Overview
A separator is only as good as its internals
Separator internals manage the incoming flow and support gas-liquid and liquid-liquid separation. Selecting the components together helps address vessel capacity, flow distribution, and outlet quality.
Evergreen designs inlet devices, flow smootheners, mist extractors, calming baffles, and coalescer media for new vessels and revamps. CFD modelling is used where the service complexity warrants, with sectional construction available to suit vessel access and installation requirements.
The package
A typical three-phase separator, end to end
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Inlet devices
Inlet devices include half-pipes and vane inlet devices, selected according to inlet momentum and service requirements. They reduce entrainment loads and help manage slug flow or process upsets.
EVERVANE
Vane Inlet Device
Series of curved vanes in a heavy-duty housing. These devices reduce inlet momentum while promoting bulk vapour-liquid separation. Sectional construction for installation through manways. Special design considerations can be made for slug-flow services. These devices have no moving parts.
Gas-side separation
FLOW SMOOTHENER
Flow Smoothener / Straightener
Specially designed assembly placed after the inlet device. Breaks foam, calms gas flow, and acts as a primary coarse separator — reducing the liquid load on downstream eliminators.
MIST EXTRACTOR
Mist Extractor / Eliminator
This is the final mist removal stage. Mesh pad (EVERMESH) or vane (EVERON) type mist eliminators are used depending on droplet-size and pressure-drop targets. Mesh-pad coalescers / agglomerators can be specified upstream of vane assemblies for better performance.
EVERSPIN
Axial-Flow Cyclone
EVERSPIN consists of multiple axial cyclone tube elements mounted in a tubesheet, used to remove mist. Centrifugal motion throws liquid outward onto the cyclone wall, where the collected liquid coalesces and drains through wall slits. EVERSPIN is suited to high-pressure applications where the capacity of mesh or vane mist eliminators is constrained by the service conditions. EVERSPIN can be coupled with EVERMESH or EVERON for better performance.
Liquid-side separation
Coalescer media support gravitational separation of immiscible liquids where the feed does not contain a stable liquid emulsion. Selection of the type of coalescer depends on the fluid properties and operating conditions; droplet-size guidance should be assessed for the specific service. Coalescer media can be used with upstream calming baffles to improve separation.
CALMING BAFFLE
Calming Plate / Baffle
Perforated plate assemblies are typically used as calming baffles and placed in the liquid phase, upstream of coalescer media. They help distribute the liquid more uniformly into the coalescing media. Single or two-stage configurations can be selected to suit the service.
EVERPACK PP / CP
Plate Coalescer Media
Parallel-plate (PP) or corrugated-plate (CP) coalescer modules can be supplied. They provide effective bulk removal of dispersed droplets in the 50–1,000 micron range. They are selected based on the amount of fouling expected.
EDC-PACK
Co-knit Wire & Fibre
Co-knits of wire and fibre. Typically used in extractor effluent, raffinates, and NGL recovery applications. Target droplet size: 10–100 microns. Relative efficiency: Medium–High.
Capacity revamps
EVERSPIN + EVERMESH / EVERON combinations
For existing vessels constrained by capacity — particularly in vertical separator configurations with large vapour loads and small liquid loads — EVERSPIN axial cyclones combined with EVERMESH or EVERON coalescer / agglomerator stages can significantly increase the capacity in the same vessel. Revamps are easier in vertical configurations than in horizontal ones. Based on your requirements, we can evaluate and recommend the right combination for your service.
Engineering support
From data sheet to installation supervision
Separator design takes the inlet zone, flow development, and outlet phase separation as one system. Our engineering support runs from initial data sheet review through CFD modelling (where warranted), fabrication, and installation supervision. We work with end users on greenfield projects and revamps alike.
Applications
Where EVERSEP separator internals are installed
- Two-phase separators
- Three-phase separators
- Knockout drums
- Slug catchers
- Compressor inlet scrubbers
- Produced-water vessels
- Onshore oil & gas production
- Offshore platforms (FPSO, fixed)
- Gas dehydration trains
- Acid gas treating
- Hydrocarbon dewpointing
- NGL fractionation