplish the separation, collection, and extraction of the first phase output 12 (liquid phase) from the second phase output 14 (gas phase). These sections may include an axial flow cyclone separation section 18, an optional liquid collection section 20 prior to a porous media section 22, and / or a porous media section 22 for liquid extraction.

[0036] The role of the porous media section 22 is to form a porous barrier that performs at least three important functions. First, section 22 acts as a barrier to allow liquid accumulation and provides physical support for the layer of liquid accumulation. Second, the pressure drop across this liquid layer and porous membrane 22 prevents gas flow to the liquid outlet because the pressure drop is much lower in the gas (vapor) outlet passage. Third, the porous media section 22 allows the flow of accumulated liquid to be extracted through the liquid outlet. Liquid can be extracted via a suction pump located downstream of the liquid outlet and / or can utilize upstream pressure in a pressurized system.

[0037] The porous media section 22 may be located in one or more locations in the axial flow separator device 10. As illustrated in Figure 6, the porous media section 22 is located at the bottom, e.g., wall or bottom, of the annular collection section located downstream of the guide vanes 24. The porous media section 22 may also be located in the wall of the cylindrical housing 16 adjacent to or just downstream from the vanes.

[0038] The porous media section 22 can be made from several types of porous materials, including, but not limited to, porous metals, polymeric membranes, foams, fibrous materials, polymers, ceramics, and / or glass. The porous metals can be made from several metal alloys, including, but not limited to, nickel, cobalt, iron, copper, aluminum, palladium, titanium, tungsten, platinum, silver, gold, and stainless steels, as well as nickel-based steels such as Hastelloy® (Haynes Stellite Company, Kokomo, Indiana).

[0039] The average pore size of the porous media section 22 can be as low as 0.1 microns and as high as 100 microns (eg, depending on fluid conditions, temperature, and / or fluid viscosity).

[0040] In some embodiments, the inner diameter of the cyclone housing 16 can range from about 0.5 to about 20 inches.

[0041] In certain embodiments, two or more parallel axial flow separator devices 10 may be employed in a parallel arrangement which may be required to split the incoming mixed two-phase flow 11 into two or more parallel flows.

[0042] 8, the device 10′ takes the form of a two-phase axial flow cyclone separator device 10′ with a tangential inlet 15 for the input feed 11. The phase separator device 10′ with the tangential inlet 15 is thus configured and dimensioned to be utilized for phase separation of the input feed 11 (two-phase mixture 11) into a first phase output 12 (e.g., into a liquid output stream 12) and a second phase output 14 (e.g., into a gaseous output stream 14).

[0043] Similar to device 10, phase separator device 10' includes a housing 16 extending from a first end to a second end, the housing 16 having one or more first openings through which first phase outputs 12 exit and one or more second openings through which second phase outputs 14 exit. One or more guide vanes 24 may be disposed within the housing 16 of phase separator device 10'. As noted above, device 10' includes a tangential inlet 15 for input feed 11.

[0044] Similar to the operation of device 10, phase separator device 10′ is configured and dimensioned to separate a darker phase (e.g., a liquid phase) present in input feed 11 from incoming input feed 11 and provide a cleaned lighter phase output 14 (e.g., second phase output 14) and a darker output 12 (e.g., a liquid stream in first phase output 12). Incoming input feed 11 and outgoing cleaned second phase output 14 may be on different axes, with the gas stream / input feed 11 entering via tangential inlet 15 tangent to the axis exiting cleaned second phase output 14. As similarly discussed with respect to device 10, device 10′ with tangential inlet 15 may include an axial cyclone separation section 18, an optional liquid collection section 20 prior to porous media section 22, and / or a porous media section 22 for liquid extraction. As also discussed, the porous media section 22 of the device 10' may be located in one or more locations in the device 10', and the porous media section 22 may be fabricated from several types of porous materials.

[0045] It should be noted that exemplary cyclone separator devices of the present disclosure (e.g., devices 10, 10', 300, 300') can be categorized based on their fluid inlet configurations (13, 15, 313, 315) and the overall flow path through the cyclone separator device. Figures 7-10 show four exemplary combinations of inlet designs (13, 15, 313, 315) and flow directions for the input (11, 311) and output (12, 14, 312, 314) fluid flows. Figures 9-10 are discussed in further detail below.

[0046] These four exemplary combinations of Figures 7-10 may be referred to as (i) axial inlet axial flow cyclone separator device 10 (Figure 7), (ii) tangential inlet axial flow cyclone separator device 10' (Figure 8), (iii) axial inlet counter flow cyclone separator device 300 (Figure 10), and (iv) tangential inlet counter flow cyclone separator device 300' (Figure 9).

[0047] It should be noted that there are numerous sub-variations of these four exemplary configurations, as depicted in Figures 7-10. For example, one potential set of sub-variations can address the location of the outlets (12, 14, 312, 314) for the separated material. For example, but not limited to, these outlets can be axially located at the bottom or sidewall near the bottom end of the cyclone separator device (e.g., 12, 14, 312).

