The process of supplying custom-designed systems begins by listening to the client. Even the smallest components or accessories sometimes need to be adjusted based on the requirements of the project. However, far beyond the small details, Mercer has dedicated itself to solving difficult design and fabrication issues. These special situations often have Mercer exploring solutions that include major changes to existing designs for particular wastewater characteristics (as pictured above). We also are involved in custom design with various choices of materials of construction, creating turnkey systems, and field issues such as designing field-assembled units for areas that are difficult to access.
Mercer has outfitted several Utility and Petrochemical companies with standard compliance master units that are mounted on trailers. This flexibility is very useful for rapid deployment in the event of a spill, or for routine cleaning of pits, sumps, manholes, and various tanks. Mercer can provide secondary and polishing filters on the trailer for discharge to non-detectable levels. We can also supply trailer mounted influent and effluent pumps as well as every level of automation for the various controls.
Mercer offers integral and stand-alone "sand interceptors" ahead of our standard oil/water separators. We incorporate sand interceptors where heavy solids are known to be in the wastewater and need a larger settling area for coarse removal before entering the coalescer compartment. By taking out the heavy solids, there is less loading on the coalescer, thereby allowing the coalescer to supply optimal results. A sand interceptor tank is also used when there is a very heavy concentration of oil as well. This tank acts as a primary tank for removal of large micron droplet sized oil. In this case as well, the interceptor tank will take the gross oil out of the wastewater upstream of the coalescer, preventing the coalescer from being "hindered" by excessive oil.
Mercer supplies sand interceptors for New Jersey Transit in ground separator systems for use in their bus wash facilities (see photo). The sand interceptors are used to catch the majority of solids before they ever enter the separator. This is a great strategy for reducing the frequency of maintenance required for the oil/water separator. By removing solids in a relatively large interceptor tank, they are never introduced into the coalescer--greatly reducing the potential for solids accumulation in the coalescer. This can cut the frequency of required maintenance in half.
Mercer fabricates a standard line of above ground rectangular oil/water separators from marine-grade aluminum (#5052), epoxy-painted carbons steel, 304L stainless steel, and 316L stainless steel. We have also built units in polypropylene, PVC, and other exotic stainless steel materials such as Duplex to meet a particular corrosion requirement. Our cylindrical below ground units are fabricated from epoxy-painted carbon steel and have various FRP coatings available for additional corrosion protection. Mercer will work directly with the consultant and end user to pick preferred coatings for a specific application based on temperatures of wastewater, and the corrosive potential of an application.
Our standard Multi-Pack coalescer's frame is built from 304L or 316L stainless steel. The coalescer plates will vary depending on the application's requirement. Coalescer plate material choices include: #5052 aluminum, 304L stainless steel, 316L stainless steel, acrylic, and PVC. FRP epoxy resins composite plates are available for lightweight, high temperature, applications where corrosion resistance is essential.
Mercer can also supply passive cathodic protection for our separators, as needed. Strategic placement of magnesium or zinc anodes will help protect the separator from naturally-occurring electrical currents or the stray electrical currents in industrial facilities (such as found at electric power stations).
Mercer can supply complete "turnkey" oily wastewater treatment systems to its clients. We've supplied oil/water separators, equalization tanks, level controls, pumps, PV&F, automatic oil skimmers, polishing filters, oil-holding tanks, sludge-holding tanks, inlet & outlet pumps, transfer pumps, as well as complete PLC/HMI based controls.. The equipment is pre-engineered, pre-packaged and pre-tested before shipping.
Click on the button below to see that plan-view layout of a recent turnkey project for a wastewater treatment system for a new electric generation power station.
In the past we have been asked by customers to supply separators so they are able to fit in very tight spaces. Therefore, there have been instances where we have designed our separators to be built in pieces and field erected. By doing this we have been able to supply large separators in basements or buildings where access is limited by a doorway or a hatchway above.