3D gradient porous structure for phase separation utilizing additive manufacturing methods

A phase separator device comprising:

• a device inlet and a device outlet that are axially spaced apart from each other, wherein the device is shaped as a cylinder with an outer surface that extends axially from the device inlet to the device outlet with a constant outer diameter;
• a cylindrical porous metal structure that is axially intermediate the device inlet and the device outlet, wherein the porous metal structure extends from a first end to a second end;
• an inlet section with an inner inlet lumen, wherein the inlet section forms an inlet hollow cylinder that extends from the device inlet to the first end of the porous metal structure to define an inlet portion of the device outer surface;
• an outlet section with an inner outlet lumen, wherein the outlet section forms an outlet hollow cylinder that extends from second end of the porous metal structure to the device outlet to define an outlet portion of the device outer surface;
• wherein the porous metal structure is without a lumen, wherein the porous metal structure defines an axially intermediate portion of the device outer surface, and wherein the porous metal structure includes a plurality of annular porous areas that are axially aligned with each other, extend between the first and second ends of the porous metal structure, and defines:
• (i) a radial inner area that extends radially outward from a radial center of the device;
• (ii) a radial outer area that radially surrounds the radial inner area and extends radially inward from the device outer surface;
• and
• (iii) at least one radial intermediate area that extends radially between the radial inner area and the radial outer area;
• wherein the radial inner area has a first plurality of pores, the at least one radial intermediate area has a second plurality of pores, and the radial outer area has a third plurality of pores;
• wherein first pores of the first plurality of pores are larger than second pores of the second plurality of pores, and the second pores of the second plurality of pores are larger than third pores of the third plurality of pores, such that pore sizes decrease from the radial center of the device to the device outer surface;
• and
• wherein the first pores of the first plurality of pores are interconnected with the second pores of the second plurality of pores, and the second pores of the second plurality of pores are interconnected with the third pores of the third plurality of pores;
• and
• wherein the porous metal structure is configured to phase separate a fluid mixture comprising a liquid and a gas as an inlet axial flow introduced to the first end of the porous metal structure via the inlet section, into a radial liquid flow and an axial gas flow such that the liquid flow exits the porous metal structure radially via the device outer surface along the porous metal structure and the gas flow exits the device as an outlet axial flow via the outlet section.