Disclosed herein are advantageous phase separator devices, and related methods of fabrication and use thereof. The present disclosure provides improved phase separator devices for phase separation of feedstreams, and improved systems/methods for utilizing and fabricating the phase separator devices. More particularly, the present disclosure provides porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow). At least a portion of the phase separator devices of the present disclosure can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.

Disclosed herein are advantageous phase separator devices, and related methods of fabrication and use thereof. The present disclosure provides improved phase separator devices for phase separation of feedstreams, and improved systems/methods for utilizing and fabricating the phase separator devices. More particularly, the present disclosure provides porous (e.g., three-dimensional gradient porous) phase separator devices for phase separation of fluid mixtures (e.g., to separate a two-phase fluid mixture) to a first fluid phase flow (e.g., to a liquid flow) and to a second fluid phase flow (e.g., to a gas flow). At least a portion of the phase separator devices of the present disclosure can be fabricated via machining, powder metallurgy (e.g., sintering), and/or produced utilizing additive manufacturing techniques.

A method of separating and reusing unconverted ammonia from cracked ammonia gas provided by an ammonia cracking unit is provided. The method includes introducing a cracked ammonia gas stream into a water wash column, thereby producing a clean gas stream and a water-containing effluent stream and introducing the water-containing effluent stream into a stripping column, thereby producing a cleaned wash water stream and a recovered ammonia stream. Wherein the cracked ammonia gas stream has an ammonia concentration of between 0.003 mol % and 10 mol %. Wherein the clean gas stream has an ammonia concentration of between 1 ppm and 2500 ppm. And wherein at least a portion of the recovered ammonia stream is used as fuel within the ammonia cracking unit.

A method of separating and reusing unconverted ammonia from cracked ammonia gas provided by an ammonia cracking unit is provided. The method includes introducing a cracked ammonia gas stream into a water wash column, thereby producing a clean gas stream and a water-containing effluent stream and introducing the water-containing effluent stream into a stripping column, thereby producing a cleaned wash water stream and a recovered ammonia stream. Wherein the cracked ammonia gas stream has an ammonia concentration of between 0.003 mol % and 10 mol %. Wherein the clean gas stream has an ammonia concentration of between 1 ppm and 2500 ppm. And wherein at least a portion of the recovered ammonia stream is used as fuel within the ammonia cracking unit.