[0048] With reference to the axial inlet 13, 313 and the tangential inlet 15, 315, it is noted that both of these inlet configurations create the high velocity swirling motion required to separate, via centripetal force, the higher mass components contained in the incoming mixed fluid stream 11, 311. For example, these inlet configurations may be (i) a tangential inlet (15, 315 in FIGS. 8 and 9) where the incoming fluid stream 11, 311 enters tangentially into the top of the cylindrical cyclone separator device 10′, 300′, and (ii) an axial inlet (13, 313 in FIGS. 7 and 10) where the incoming fluid stream 11, 311 passes through a set of swirling (guide) vanes 24.

[0049] The overall flow paths through exemplary separator devices may be classified as: (i) axial flow (devices 10, 10' of Figures 7 and 8), and (ii) counter-flow (devices 300, 300' of Figures 9 and 10).

[0050] In an axial flow separator configuration (devices 10, 10' of Figures 7 and 8), the incoming fluid stream 11 and the outgoing cleaned / separated fluid stream 14 may be coaxial with the outgoing gas / input stream 11 and cleaned / separated stream 14 in the same traveling direction. In a counter-flow separator configuration (devices 300, 300' of Figures 9 and 10), the flow path of the cleaned / separated fluid 314 undergoes a 180 degree reversal in its axial flow direction as the fluid 314 enters the lower portion of the separator housing 316 and then exits in the opposite direction through an outlet tube located in the upper section of the separator device 300, 300'.

[0051] It should be noted that each of these four exemplary cyclone separator device configurations 10, 10', 300, 300' can be combined with porous media 22, 322 to produce an advantageous two-phase separator device 10, 10', 300, 300' as provided by the present disclosure.

[0052] 6 and 10 / 11 illustrate two examples of two design embodiments of a two-phase flow cyclone separator device 10, 300 (e.g., for liquid / gas mixtures). Both designs 10, 300 utilize two distinct sections, and may utilize a third to achieve separation, collection, and extraction of the liquid phase from the gas phase. These sections may include a cyclone separation section 18 (axial flow), 318 (counterflow), an optional liquid collection section 20, 320 prior to the porous media section 22, 322, and / or a porous media section 22, 322 for liquid extraction with a liquid extraction section below the porous media section 22, 322.

[0053] In an embodiment, as shown in Figures 10 and 11, an exemplary phase separator device 300 (e.g., a two-phase counter-flow cyclone separator device 300 with an axial inlet 313 for the input feed) utilizes radial flow swirl (guide) vanes 324 coupled with the design of the counter-flow cyclone separator device 300. Figure 11 illustrates such a configuration. As discussed further below, it should be noted that device 300 includes several similar components to device 10, and that such similar components of device 300 can function in a similar manner as such similar components of device 10.

[0054] The primary difference between device 300 relative to device 10 is the location for the exit of the gas phase (314) and liquid phase (312). In a counterflow design (e.g., two-phase counterflow cyclone separator device 300 with an axial inlet 313 for the input feed) as depicted in FIGS. 10 and 11, the gas undergoes a reversal of its flow direction (e.g., a 180-degree turn), thereby exiting in the opposite direction of the incoming fluid 311. The separated liquid stream 312 now passes through a porous media section 322 (e.g., a section 322 shaped as a disk rather than an annular-shaped porous media 22), which can be located at the bottom or side of the housing 316. In either case, a porous media membrane 322 is utilized to form an imperious barrier to the vapor and support the liquid layer 320.

[0055] As noted above, Figure 11 illustrates an exemplary design and configuration of an embodiment of a phase separator device 300 (e.g., a two-phase counter-current separator device 300) for an input feed (e.g., for an input feed of a liquid / gas mixture). As shown in Figure 11, device 300 takes the form of a two-phase counter-current cyclone separator device 300 with an axial inlet 313 for input feed 311. Phase separator device 300 is therefore configured and dimensioned to be utilized for phase separation of input feed 311 (two-phase mixture 311) into a first phase output 312 (e.g., into a liquid output stream 312) and a second phase output 314 (e.g., into a gas output stream 314).

[0056] More specifically, the phase separator device 300, discussed further below, includes a housing 316 extending from a first end to a second end, the housing 316 having one or more first openings through which the first phase output 312 exits and one or more second openings through which the second phase output 314 exits. One or more swirl (guide) vanes 324 positioned in series are disposed within the housing 316 of the phase separator device 300.

[0057] In general, phase separator device 300 is configured and dimensioned to separate a darker phase (e.g., a liquid phase) present in input feed 311 from the incoming input feed 311 and provide a cleaned lighter phase output 314 (e.g., second phase output 314) and a darker output 312 (e.g., a liquid stream in first phase output 312). The incoming input feed 311 and cleaned second phase output 314 can be on the same axis as the gas / input feed 311; however, the input feed 311 and output 314 exit in opposite directions.

[0058] The design of the exemplary phase separator device 300 can utilize two distinct sections, and may utilize a third section, to achieve separation, collection, and extraction of the first phase output 312 (liquid phase) from the second phase output 314 (gas phase). These sections can include a countercurrent cyclone separation section 318, an optional liquid collection section 320 prior to a previous media section 322, and / or a porous media section 322 for liquid extraction.

