By separating solids from the liquid phase, the system helps recover reusable drilling fluid and water where applicable, while reducing the volume and moisture content of drill cuttings requiring further handling or disposal. This helps improve drilling fluid utilization and supports more efficient waste management at the drilling site.

The system can be configured with different separation and conveying equipment according to drilling conditions, mud properties, waste characteristics and required treatment capacity. Its integrated configuration is suitable for land-based drilling projects where efficient water-based mud and cuttings treatment is required.

Key Benefits

• Efficient Solid-Liquid Separation: Separates drill cuttings and suspended solids from water-based drilling fluid for more effective waste handling.
• Drilling Fluid Recovery: Helps recover reusable drilling fluid and water, reducing fluid loss where process conditions allow.
• Reduced Waste Volume: Removes excess liquid from drill cuttings and reduces the volume of material requiring further disposal.
• Integrated System Design: Combines multiple treatment units into an integrated system to simplify installation and operation.
• Flexible Configuration: Equipment and treatment capacity can be configured according to project requirements and site conditions.

How the System Works

The water-based drilling waste treatment process typically includes:

Depending on the drilling fluid properties and project requirements, KOSUN can integrate equipment such as vibrating screens, centrifuges, screw conveyors and other separation units to achieve the required treatment performance.

The specific process configuration is customized according to drilling fluid composition, solids loading, required capacity and local environmental requirements.

Applications

The Water-Based Drilling Waste Management System can be applied to:

• Oil & gas drilling
• Shale gas and tight oil drilling
• Coalbed methane drilling
• Geothermal drilling
• Mining exploration and development
• Water well drilling

KOSUN provides customized drilling waste management solutions based on drilling conditions, waste characteristics, treatment requirements and site conditions.

Why Choose KOSUN

With decades of experience in solids control, solid-liquid separation and drilling waste management, KOSUN provides both individual treatment equipment and integrated drilling waste management systems.

From equipment selection and process design to system integration and commissioning, KOSUN develops treatment solutions based on actual drilling conditions and project requirements.

Water-Based Drilling Waste Management System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

During drilling operations, oil-based mud is separated from drill cuttings through a combination of mechanical conveying, centrifugal separation and fluid recovery processes.

The treatment system is designed to:

• Continuously receive and transfer drill cuttings from the drilling operation
• Separate recoverable drilling fluid from drill cuttings
• Reduce residual oil-based drilling fluid on treated cuttings
• Recover drilling fluids for potential reuse
• Reduce the volume of solids requiring transportation and final disposal
• Support cleaner and more efficient drilling waste management at the rig site

Key Equipment

The system can integrate the following equipment:

Vertical Cuttings Dryer
Uses high-speed centrifugal separation to remove drilling fluid from drill cuttings and improve liquid recovery.

High-Speed Decanter Centrifuge
Provides further solid-liquid separation of recovered drilling fluid and helps remove fine solids.

Screw Conveyor
Provides continuous and controlled transfer of drill cuttings between different treatment stages.

Skid-Mounted Tank
Provides process fluid collection and temporary storage within the integrated treatment system.

Slurry Pump and Agitator
Support stable fluid transfer and maintain solids suspension during treatment.

Cuttings Collection Container
Collects treated drill cuttings for subsequent transportation or disposal.

Treatment Process

The typical treatment process consists of:

The specific equipment configuration and process flow can be customized according to drilling fluid properties, cuttings characteristics, required capacity and site conditions.

Key Benefits

Efficient Continuous Treatment
Designed for continuous feeding and treatment to support uninterrupted drilling operations.

Improved Drilling Fluid Recovery
Separates recoverable drilling fluids from drill cuttings, helping reduce fluid losses and operating costs.

Reduced Residual Oil on Cuttings
The combination of centrifugal separation technologies helps reduce the amount of residual drilling fluid remaining on treated cuttings.

Reduced Waste Volume
Separating recoverable fluids from solids can reduce the volume of waste requiring transportation and final disposal.

Modular Skid-Mounted Design
The modular configuration facilitates transportation, installation and relocation between drilling sites.

