Mercer International offers above ground separators that supply both high efficiency and low maintenance--plus the versatility to field customize to suit your particular application. Our extraordinary design achieves extraordinary results. The Compliance Master™ design features the unique Multi-Pack™ coalescer that allows field adjustment to obtain the highest possible efficiency with the lowest practical maintenance frequency. The above-ground oily water separator market is littered with cheap "me too" corrugated plastic and steel coalescers. Although some of these are termed "enhanced" coalescers, they prematurely plug up with solids and sludge. These coalescers are difficult to clean--and very often need replacement--producing a high cost of ownership. Mercer's Multi-Pack coalescer is easily cleaned and is typically used for the life of the separator.
Our "low flow" series offers an industrial-duty design in a compact size. This separator series is ideally suited for smaller vehicle wash stations. These separators are also well suited for wastewater from small sumps, small stormwater treatment applications, groundwater pump and treat systems, and various other low-flow applications. Our "low flow" series incorporates the same features in our standard sized separators that have helped Mercer build its sterling reputation—but in a compact design.
A step above the "low-flow" separator, is our 50-100 gpm family of units. This separator series features a true "V-shaped" coalescer which incorporates a full-width Chimney-Zone™ (zero velocity solids settling area) designed to process solids down and out of the coalescer. A coalescer design which processes the solids out of the coalescer, instead of simply filtering the solids as they pass through, will produce cleaner effluent and for much longer intervals between required maintenance. This family of Compliance Master separators is designed for a broad range of applications including the Food and Chemical industries (that require high efficiency while properly handling the solids present in the wastewater). The Oil & Gas industry also utilizes this size for their pilot test units before scaling up to larger flow solutions.
This is truly where the Mercer advantage is highlighted. Here, we see that the actual field performance of the separator approaches the "theoretical" calculations produced during the design and engineering stage. It's all about solids removal and the coalescer’s 's ability to handle and process solids efficiently; allowing very long, efficient run times between routine maintenance requirements.
This series bridges the gap between our "small" separators lines and our "large" separators. It is with these "in-between sized" separators that the materials of construction become an important consideration based on performance and price. Whether it is an environmental engineer that understands the complexities of certain applications, or a concerned maintenance professional trying to avoid the past problems of equipment corrosion, the choices are very important in the long-term "cost of ownership". Mercer International builds separators of various materials of construction, including epoxy-painted carbon steel, marine-grade aluminum, 304L and 316L stainless steel, as well as other metal alloys. We also offer heavy-duty, reinforced plastic tanks, such as polypropylene to help combat corrosion in extreme conditions.
As flow rates become larger, the inherent design advantages of the Multi-Pack™ coalescer become vital for maintaining high efficiencies within reasonable maintenance intervals. With oil water separators of this size, it quickly becomes apparent how the Multi-Pack featuring flat-plate, herringbone design enhances performance. Why is this important? Simply stated, large units have large coalescers which are hard to access and difficult to lift and maneuver for cleaning. Removable, flat-plate coalescers with a herringbone coalescer plate configuration and built-in Chimney Zone™ settling features need to be cleaned much less often, saving both time and money. This greatly reduces the overall "cost of ownership". The unique design was first embraced by the Electric Utility marketplace over 25 years ago and is widely used in the treatment of frac flowback and produced waters in both conventional and unconventional drilling worldwide . At the 400-600 gpm size range the ability to process solids out of the coalescer, instead of simply trapping them in the coalescer (like a coarse "filter"), is a system benefit that both the environmental and maintenance departments continue to appreciate.
We are often called upon by the Oil &Gas E&P companies, as well as their Oil Field Servicing patnersto provide our separators in a "plug and play" skid, all pre-assembled and pre-wired, ready for immediate operation.
As the flow rates become larger, the importance of dedicated settling (solids) and rising (oil) zones become critical to obtain a truly non-fouling design. Not only do the Chimney Zone area process oils and solids out of the coalescer, they naturally create an break in the coalescer plate, providing shorter plate widths perpendicular to the flow direction. Shorter plate widths yield a lower "equivalent diameter" which is a measure of how a coalescer plate configuration will perform with solids present. In a large separator with a standard-type coalescer, solids particles entering the coalescer, say at the upper left-hand portion of the coalescer (in the entry area view), will have to slide down the coalescer plate for up to 6-10 feet (or more) until the solids finally exit the plate pack at some lower left portion of the coalescer, where theoretically the solids are to be processed out of the coalescer. However, with plate of that length as with typical coalescer designs (having lots of nooks and crannies) the likelihood of solids actually being processed out of the coalescer is quite low. Therefore fouling time increases dramatically. Our short plate-width design reduces the fouling problems significantly.
Mercer supplies shop-fabricated units as large as can be physically shipped (up to 5,000 gpm or more). These are typically custom designed units with various sizes and shapes to best meet our client's field conditions. We can also supply field erected separator tanks for the larger flow requirements.
We supply various flow configurations to maintain high efficiency and aide in maintenance procedures. Units in this size range are typically designed to have the wastewater internally split into two or more flow trains within the unit. Our "split flow" design feature best utilizes the separator tank to reduce the velocity through the coalescers. This is done in order to maintain our stringent design criteria at very large flow rates. Our "split flow" design also offers the end user the ability to shut half of the separator down for maintenance while still allowing the other half to remain in operation.
For our largest pre-fabricated separators, we design a "double-split flow" system allowing the most efficient use of coalescers and tank volume, enabling the end user to obtain maximal results (photo on left).