[0059] The exemplary device 300 may utilize an optional conical skirt 328. This skirt is located on the outside of the gas outlet tube 326 and below the swirler vanes 324. One or more skirts 328 may be incorporated into the design of the device 300. The function of the skirt is to improve liquid separation efficiency by directing the liquid against the outer wall of the separator housing 316 and away from the inlet and into the gas outlet tube. Note that devices 10, 10', 300' may also utilize an optional conical skirt similar to conical skirt 328.

[0060] Similar to the device 10 discussed above, the design of the exemplary phase separator device 300 can utilize two distinct sections, and may utilize a third section, to achieve separation, collection, and extraction of the first phase output 312 (liquid phase) from the second phase output 314 (gas phase). These sections can include a countercurrent cyclone separation section 318, an optional liquid collection section 320 prior to a porous media section 322, and / or a porous media section 322 for liquid extraction.

[0061] Similar to section 22, the role of porous media section 322 is to form a porous barrier that performs at least three important functions. First, section 322 acts as a barrier to allow liquid accumulation and provides physical support for the layer of liquid accumulation. Second, the pressure drop across this liquid layer and porous membrane 322 prevents gas flow to the liquid outlet because the pressure drop is much lower in the gas (vapor) outlet passage. Third, porous media section 322 allows the flow of accumulated liquid to be extracted through the liquid outlet. Liquid can be extracted via a suction pump located downstream of the liquid outlet and / or can utilize upstream pressure in a pressurized system.

[0062] The porous medium section 322 may be located in one or more locations in the axial flow separator device 300. As shown in Figure 11, the porous medium section 322 is located at the bottom, e.g., at the wall or bottom, and is located downstream of the guide vanes 324. It should be noted that the exemplary section 322 may be formed as a disk or the like, although the disclosure is not limited thereto. The porous medium section 322 may also be located / located at and / or beyond the wall of the cylindrical housing 316 adjacent to or just downstream from the vanes.

[0063] The porous media section 322 can be made from several types of porous materials, including, but not limited to, porous metals, polymeric membranes, foams, fibrous materials, polymers, ceramics, and / or glass. The porous metals may be made from several metal alloys, including, but not limited to, nickel, cobalt, iron, copper, aluminum, palladium, titanium, tungsten, platinum, silver, gold, and stainless steels, as well as nickel-based steels such as Hastelloy® (Haynes Stellite Company, Kokomo, Indiana).

[0064] The average pore size of the porous media section 322 can be as low as 0.1 microns and as high as 100 microns (eg, depending on fluid conditions, temperature, and / or fluid viscosity).

[0065] In some embodiments, the inner diameter of the cyclone housing 316 can range from about 0.5 to about 20 inches.

[0066] In certain embodiments, two or more parallel axial flow separator devices 300 may be employed in a parallel arrangement that may be required to split the incoming mixed two-phase flow 311 into two or more parallel flows.

[0067] 9, the device 300′ takes the form of a two-phase counter-flow cyclone separator device 300′ with a tangential inlet 315 for the input feed 311. The phase separator device 300′ with the tangential inlet 315 is thus configured and dimensioned to be utilized for phase separation of the input feed 311 (two-phase mixture 311) into a first phase output 312 (e.g., into a liquid output stream 312) and a second phase output 314 (e.g., into a gaseous output stream 314).

[0068] Similar to device 300, phase separator device 300′ includes a housing 316 extending from a first end to a second end, the housing 316 having one or more first openings through which first phase outputs 312 exit and one or more second openings through which second phase outputs 314 exit. One or more guide vanes 324 may be disposed within the housing 316 of phase separator device 300′. As noted above, device 300′ includes a tangential inlet 315 for input feed 311.

[0069] Similar to the operation of device 300, phase separator device 300′ is configured and dimensioned to separate a darker phase (e.g., a liquid phase) present in input feed 311 from incoming input feed 311 and provide a cleaned lighter phase output 314 (e.g., second phase output 314) and a darker output 312 (e.g., a liquid stream in first phase output 312). Incoming input feed 311 and outgoing cleaned second phase output 314 may be on different axes, with the gas stream / input feed 311 entering via tangential inlet 315 tangent to the axis exiting cleaned second phase output 314. As similarly discussed for device 300, device 300′ with tangential inlet 315 may include a countercurrent cyclone separation section 318, an optional liquid collection section 320 prior to porous media section 322, and / or a porous media section 322 for liquid extraction. As also discussed, the porous media section 322 of the device 300' may be located in one or more locations in the device 300', and the porous media section 322 may be fabricated from several types of porous materials.

[0070] FIG. 12 shows a radial / spirally wound liquid phase extractor element 128. FIG. 12 shows the element 128 used to separate the liquid phase from the flowing two-phase fluid 111 (liquid and vapor input 111—FIG. 13). In an exemplary embodiment, a threaded rod 124 can be taken and enclosed in a porous media tube 126. The two-phase fluid 111 follows the spiral flow path shown in FIG. 12, and inertial energy due to the circular flow path causes the denser fluid (e.g., liquid) to move radially outward and the less dense fluid (e.g., vapor) to move inward. This separation places the liquid phase in intimate contact with the porous tube 126, etc. A pressure differential is then applied between the inner flow path of the porous tube 126 and the outer volume, causing liquid flow through the porous tube 126. The magnitude of this pressure differential, the diameter and length of element 128, the thread pitch and groove dimensions, the wetted surface area, thickness and density, and the average pore size of tube 126 can all be adjusted to provide near 100% efficiency in capturing the liquid phase and extracting it from element 128.

