Chain & Flight type Sludge and Scum Collectors
The MD ''One Only” collector chain is our latest launched product development. Unlike other collector chain designs available in the market, the MD ”One Only” collector chain does not require any pin, locking ring or intermediate bushing. This unique light-weight MD chain is made of advanced materials and provides durable strength, wear resistance, chemical resistance, and long service life. In addition, this design meets the specific requirements of each installation, whether for new construction or when retrofitting existing collector chain, despite of pitch sizes. This is also ideal for applications with elevated grit levels or sludge loads where a stronger, more robust chain is required.
ME-720S Collector Chain does not require any pin, locking ring, intermediate bushing or separate links. Due to this unique design feature, the assembly and disassembly of the chain is super-fast.
The ME-E200 Flight is pultruded out of UV-inhibited Fiberglass reinforced isophthalic polyester resin (FRP) designed to sweep the sludge and scums effectively across the entire tank floor and the surface. Unlike C-channel flights, the ME-E200 flight design avoids re-circulation of the sludge while the flight is turning from bottom to the surface.
All the return tracks and wall brackets are made of 304 or 316 stainless steels in accordance with customer requirements. The return tracks are easy to fix, easy to adjust, and no welding is required. They can be used in both new and existing rectangular sludge collectors.
ME-720 series head and idler sprockets are split design, made of UHMW PE material for easy installation and removal. The UHMW PE materials provide a long-lasting wear resistance during operation in a treatment plant’s corrosive environment.
All shafts and wall bearing holders are made of 304 and 316 Stainless Steel according to customer requirements, and is virtually maintenance free. All Merdec sludge scraper systems are provided with smart synchronised surface tension mechanisms.
Merdec provides both metallic and non-metallic drive chains, drive and driven sprockets, as well as float type tensioner to meet any application requirements. An electronic type over and under load dual limit will be equipped to measures motor power, kW[%] variation constantly.
To avoid excessive wear and tear, Merdec has developed Smart G-force tensioner to provide constant amount of tension force to the collector chains, increasing life span of the entire system.
For the automatic control of the Merdec Chain and Flight Scraper systems, each sludge collector will be equipped with local control panel which is capable of operating locally or auto/remote modes. Real-time data such as functional status can be sent to any mobile device via HMI/SCADA user interface, depending on plant operating platform and requirements.
The removal of scum during clarification is a necessary step to decease organic loadings and scum build-up in the treatment processes. Merdec provides various types of skimmers with manual/auto/remote facilities.
System Components
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ME-720S Collector Chain does not require any pin, locking ring or intermediate bushing and it is among the strongest Collector Chains on the market. The Merdec ME-720S Collector Chain was designed to meet the need for a stronger non-metal chain with excellent chemical and corrosion resistance. The ME-720S Collector Chain is the perfect replacement for any type of collector chain available in the market.
Light weigh ME-720S collector Chain is manufactured from UV-inhibited acetal polymers for optimal strength. This lightweight chain is designed for easy installation. The lighter weight of the ME-720S chain reduces the additional work associated with installing heavy chains and requires less power during operation. No tools are required for chain assembly. Long lasting Our engineers and technicians have decades of experience designing, developing, and manufacturing various types of non-metallic chains. They have pioneered the invention, improvement, application, and manufacturing of this unique lightweight ME-720S chain. This lightweight chain withstands extremely high sludge loading. Multi applications Applications range from any type of primary and secondary applications to any kind of industrial wastewater application where sludge loads require strong durable chain. Through our knowledgeable distributor network, we offer the widest variety of materials, processes, designs and custom services available. We can meet almost any specification or application. |
 | Light weight, yet robust The ME-E200 Flight is pultruded out of UV-inhibited Fiberglass reinforced isophthalic polyester resin (FRP) designed to sweep the sludge and scums effectively across the entire tank floor and surface. Scraper flights are customer fabricated to suit any application and designed to handle wider tank spans than C-Channel Flights. This unique design gives it exceptional resistance to deflection and twist, ensuring the flights remain strong and stiff throughout their service life. Unlike C-Channel flight, ME-E200 flight design avoids re -circulation of the sludge while turning the scraper flight from bottom to surface.
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 | Snap lock, multi-position synchronization The high strength ME-E200 flight can handle heavy sludge loads or be used in tanks over 10m in width. |
 | Return tracks and multi-adjustable brackets All the return tracks and wall brackets are made of 304 or 316 stainless steels in accordance with customer requirements. They can be used in both new and existing rectangular sludge collectors. The wall bracket is adjustable in both vertical and horizontal directions in order to allow accurate wall positioning. The return tracks are easy to fix, easy to adjust and no welding is required. The return wear shoes of the scrapers which are made of UHMW PE slide against the surface of stainless-steel return tracks which provide low coefficient friction compared to other counterfaces. | |
 | Carry tracks (wear strips) Two option materials are available for the carry tracks (wear strips) in Merdec scraper systems viz. stainless steel and UHMW PE. When the UHMW PE material is used, then the carry wear shoes of the flights will be in stainless steel in order to provide low coefficient friction. Sufficient clearance will be provided for both slotted holes and ends of wear strips to allow thermal expansion. | |
 | Eco friendly option Carry tracks (wear strips) can be replaced with the scraper flight that are equipped with carrying wheels, which will roll on the bottom surface of the tank. This is the more economical option, as it will eliminate entire mounting work of the carry tracks (wear strips). This reduces the costs and the carbon footprint associated with manufacturing and shipping these bulky components. |
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Split design, superior wear resistance ME-720 series head and idler sprockets are split design, made of UHMW PE material for easy installation and removal. The UHMW PE materials provide a long-lasting wear resistance during operation in a treatment plant’s corrosive environment. |
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Idler shaft sprockets will rotate freely on bearing sleeves clamped to the static shafts. ME-720 series head and idler sprockets are applicable in all scrapers systems using 720S chain. ME-720 series head and idler sprockets are corrosion resistant, abrasion resistant and water resistant.
