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Oil & Gas: Upstream

Gun’Barrel Be Gone: Separation on the Fly for Modern Drilling

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INDUSTRY INSIGHT

Industry Overview

Mercer International’s enhanced gravity oil-water separators are redefining wastewater management for upstream oil and gas production. Don’t store it and wait — pull out oils and solids on the fly and keep moving.

From wellhead to tank battery, these systems handle the toughest produced and flowback water challenges, removing up to 99.9% of oils and solids while slashing maintenance and downtime.

The Compliance Master™ equipped with Mercer’s Multi-Pack™ coalescer system replaces outdated gun-barrel tanks, frac tank brigades, and 60,000-barrel ASTs that consistently accumulate feet of oils and solids with no place to go.

Designed for both traditional and unconventional drilling, these systems allow operators to treat water at the source — recycling or discharging with confidence, protecting injection wells, and recovering low-BS&W, saleable oil that would otherwise be lost.

ENERGY INDUSTRIES

Upstream Applications

Produced Water Treatment

Mercer’s enhanced gravity separators efficiently remove free and dispersed oil from produced water, protecting secondary treatment, polishing steps, injection or reuse activities, and preventing loss of product.

Flowback Water Management

Handle variable, high-volume flows from fracturing operations with systems built for the true “witches’ brew” nature of muds, sands, and chemicals typical at the earliest stages of well maturity.

Tank or Tankless Batteries & Well Pad Drainage

Treat oily water from storage and production facilities to meet compliance limits, reduce hauling, and capture valuable oil product.

Saltwater Disposal (SWD) Pre-Treatment

Shield SWD wells from oil carryover, scale, and plugging. Mercer’s system performance maintains consistent injection pressure and uptime while delivering measurable ROI through recovered oil volumes.

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MERCER ADVANTAGE

The Mercer Difference

Eliminates Corrugated and Gun-Barrel Limitations

No small pockets for solids to hide, no clogging, and no false “coalescing” media designed for air scrubbers. Mercer’s Multi-Pack™ design creates optimal hydraulic conditions for oil rise and solids settling, achieving efficiency without fouling.

Enhanced Gravity, Not Guesswork

Precision plate spacing and flow control ensure oil droplets coalesce naturally under gravity — no chemical dependency or turbulent mixing zones.

Compliance Built In

Every Compliance Master™ unit is engineered to exceed API 421 intent and modern discharge requirements, ensuring dependable environmental compliance across variable flow and load conditions.

Low Maintenance, High Uptime

Removable packs that resist fouling and simplify inspection and cleaning.

Recover More. Dispose Less.

Recovered hydrocarbons offset treatment costs, while cleaner water reduces disposal fees — a measurable win-win for operators and the environment.

Mobility

Mobile solutions allow these heavy solids/oil-removal workhorses to go anywhere.

Technical Highlights

Real-World Performance

Supporting Upstream Sustainability

By replacing obsolete separators and reducing hauling and chemical usage, Mercer’s systems help operators meet ESG goals while protecting revenue streams. The result is a cleaner operation — one that’s compliant, efficient, and built for the realities of today’s oilfield.

Let’s Talk About Your Produced Water Challenge

Learn how Mercer can optimize your upstream separation process and protect your disposal assets.

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