[0071] In exemplary embodiments, the diameter of the threaded component 124 can be very small (on the order of 1 / 16 inch) to very large (several feet), depending on the flow rate of the two-phase fluid and the allowable pressure drop. The thickness of the porous tube 126 can range from 0.10 inches to several inches, depending on the application. The average pore size in the tube 126 can be as low as 0.1 microns and as high as 100 microns, depending on the flow conditions, temperature, and / or fluid viscosity.

[0072] For embodiments disclosed herein, the dimensions of the spiral channel and porous media may remain constant along the length of the channel. It is recognized that improved separation performance can be obtained by varying the dimensions of the spiral channel, including the cross-section and pitch along the fluid flow path. Additionally, the thickness of the porous media can also be adjusted along the length of the channel to improve phase separation. For embodiments disclosed herein, the porous media may have a constant average pore size and density, and further optimization of performance can be achieved using a gradient pore size distribution within the porous media.

[0073] 13, to utilize a liquid extraction element 128 (or multiple elements 128), the element 128 can be inserted into a housing 116 that provides one inlet for the input feed 111 (liquid-vapor mixture feed 111) and two outlets, one for the first phase output 112 (e.g., liquid output) and one for the second phase output 114 (e.g., vapor). Each element 128 of the phase separator device 100 directs the two-phase fluid 111 entering the inlet for feed 111 to flow into a spiral flow path at one end (the input 111 end) of each element 128. A vapor outlet for the second phase output 114 of the device 100 can be connected to the opposite end of each element 128. A second outlet for the first phase output 112 (e.g., liquid) can be attached to the housing 116 surrounding each element 128, and the second outlet for the first phase output 112 (e.g., liquid) can receive the liquid phase flowing through the various porous media 126.

[0074] The porous media 126 can be made from several types of porous materials, including, but not limited to, porous metals, polymeric membranes, foams, fibrous materials, polymers, ceramics, and / or glass. The porous metals can be materials from several metal alloys, including, but not limited to, nickel, cobalt, iron, copper, aluminum, palladium, titanium, tungsten, platinum, silver, gold, and stainless steels, as well as nickel-based steels such as Hastelloy® (Haynes Stellite Company, Kokomo, Indiana).

[0075] The device 100 may include a single element 128 as described above, or the device 100 may include multiple elements 128 in either a series and / or parallel flow path configuration. Depicted in Figure 13 is such an exemplary device 100 including 31 liquid phase separator elements 128, the elements 128 being in a parallel flow path configuration.

[0076] FIG. 16 shows a phase separator device 200 used to separate phases from a flowing two-phase fluid 211 (liquid and vapor). The design is a spiral passage, possibly with a variable surface area, with one surface of the passage being a porous medium, as shown in FIG. 17. The mixed-phase fluid 211 enters the spiral passage tangentially, as shown in FIGS. 16 and 19. The two-phase fluid 211 follows the spiral flow path shown in FIG. 18, with only the liquid phase exiting the spiral passage tangentially via output 212. The centripetal force of the circular flow path causes the denser fluid (liquid) with more inertia to move radially outward, thus displacing the less dense fluid (vapor) with more inertia inward. This separation places the gas phase in intimate contact with the porous medium. The other side of the porous medium provides a pressure differential that allows the gas, at a lower pressure, to flow through the porous medium. The gas phase exits at both ends via output 214, spiraling along the central axis and is collected via additional piping (not shown).

[0077] The diameter, length, convolution pitch, convolution dimensions, thickness, density, and average pore size of the porous medium of the device 200 can be varied based on the application of the device 200 and the requirements of the input / fluid 211 to be separated.

[0078] The porous media of device 200 can be made from several types of porous materials, including, but not limited to, porous metals, polymeric membranes, foams, fibrous materials, polymers, ceramics, and / or glasses. Porous metals can also be materials from several metal alloys, including, but not limited to, nickel, cobalt, iron, copper, aluminum, palladium, titanium, tungsten, platinum, silver, gold, and stainless steels, as well as nickel-based steels such as Hastelloy® (Haynes Stellite Company, Kokomo, Indiana). [Example]

[0079] The following examples are merely illustrative of the phase separator devices disclosed herein and are not intended to limit the scope thereof. Note that surrogate fluid testing of exemplary proposed designs utilizing inertial separation with a porous media vapor barrier verified the feasibility of liquid / vapor phase separation. This was the primary objective of this project phase, and therefore the exemplary project was successful. The performance of both Designs A and C (discussed below) exceeded the minimum performance specifications for this exemplary project phase, which were greater than 75% liquid capture efficiency and less than 5 PSID pressure drop for each fluid path.

[0080] The counter-flow cyclone (Design A) provided the highest liquid capture efficiency of the three designs evaluated. Measured liquid capture efficiencies ranged from 93% to 100%, depending on quality factors. This design also provided the lowest pressure drop across the separator, with a pressure drop of less than 1 PSID for both the liquid and gas flow paths.