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 | Head shaft is the driving shaft of the chain and flight mechanism, with the driven sprocket being driven by chain connected to the drive unit. Generally, the head shaft is subjected to greater forces than the other shafts and is normally larger in diameter. Head shafts and wall bearing holders are made of 304 and 316 Stainless Steel according to customer requirements, and is virtually maintenance free. The wall bearings, as well as bearing blocks are made of UHMW-PE and they don‘t require any lubrication. All headshaft sprockets are keyed and locked with set screws so that the collector chains are aligned and move together at the same rate. Keyways are machined in such a way so that the sprockets can be adjusted along the shaft for proper alignment. All items on the head shaft are split construction for easy assembly. |
 | Static tensioning shaft assembly The wall mounting mechanism of the static tensioning shaft is designed in a way that they can be adjusted parallelly on horizontal direction, in order to provide even tensioning force for the collector chain mechanism. All Merdec sludge scraper systems are provided with smart synchronised surface tension mechanisms. As an option Merdec also provides smart G-force auto tensioner which will keep actual required tensioning force constant during the operation. |
 | Metallic (stainless steel) Merdec provides standard stainless-steel chain, drive and driven chain sprockets and float tensioner to meet any application requirements. Stainless steel chain can maintain accurate average transmission ratio, high transmission efficiency, strong overload capacity can work better at low speed and heavy load. This chain has good corrosion resistance and can adapt to higher or lower temperature working environments. The float type chain tensioner due to its’ unique design allows it to slide up and down the drive chain wherever there is slack. Its reliability and lack of needed maintenance make it the tensioner of choice.
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   | Non-Metallic As an option to stainless steel chain and chain sprockets, Merdce provides 78 non-metallic drive chain, drive and driven sprockets and float tensioner. Injection molded from reinforced nylon, 78 chain is strong, lightweight, and resistant to corrosion and chemicals. This non-metallic chain is simple to install and maintain. The float type chain tensioner or similar device will be provided for chain tensioning. The 78 series none metallic chain, sprockets and other associated components can be retrofitted or interchangeable with any reputable sludge collector manufacturer’s parts and components. | ||||
 | Drive and overload protection All the gear motors used in Merdec scrapers systems are from world-class suppliers. These gear motors are applicable in almost every working environment. To protect the entire scraper system, Merdec provides electronic over and under load dual limit monitor which measures motor power, kW[%], with both over-and underload detection. This device will provide an accurate and linear motor load value across the whole load range. Drive unit will have its own protection cover made of AISI304. | ||||
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Smart G-force tensioner Smart G-force tensioner Correct operating tension is an important factor in the satisfactory performance and life of chain collector system. As chains wear, they elongate, which results in sway, slap and this puts undue jolt into the scraper mechanism resulting an excessive wear and tear. In addition, as the chain elongates, it "crawls" out of the sprocket teeth resulting in damage to the scraper system. To avoid excessive wear and tear, Merdec has developed Smart G-force tensioner to provide constant amount of tension force to the collector chains, increasing life span of the entire system. Economical, easy to install, maintenance free, the Smart G-force tensioner is the answer to the problem of controlling collector chain tension. Real-time data such as functional status can be sent to any mobile device via HMI/SCADA user interface, depending on plant operating platform and requirements. This Cloud-based HMI user interface is available as an option. |
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Provides synchronised optimum tensioning The functions of the Smart G-force tensioner are based on gravity force and it constantly synchronizes the optimum amount of tension force to the collector chain in accordance with sludge loading. This Smart G-force tensioner can be retrofitted to any manufacturer’s sludge collector system. |
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Optical control of chain elongation Once the tension of the collector chain is set, the elongation of the chain will be followed optically
After this point the collector chain has reached its maximum allowable elongation and it is required to take off one link of the collector chain and readjust the Smart G-force tensioner to initial position. |
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Simple and economical The removal of scum during clarification is a necessary step to decease organic loadings and scum build-up in the treatment processes. From a design point of view, a Rotary Skimmer is the most economical and most common type of surface scum skimmer. It effectively removes sewage scum and floating materials from sedimentation tanks and discharge it into scum trough. Merdec scum troughs are available in a range of 200mm – 400mm pipe diameter and maximum tank width of 12m. The scum troughs are fabricated of AISI306 or 316 material depending on site.
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Cross Collectors Chain and Flight as well as Screw Conveyor type Cross Collectors are available with all ancillary components. A Screw Conveyor Cross Collector may be used as an alternative to Chain and Flight Cross Collectors. It serves the same purpose of concentrating the sludge into a sump pit. Power skimmers
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