A 1 T/H oily sludge treatment system supplied by KOSUN has been completed for an African waste oil recovery company. Combining thermal washing with three-phase centrifugal separation, the system is designed to recover oil from petroleum sludge, recycle process water, and reduce the amount of solid waste requiring disposal.
Addressing Oily Sludge Disposal Challenges
Oily sludge generated by onshore and offshore oilfield operations presents challenges in waste management and resource recovery. In the client’s operating region, incineration had traditionally been used for disposal, bringing high treatment costs and environmental concerns.
The project required a treatment solution that could recover valuable oil while improving water utilization and reducing residual waste. KOSUN’s integrated system brings together sludge conditioning, heating, chemical dosing, centrifugal separation, oil storage, and automatic control.
How the Oily Sludge Treatment Process Works
The system uses a combined thermal washing and three-phase separation process to separate oil, water, and solids.
Step 1: Thermal Washing and Sludge Conditioning
Incoming oily sludge is fed into a conditioning tank. Steam heating, chemical additives, and mechanical mixing help break down the sludge structure and release oil attached to solid particles, preparing the material for separation.
Step 2: Oil, Water, and Solids Separation
The conditioned sludge is transferred to a KOSUN LWS350 three-phase decanter centrifuge. The centrifuge uses density differences to separate the mixture into three streams:
- Recovered oil: Collected in the oil storage unit for further use or recovery.
- Separated water: Treated and returned to the thermal washing process for reuse.
- Separated solids: Discharged for appropriate downstream handling.
By recycling process water, the system helps reduce freshwater consumption and supports more efficient use of water during oily sludge treatment.
Integrated System Design
The complete treatment system includes six integrated units:
- Pretreatment
- Three-phase separation
- Oil storage
- Chemical dosing
- Heating
- Automatic control
Its skid-mounted configuration allows the equipment to be assembled and commissioned at the factory before delivery, simplifying site installation and integration.
PLC-based control coordinates system operation and supports process monitoring. Explosion-proof electrical components and corrosion-resistant structures can also be incorporated to meet project-specific operating conditions.
Supporting Resource Recovery and Waste Reduction
Recovering Valuable Oil
Separating oil from sludge creates opportunities to recover usable petroleum resources rather than treating the entire mixture as waste.
Reducing Residual Waste
Removing recoverable oil and separating the water phase helps reduce the amount of residual material requiring further treatment or disposal.
Improving Water Utilization
The recirculating water arrangement returns treated process water to the thermal washing stage, helping reduce demand for fresh water.
Adapting to Different Oily Waste Streams
Depending on feed composition and process requirements, the system can be configured to treat tank-bottom sludge, oily drilling sludge, oil-contaminated soil, and oil-based drill cuttings.
Integrated Solutions for Oily Waste Management
Effective oily sludge treatment requires more than separating oil from solids. Heating, chemical conditioning, phase separation, water management, and process control must work together to support reliable operation.
Through integrated treatment systems, KOSUN supports oil recovery, waste volume reduction, and process water reuse for demanding industrial and oilfield applications.