[0081] The liquid extractor (design C) performed similarly to design A with the same low pressure drop across the gas flow path. This design showed slightly lower liquid capture efficiency at 40% and 50% quality and had a higher liquid pressure drop.

[0082] The gas extractor (design B) did not perform well in initial testing, with superior performance achieved with designs A and C, so no record runs were performed using this configuration.

[0083] Mathematical models were developed to predict the pressure drop across both the gas and liquid flow paths. These models consider the effects of liquid and gas properties and operating pressure, temperature, and flow rate. The models are designed to be suitable for subsequent scale-up of the separator and operation with the working fluid.

[0084] A proof-of-principle (PoP) study was conducted to determine whether inertial separation techniques combined with exemplary porous media technology could be used to create a vapor / liquid phase separator for use in cooled lasers in directed energy weapon systems. For this current phase, the target liquid separation efficiency was greater than 75%, with a 50% purity and a fluid pressure drop of less than 15 psid. Surrogate fluids, including water and air, were used to test the functionality of three different exemplary phase separator designs scaled down to approximately 1% by mass of the flow rate of the full-scale final device. Experimental results from this study were evaluated against the aforementioned targets. Additionally, data was used to validate analytical models. These models can be scaled to scale and further developed to optimize designs for future phases of this multi-phase project.

[0085] Test Procedures / Equipment A custom test bench was constructed to evaluate an exemplary phase separator design for operational performance under near-ambient conditions using surrogate fluids, water and air. These surrogate fluids were used to simulate a two-phase mixture of a refrigerant at its critical temperature at its operating pressure (R717 at 20 °C and 124 PSIG). Figure 20 shows a schematic diagram of this custom test bench. Pressurized water and air were supplied through a flow meter (left) entering a water atomizer, in this case a conventional paint spray gun modified for this purpose. The resulting two-phase mixture was then supplied to the inlet port of the PoP phase separator. The device separated the gas and liquid, which exited through their respective outlets. A valve located at the outlet was used to adjust the pressure within the system. The output stream then passed through a trap to separate the two phases, and the gas flow rate was measured with a flow meter. Pressure sensors located at the inlet and outlet ports were used to monitor the system pressure and pressure drop. Gas temperature and relative humidity (RH) were monitored in a liquid trap on the gas outlet flow path.

[0086] A brief description of the test procedure is as follows: (i) place the phase separator on the test bench and ensure all connections are leak-free; (ii) set the water and air input flow rates to the desired quality; (iii) adjust the gas outlet backpressure valve to reach the desired system input pressure and the liquid outlet backpressure valve for optimal liquid capture efficiency; (iv) wait for the system to stabilize and record all pressures, flow rates, temperatures, and RH; and (v) repeat for each quality level to be tested.

[0087] Assuming a 0% relative humidity (RH) input, a maximum flow rate of 80 standard liters per minute (SLPM) was used during testing, and a maximum RH output of 80% was observed during testing with air temperatures between 15 and 20°C. Note that the maximum amount of water that air can hold is 12.8g / m3 at 15°C and 17.3g / m3 at 20°C.

[0088] Design A - Reverse flow cyclone Figure 10 is a schematic diagram showing the main components of the proposed design (Design A version). Regarding the operation of Figure 10 (Design A version), note that (i) flow through the counter-flow cyclone vanes creates a centripetal force to separate the liquid from the gas, (ii) the liquid flows to the exterior and bottom of the housing, (iii) the porous membrane and liquid layer provide an impermeable barrier to gas flow, (iv) liquid extraction occurs via a controlled differential pressure across the membrane, and (v) the vapor phase exits through a vertical outlet. Note that such an exemplary cyclone separator is robust in design and highly reliable. Note that the use of a porous media to support the liquid layer advantageously provides a barrier to vapor transmission while allowing the liquid to pass through.

[0089] Figure 9 shows another version of the Design A phase separator and its key components that were constructed for evaluation. The vane assembly provides cyclonic motion to separate the liquid and vapor phases, and the conical skirt 328 reduces the amount of liquid exiting the separator through the vapor exhaust port. The upper housing was constructed using PVC tee fittings, the liquid outlet housing was constructed using PVD caps, and the main housing and vapor exhaust tubing were constructed using clear polycarbonate tubing. Note that the version of the Design A phase separator shown in Figure 9 was assembled and tested using the custom test stand shown in Figure 20.

[0090] Numerous experiments were performed utilizing the Design A phase separator version shown in Figure 9, adjusting the length of the main housing body, the relative placement of the impeller and the connection to the internal vapor extraction tube and media grade (average pore size), as well as the thickness of the porous media before performing record runs. Application of Media Grade 2 porous media with an inlet pressure of 4.0 psi was found to result in efficient separation of greater than 90% liquid at all mixture quality levels tested for this scale-sized phase separator (the Design A phase separator version shown in Figure 9).

[0091] Table 1 shows some key summary results based on record test runs for the Design A phase separator version shown in Figure 9. Note that at all quality levels, no gas was observed exiting the device through the liquid port.

[0092] [Table 1]

[0093] The results shown in Table 1 indicate that Design A (Figure 9) met the performance requirements with liquid and gas pressure drops across the separator all less than 1 PSID and was close to the target with a liquid capture efficiency greater than 93%.