Integrated PLC Control
Centralized control of major system components improves operational efficiency, monitoring and system safety.

Applications

The Oil-Based Mud Drilling Waste Management System can be applied to drilling operations where oil-based mud and drill cuttings require controlled on-site treatment, including:

• Oil and gas drilling
• Shale gas drilling
• Onshore drilling operations
• Offshore drilling operations
• Coalbed methane drilling
• Geothermal drilling
• Mining and exploration drilling
• Drilling operations in environmentally sensitive areas

KOSUN can configure the treatment system according to the drilling method, mud properties, cuttings characteristics, processing capacity and site requirements.

Field Application

KOSUN oil-based drill cuttings treatment systems have been applied in international drilling waste management projects, including projects in Algeria.

The system configuration can be adapted to different drilling conditions and environmental requirements to support efficient on-site treatment and responsible disposal of drilling waste.

Customized Drilling Waste Management Solutions

Every drilling operation has different waste characteristics, drilling fluid properties and site conditions. KOSUN provides customized oil-based mud treatment and drilling waste management solutions based on the required processing capacity, equipment configuration and project requirements.

Contact KOSUN to discuss your drilling waste treatment requirements.

Oil-Based Mud Drilling Waste Management System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

The KOSUN KD-500 slurry separation system uses a modular design for medium- and large-scale slurry balance shield tunneling projects, offering strong adaptability and stable operation. The system has three main modules: coarse screening, desanding, and desilting, which work together to purify slurry step by step. The coarse screening module removes large solids. The desanding module uses a hydrocyclone and fine-mesh vibrating screen to remove smaller sand particles. The desilting module uses a secondary hydrocyclone for fine separation based on site needs. The system operates in a closed-loop mode, producing waste residue with low moisture content to reduce pollution. All internal parts are made of anti-corrosion and wear-resistant materials, ensuring long life, low failure rates, and reliable performance even in harsh conditions.

Slurry Separation System Parameters 

Slurry Separation System Features 

1. The treatment process is simple and practical, with easy installation, straightforward operation, and low maintenance requirements, effectively reducing labor costs.

2. The system uses a modular integrated design built to standard container dimensions for convenient transportation and rapid installation. It includes a foldable operating platform for a compact structure and small footprint, thus greatly improving on-site flexibility and convenience.

3. The vibrating screen allows flexible adjustment of excitation force, screen angle, and mesh size. The system has strong adaptability and can efficiently handle different geological conditions, thereby ensuring stable purification performance.

4. The processing flow can be customized based on the D50 separation point to meet different material separation requirements. The processing capacity ranges from 100 to 3000 m³/h, making it suitable for various construction scales.

5. The power supply system is flexible and can be adapted to different electrical standards based on site requirements. In particular under special working conditions, the system can be equipped with a generator set to ensure uninterrupted operation regardless of power supply conditions.

6. The system uses a skid-mounted integrated design with a stable structure and easy mobility. Consequently operators can also modify the system into a vehicle-mounted mobile processing unit according to actual requirements, thereby making it suitable for mobile construction scenarios.

Slurry Separation System Application Fields 

The KOSUN KD series slurry separation system effectively adapts to the following four major construction fields:

1. Slurry treatment for slurry balance shield tunneling.

2. Slurry treatment for bored pile foundation construction, including slurry generated by rotary drilling rigs, reverse and positive circulation drilling rigs, impact drilling rigs, and other drilling methods.

3. Slurry treatment for diaphragm wall construction, including slurry generated during trenching operations using equipment such as diaphragm wall machines and dual-wheel milling systems.

4. Slurry treatment for trenchless construction, including slurry generated by horizontal directional drilling (HDD), slurry pipe jacking, and other trenchless construction methods.