[0094] Design B - Gas Extractor Figure 16 is a schematic diagram showing the main components of this proposed design. Note that with regard to the operation of Figure 16 (Design B), (i) flow through the spiral passage creates a centripetal force to separate the liquid from the gas, (ii) the liquid moves outward and travels the full length of the spiral channel, and (iii) the gas flows inward, passing through the inner porous membrane via a controlled pressure differential and exiting the device axially.

[0095] This proposed design (Design B) is unique and significantly different from Design A. The two-phase mixture is intended to follow the spiral flow path, with all of the gas phase moving toward the center and through the porous medium. The liquid continues to flow through the spiral path and exits the device.

[0096] Figure 16 shows a constant cross section through a spiral flow channel. It was recognized early on that there was a significant pressure drop associated with the gas exiting along the spiral flow channel, and modifying the spiral flow channel to a variable-pitch, variable-cross-section spiral was feasible. Thus, the first-generation prototype was created. For the first-generation prototype, the two-phase inlet channel began with a 1-inch diameter and continuously decreased to approximately 1 / 8-inch diameter at the liquid outlet port. The spacing between channels remained constant, resulting in a variable pitch along the flow channel length. The purpose of this modification was to create a more uniform pressure drop across the length of the porous media, producing consistent gas extraction. It should be noted that initial testing of this prototype resulted in poor separation efficiency. Almost all of the liquid phase exited through the porous media, accompanied by the gas phase. It was hypothesized that this design did not have sufficient centripetal force to separate the two fluids, and creating a modified design with a much smaller diameter would result in greater inertial separation and therefore better performance.

[0097] It should be noted that a second-generation Design B phase separator was fabricated. This design had a significantly smaller and deeper aspect ratio of the internal spiral channels. Continuing testing of this design demonstrated better separation performance levels than the first-generation design at various flow rates and media grades of the porous element. Testing observed liquid capture efficiency levels of up to 50% at the 20% quality level, with much lower liquid capture efficiencies observed above 20% quality. Record-keeping tests were not performed on this design due to the low phase separation efficiency.

[0098] Design C-Liquid Extractor Figure 12 is a schematic showing the proposed structure of the individual liquid extractor elements, and Figure 13 shows how they can be arranged in a bundle and operated in parallel to scale up. Note that with respect to the operation of Figure 13 (Design C), (i) flow through the spiral passage creates a centripetal force to separate the liquid from the gas, (ii) gas flows inward and travels the entire length of the spiral channel, (iii) the porous membrane and liquid layer provide an impermeable barrier to the gas flow, (iv) liquid flows outward and passes through the outer porous membrane using a controlled pressure differential, and (v) the liquid exits through a side port of the separator.

[0099] This design is similar to Design A in that it uses inertial energy to separate the liquid and vapor phases, with the separated liquid passing through a porous medium. It differs from Design A in that the liquid immediately contacts the porous medium during separation.

[0100] A single spiral element (e.g., Figure 12) was used for this PoP test. The two-phase fluid enters from the right through an ABS plastic housing with internal vanes to initiate cyclonic motion. The fluid then passes through the spiral cavity, pushing the liquid outward and maintaining the vapor phase toward the center. The liquid passes through the porous medium, and the vapor phase exits to the left through the spiral channel. The center housing was made using clear polycarbonate plastic so that the vapor phase could be observed passing through the porous medium. Note that the Design C phase separator was assembled and tested utilizing a custom-built test stand, Figure 20.

[0101] Numerous experiments were performed adjusting the length of the main housing body (1 or 2 inches), media grade (average pore sizes of 0.2, 0.5, and 2), and porous thickness (0.062 and 0.125 inches). It was found that using media grade 2 porous media with an inlet pressure of 5.0 psig resulted in liquid separation efficiencies of approximately 80% or greater at all mixture quality levels tested.

[0102] Table 2 shows some key summary results of the run-for-record (R4R) testing for Design C. Note that in all cases, no gas was observed exiting the device through the liquid port.

[0103] [Table 2]

[0104] Discussion-Test Analysis-Design Comparison: Table 3 below shows the combined summary results for both Designs A and C. The liquid and gas phase pressures drop across each design along with their quality relative to their liquid capture efficiency. The results clearly show that Design A, a counter-flow cyclone, outperforms Design C, a liquid extractor, in terms of liquid capture efficiency. Design A started at 50% quality with an efficiency of 93% and quickly rose to 99% at low quality. At this time, the low efficiency of 30% can be attributed to implementation / setup error. Design C started at a low liquid capture efficiency of 79% and rose to very high efficiency at low quality, but at a slightly slower rate.

[0105] Designs A and C both started with approximately 1 PSID pressure drop at the gas outlet and both steadily decreased to 0 PSID as the quality decreased from 50% to 0%. This steady decrease in gas phase pressure drop with quality is expected, and the trend is consistent with the engineering design model.