KOSUN has many years of experience in mud treatment and solid-liquid separation. The company provides customers with:

• Integrated mud treatment solutions
• Customized process design
• Overseas on-site commissioning services
• Rapid spare parts support
• Full life-cycle technical services

KD-500 Slurry Separation System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

Classification of oily sludge

1. Oily sludge produced during crude oil exploitation. In the drilling operation, when the oil layer is detected,
 the operation of drilling and well testing may cause oil spill or blowout and produce oily sludge due to the action of ground pressure.
 In the process of crude oil production, crude oil detection, plugging, tubing fracture, workover operations, etc., may produce landing oil mud.
This oily sludge has the characteristics of large oil content, fine particles, large viscosity and difficult water removal.

2. Oily sludge produced in the gathering and transportation process of oil fields.
Oil field gathering and transportation is the process of collecting and treating the crude oil produced by each oil well in the oil field and transporting it to the oil depot or the export station respectively.
The gathering station is a place where oil, water and gas are separated from the extracted crude oil, and the sewage station treats the separated water and refills the oil well.
The gathering station and the sewage station are called the combined station. In order to maintain the formation pressure, most of the crude oil is injected with water first and then surfactant. After the formation pressure exists, the crude oil is transported to the surface through the oil well. With the deep exploitation of the oil field, the water content in the produced oil is increasing. Therefore, the oily sludge produced in the oil-water separation process of the joint station usually has a high oil content and water content, and a low solid content, which not only has asphaltene, aging crude oil, bacteria, but also has corrosion inhibitors, scale inhibitors, flocculants and other agents added in the sewage treatment process. There are two sources of oily sludge in the joint station: one is the bottom sludge of crude oil storage tank, settling tank and sewage tank; The second is the oily sludge formed by the overflow of sewage storage tank.

3. Oily sludge produced by the refinery sewage treatment process. Oil-bearing sludge in oil refinery, commonly known as "three mud", has a large output, and usually has the characteristics of complex composition, difficult degradation, difficult settlement, difficult concentration and difficult treatment.

Characteristics and hazards of oily sludge

Oily sludge density is generally larger than water, oil content is high, generally 10%-50%, water content is 50%-90%, viscosity is large,
dehydration is difficult, is a black viscous semi-fluid. The composition of oily sludge is complex, not only with a large number of aging crude oil, asphaltene,
wax, colloids, bacteria, solid suspended matter, salts, corrosive products, acid gas, etc., but also in the production process added corrosion inhibitors,
coagulants, fungicides, scale inhibitors and other water treatment agents, is one of the main pollution sources in the oil industry

Oily sludge is rich in organic matter, salt, nitrogen, phosphorus, sulfur and other nutrients. If it is directly discharged into the surface water body or under the action of precipitation, the organic matter and ammonia nitrogen will consume a large amount of oxygen in the water body, resulting in eutrophication of the water body and seriously affecting the balance of the aquatic ecosystem. In addition, oily sludge also contains heavy metals such as copper, zinc, chromium, cadmium, mercury, lead and pathogenic bacteria, parasites (eggs), polychlorinated biphenyls, dioxins, radionuclides and other toxic and harmful substances that are difficult to degrade, which will not only pollute the environment, but also affect human health, leading to many fatal diseases, and even carcinogenic, teratogen, mutagenic effects. Therefore, in 1998, the State Environmental Protection Bureau classified oily sludge as waste mineral oil and mineral oil waste (HW08 item) hazardous solid waste, and required harmless disposal before discharge.

The processing process is: The material to be treated is fed by the belt conveyor into the spiral sand washing machine,
the sand treated by the spiral sand washing machine enters the fine particle sand removal machine, the fine particle sand is crushed and cleaned,
part of the oil is separated into the oil storage tank by the scraper, the sediment is transported to the vibrating screen by the centrifugal pump for dehydration,
 and the particles larger than 0.5mm are separated. >74 micron<0.5mm particles and sediment are processed by centrifugal pump into cyclone,
<74 micron particles are separated and dehydrated by centrifuge, and <2 micron materials are processed by air flotation machine.
The sand after air flotation treatment is discharged and dried, and the water after air flotation treatment is reused by spiral sand washing machine.
The oil sewage of the spiral sand washing machine enters the oil sand separation tank for treatment. After treatment,
the oil enters the oil storage tank for recovery through the scraper. The fine sediment after precipitation is transported to the vibrating screen by the centrifugal pump.
 

sludge sand treatment最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

Integrating the structural features and design concepts of the mobile and skid-mounted solids control system for satisfying the drilling requirements on time reduction, moving speed improvement and cost trimming, KOSUN has developed Mobile Solids Control System giving priority to safety which is followed by efficiency and environmental protection and has greatly increased the system automation. Actual application also proves that it not only has the advantages of simple structure, security and compact design, but also has the unparalleled edges as ease of moving and large scale of application.>>Send an Enquiry sales@adkosun.com<<

KOSUN Mobile Solids Control System Pictures:

Mobile Solids Control System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

Oily sludge refers to a mixture of oil, water, and solids. KOSUN can provide complete sets of equipment for oily sludge treatment to treat the sludge and recover oil and water. The thermal washing technology for oily sludge treatment can achieve lower-cost solid disposal and maximize oil recovery.

Oil-containing sludge is the main pollutant generated during the production process of oil, including crude oil extraction, storage, transportation, processing, and treatment of produced water. Oil-containing sludge is typically a stable suspension emulsion system consisting of water-in-oil (w/o), oil-in-water (o/w), and suspended solids. It has poor dewatering effect and its composition and properties are influenced by factors such as wastewater quality, treatment processes, and additives, resulting in high variability and difficulty in treatment. The oil content of oil-containing sludge varies significantly, and some of it has potential for recycling. Additionally, oil-containing sludge contains harmful substances such as heavy metals, posing a risk of environmental and radioactive pollution.

Oil content in oily sludge is relatively high, making it a valuable resource in waste. If not properly recovered, it would result in significant material waste. Storing or landfilling oily sludge occupies a large amount of arable land while polluting the surrounding environment. The volatile components of oil in oily sludge can pollute the air when released. When rainwater carries oil from the sludge into water bodies, it causes severe pollution and disrupts the aquatic ecosystem. The petroleum in the sludge can harm the soil’s microbial and plant ecosystems when it enters the soil. Furthermore, many harmful substances in crude oil have mutagenic and carcinogenic properties, causing serious harm to human health through direct and indirect exposure. Therefore, it is crucial to properly treat oily sludge using suitable methods to achieve both resource recovery and environmental protection goals, considering both environmental protection and resource recycling perspectives.

The large-scale thermal washing and skid-mounted treatment system for oily sludge produced by Xi’an KOSUN consists of pre-treatment module, oil-sand separation module, screening module, oil-water separation module, etc. The system aims to address the treatment of waste oil sludge generated during drilling processes. The system has a processing capacity of 30t/h, and the oil content in the solid phase after treatment can reach less than 3%. The thermal washing and skid-mounted treatment system for oily sludge achieves good treatment results and effectively reduces the cost of solid waste treatment, achieving harmless and resource-oriented disposal. It is worth mentioning that the water in this system is recycled, resulting in minimal water consumption, environmental safety, and no secondary pollution.

Application scope:

Bottom sludge from oilfield central stations, aged sludge from oilfield central stations, land-based oil sludge, complex mixed sludge from industrial waste pits in oilfields, intermediate sediment isolation layers from natural settlement and dewatering in oilfield water treatment processes, oil-containing sludge generated during oil drilling oil-based cuttings oil removal processes, bottom sludge from offshore oil tanker compartments, oil sludge residue discharged from separation machines for ship fuel oil and lubricants, oil sludge treatment in petrochemical plants, waste lubricating oil and emulsified oil treatment, treatment of other mineral oil sludge and sediment, and storage of coal tar in coal chemical industries.

Oil Sludge Thermal Washing and Disposal System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

Large Capacity, Vertical Design:

KOSUN offers various Mud Storage Station capacities 7500 BBL, 15000 BBL, 30000 BBL, 45000 BBL. Our innovative Vertical Mud Tank layout significantly reduces the required footprint by over 40% compared to traditional horizontal tanks or earthen pits.