[0106] [Table 3]

[0107] Comparison of model predictions and experimental data – Design A Table 4 and Figure 21 are tables and graphs showing the predicted gas-phase pressure drop quality calculated using the analytical model and experimentally measured values ​​for Design A. In Figure 21, the modeled pressure drop is indicated by diamonds, and the experimental results are indicated by rectangles on the graph. Except for the 10% quality data point, the model-predicted pressure drop is, on average, within 20% of the experimentally measured data and follows a similar nonlinear upward trend. When plotted as a function of gas flow rate, the data shows that the pressure increases primarily as the square of the gas flow rate plus some secondary factors, which is expected from a fundamental perspective. The model accounts for fluid density, viscosity, and actual gas velocity within the separator, which are dependent on temperature and pressure.

[0108] [Table 4]

[0109] Table 5 and Figure 22 are a table and graph showing the predicted liquid phase pressure drop calculated using the analytical model and experimentally measured values ​​for Design A. In Figure 22, the modeled pressure drop is shown as a diamond, and the experimental results are shown as a rectangle on the graph. The model accounts for fluid density, viscosity, and actual gas velocity in the separator, which are dependent on temperature and pressure.

[0110] With the exception of the 0% quality data point, the model's predicted pressure drop is, on average, within 10% of the experimentally measured data. Interestingly, the pressure drop data is relatively constant when plotted as a function of quality or liquid flow rate. Thus, the pressure drop is relatively independent of liquid flow rate. At first glance, this result seems to contradict the basic belief that pressure drop typically increases with increasing flow rate. However, the data is certainly correct, and this unusual finding results from two aspects that combine to define the overall pressure drop in the liquid flow path. The first portion of the pressure occurs across the cyclone's inlet region and swirler vanes. In this region, the pressure drop of the mixed fluid flow is primarily a result of the gas flow rate. Furthermore, this pressure drop dependence varies as the square of the gas flow rate plus some secondary factors. The pressure drop decreases with decreasing gas flow rate and mixture quality. The second main region for liquid pressure drop occurs across the exemplary porous metal media. Here, the pressure drop increases linearly with liquid flow rate, thus decreasing mixture quality. These two tendencies, one increasing while the other decreasing, result in a pressure that is relatively independent of the quality of the mixture.

[0111] [Table 5]

[0112] Comparison of model predictions and experimental data – Design C Table 6 and Figure 23 are tables and graphs showing the predicted gas-phase pressure drop calculated using the analytical model and experimentally measured values ​​for Design C. In Figure 23, the modeled pressure drop is indicated by diamonds, and the experimental results are indicated by rectangles on the graph. The modeled data is slightly more than half the experimental data, but shows the same overall trend. As mentioned in the Results section, a series of swirling vanes were installed on the inlet housing to initiate cyclonic motion before the fluid reached the separator element. This was not considered in our modeling and may explain the higher-than-expected pressure drop. The black circles shown in Figure 23 are the predicted pressure drop with adjustments to account for these additional vanes and other limitations in the device. The adjusted model results follow the same trend as the experimentally measured results, following the quadratic curvature theoretically expected.

[0113] [Table 6]

[0114] Looking at the modeled liquid pressure drop and measured experimental results for Design C, there appears to be no direct correlation. Table 7 and Figure 24 are tables and graphs showing the predicted liquid-phase pressure drop versus quality calculated using the analytical model and experimentally measured values. In Figure 24, a linear change in quality versus liquid pressure drop in the triangle predicted for laminar flow is predicted by the model. The experimentally measured values ​​are reasonably close to the predicted values ​​at 0% quality, but at all higher qualities, the measured values ​​stabilize at approximately 2 PSID, which does not agree with the analytical model. The measured liquid pressure drop should decrease with increasing quality as the liquid flow rate through the media decreases. This could be an implementation issue or a Venturi effect, where high-velocity gas passes through the separator, creating lower pressure and affecting the liquid pressure drop measurement. Another issue is that water generally does not wet stainless steel well, and trapped air in the porous media could restrict flow and cause a higher-than-predicted pressure drop.

[0115] [Table 7]

[0116] Conclusions and Recommendations Studies of the PoP prototype demonstrate that using inertial energy in exemplary porous media is a viable option for achieving liquid / gas phase separation. It should also be recognized that limited work has been done to optimize the separation performance of these two designs, and additional work can be performed to improve their performance before moving on to evaluation with refrigerant fluids. Continued testing with alternative fluids to optimize these designs can be performed at significantly lower cost and in much less time than attempting to optimize performance levels using ammonia or other refrigerants.

[0117] While Design A outperforms Design C in terms of liquid capture efficiency, it should be noted that Design A has some limitations related to its orientation. When operating in an environment where gravity is prevalent, Design A must generally orient the liquid outlet downward for proper operation. This means that for stationary, ground-based applications, Design A should perform well. In certain embodiments, for flying platform applications, Design A may not perform as designed. Furthermore, Design A should operate in microgravity situations because these types of designs have previously been shown to work in other applications. When looking at Design C, this design has no known limitations in its orientation and is expected to operate in orientations where gravity is present, including microgravity environments. For this reason, further optimization work to improve liquid capture efficiency should be performed before making a final design selection.

[0118] Record run on a proof-of-principle phase separator The following is a Record for Record (R4R) test procedure for a Phase 1 Proof-of-Principle (POP) design for a liquid / vapor phase separator (e.g., as employed in laser cooling applications). During R4R testing, all adjustable parameters (hardware dimensions, device orientation, etc.) remain unchanged for the duration of testing and data collection for each of the three designs.