Modular Design, Flexible Deployment

The drilling mud station system adopts a modular design concept, allowing for flexible expansion or combination based on specific project requirements, which enables rapid installation and relocation, and significantly enhances equipment utilization and project adaptability.

Integrated, Intelligent All-Process Liquid Mud Plant System

The LMP is a complete Mud Treatment System ecosystem designed for intelligent operation.

Intelligent Storage and Mixing

Vertical storage tanks feature smooth inner walls and anti-sedimentation devices. Integrated automated batching and agitation units enable precise, real-time control of Mud Density and Viscosity, ensuring optimal mud performance.

High-Efficiency Purification and Circulation

Built-in Multi-Stage Purification modules, Shale Shakers, Desanders, Desilters, and Decanter Centrifuges rapidly remove harmful solid phases.

The treated mud is reused in a closed-loop system, dramatically reducing the cost of purchasing new materials.

Comprehensive Solid-Waste Separation

Drill cuttings and waste residues are dewatered using Filter Presses, forming low-moisture "mud cakes."

This "solid-liquid separation, dry waste transport" approach significantly reduces the volume of hazardous waste disposal.

The Core Value of Liquid Mud Plant

Saves Space: Vertical design conserves land resources.

Saves Material: High mud recycling rates lower procurement costs.

Saves Cost: Waste minimization reduces disposal fees.

Saves Manpower: Automated controls minimize manual intervention and operational risks.

Environmental Compliance and Safety

Fully enclosed operations eliminate mud spills, protecting soil and groundwater.

The LMP helps projects easily achieve "Green Construction" and "Clean Production" goals, enhancing corporate social responsibility image.

Enhancing Engineering Quality and Efficiency

Stable mud performance provided by the LMP System offers reliable assurance for core engineering processes such as Oil & Gas Drilling, Foundation Piling, and Tunneling.

Application Fields for the Liquid Mud Plant

Widely used in Oil & Gas Drilling, Trenchless Engineering HDD, Piling Construction, Tunnel Shield Excavation, and River Dredging.

The KOSUN LMP mud station is not just a tool for processing mud; it's a strategic partner for achieving cost reduction, efficiency gains, and sustainable green construction. We are committed to using innovative technology and reliable products to help you navigate complex mud management challenges and win broader market opportunities.

Liquid Mud Plant (LMP )最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

The multifunctional design of KOSUN Skid-mounted Solids Control System enables the overall system to meet the requirements of various well depths and drilling fluids. Each solid control equipment can operate independently or collectively with the others. KOSUN is able to manufacture the mud circulating system for 350HP, 450HP, 550HP, 650HP, 750HP Workover Rig and for 1000HP, 1500HP and 2000HP Skid-mounted Land Rig.>>Send an Enquiry sales@adkosun.com<<

KOSUN Skid-mounted Solids Control System Working Sites:

Skid-mounted Solids Control System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

KOSUN is able to customize its system to produce the arctic solids control system which is solely applied under extremely cold temperature to meet the requirements of the polar cold ( minus 40 degrees centigrade ) working conditions.>>Send an Enquiry sales@adkosun.com<<

KOSUN Arctic Solids Control System Working Site:

Arctic Solids Control System最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。

Sludge has been listed in the "National Hazardous Waste List" of waste mineral oil (HW08 category), and relevant laws such as the "National Clean Production Promotion Law" and "Solid Waste Environmental Pollution Prevention Law" also require that sludge must be harmless treatment.

Xi 'an KOSUN closely follows the national policy, vigorously develops green and environmentally friendly sludge treatment and soil remediation equipment,
 combines vibration separation technology, centrifugal separation technology and fluid mechanics to solve the problem of solid-liquid two-phase separation in the process of environmental protection waste treatment,
 and reduces pollutant emissions through follow-up treatment functions. Recycle available resources and meet local government emission standards and environmental requirements

Oily sludge hot wash Processing system最先出现在Solids Control System, Slurry Treatment Plant, HDD mud recycling system-KOSUN。