[0119] Table 8 below shows the calculated volumetric flow rates of water and air to achieve the indicated quality levels. These values ​​represent 1.25% and 2.5% by volume, and 0.25% and 0.5% of the full-scale total mass flow rate, for a system running R717. The choice of operating at a low or high flow rate range was chosen based on laboratory-scale prototype size and preliminary testing of each design prior to actual recording runs. Efforts were made to target one of these two flow rate ranges if any of the designs required a different flow rate to operate properly. The water and air flow rates for each quality level can be recalculated for these cases.

[0120] [Table 8]

[0121] Measurements: The following ports were installed to monitor pressure, temperature, and relative humidity, where applicable, for each design: pressure at the two-phase inlet, pressure at the gas outlet (before the back-pressure regulator if employed to optimize performance), pressure at the liquid outlet (before the back-pressure regulator if used to optimize performance), liquid pressure drop across the porous media (design A only), gas pressure at the time of test, gas temperature at the outlet, air relative humidity at the outlet, liquid outflow rate, flow rate at the gas outlet, a capped vessel at the liquid outlet, a rotameter at the vent to measure air flow rate, and a water droplet trap at the gas outlet to measure air and water flow rates separately.

[0122] [Table 9]

[0123] While particular embodiments have been described, presently unforeseen or unforeseen alternatives, modifications, variations, improvements, and substantial equivalents may occur to applicant or those skilled in the art. Accordingly, the appended claims as filed, and the claims as they may be amended, are intended to embrace all such alternatives, modifications, variations, improvements, and substantial equivalents.

[0124] All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., the range "up to 25 wt.%, or more specifically, 5 wt.% to 20 wt.%" includes the endpoints of the range "5 wt.% to 25 wt.%" and all intermediate values). A "combination" is inclusive of blends, mixtures, alloys, reaction products, and the like. The terms "first," "second," and the like do not denote any order, amount, or importance, but rather are used to distinguish one element from another. The terms "a," "an," and "the" do not denote quantitative limitations unless otherwise indicated herein or clearly contradicted by context, and should be interpreted to cover both the singular and plural forms. "Or" means "and / or" unless expressly stated otherwise. Throughout this specification, references to "some embodiments," "embodiments," and the like mean that the particular element described in connection with an embodiment is included in at least one embodiment described herein and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. "Combinations thereof" is open and includes any combination including at least one of the listed components or features, optionally including similar or equivalent components or features not listed.

[0125] Unless otherwise defined, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in this application contradicts or conflicts with a term in an incorporated reference, the term from this application shall take precedence over the conflicting term from the incorporated reference.

[0126] While the systems and methods of the present disclosure have been described with reference to exemplary embodiments thereof, the present disclosure is not limited to such exemplary embodiments and / or implementations. Rather, the systems and methods of the present disclosure are susceptible to numerous implementations and applications, as will be readily apparent to those skilled in the art from this disclosure. The present disclosure expressly encompasses such modifications, improvements, and / or variations of the disclosed embodiments. Because numerous changes can be made in the above-described structures, and many widely varying embodiments of the present disclosure can be made without departing from its scope, it is intended that the drawings and all matter contained herein be interpreted as illustrative and not in a limiting sense. Additional modifications, variations, and substitutions are contemplated in the foregoing disclosure. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the present disclosure.

Claims

1. 1. A phase separator device comprising: a housing extending from a first end to a second end; The housing comprises: an inlet at the first end of the housing for the introduction of an input feed comprising a mixture of a first liquid phase and a second vapor or gas phase; one or more first openings for exiting a first liquid-phase output; and one or more second openings forming an outlet passageway for a second vapor or gas phase output; The housing comprises: an axial flow cyclone separation section between the inlet and the porous media section; one or more guide vanes between the inlet and the axial cyclone separation section; a liquid collection section between the axial flow cyclone separation section and the porous media section; the one or more first openings for a first liquid-phase output are between the porous media section and the second end of the housing; the outlet passage for a second vapor or gas phase output extends from the axial flow cyclone separating section to the second end of the housing; the inlet and outlet passages are aligned along the same axis such that the input feed and second vapor or gas phase output flow along the same direction of travel; the axial flow cyclone separation section and the porous media section are configured to separate the input feed into the first liquid phase output and the second vapor or gas phase output; the porous media section physically supports the liquid collection section; a pressure drop across the first liquid phase and the layer of porous media section greater than the pressure drop in the outlet passageway, preventing entry of the second vapor or gas phase into the one or more first openings.

2. 10. The phase separator device of claim 1, wherein the input feed comprises two different constituent liquids and gases.

3. 10. The phase separator device of claim 1, wherein the input feed comprises liquid and vapor phases of the same constituents.

4. 10. The phase separator device of claim 1, wherein the input feed introduced into the housing comprises ammonia.

5. 10. The phase separator device of claim 1, wherein the input feed introduced into the housing comprises water and air.

6. A phase separator device as described in claim 1, further comprising a liquid collection section in the housing.

7. 10. The phase separator device of claim 1, wherein the porous media section has an average pore size of from 0.1 micrometers to 100 micrometers.

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