KOSUN

分类： Industry Update

KOSUN exclusively manufacture solids control system,drilling mud solids control equipment,Oilfiled Solids Control,oil and gas drilling waste managemen

  • Drilling waste treatment: Reducing costs and increasing efficiency, creating a New Era of green drilling!

     
    Amid the roar of oilfield development, drilling operations are advancing efficiently. However, the drilling waste that comes along with it has become a persistent problem plaguing the industry's development – the traditional disposal methods are costly, environmental protection pressure follows closely, and the waste of resources is truly regrettable. How to break the deadlock? The drilling waste treatment technology developed by Xi 'an KOSUN offers you a one-stop green solution!

     

     

    The first step: Reuse and "cut off the flow" from the source
    In traditional drilling, the landing of mud is the "starting point" of pollution – mud mixed with heavy metals and petroleum substances seeps into the soil and is difficult to degrade naturally for 30 years.
    The solid control equipment combined with the mud non-landing technology enables the mud to circulate in a "closed loop" within the drilling system.
     
    Step 2: Reduction treatment + recycling, turning "waste" into "treasure"
    During the drilling process, barite (a key raw material for drilling mud) is quite expensive. If it is lost along with the waste, it is equivalent to "pouring money into the mud".
    The barite recovery technology of this system can efficiently extract barite from waste and reuse it for slurry preparation.
     
    Step 3: Emission safety net, Zero risk for Compliance
    Even after multiple layers of recycling, there is still a small amount of waste that needs to be discharged. The solidification,
    biodegradation and thermal desorption technologies in the system make the emissions "harmless".
    The working principle of the drilling waste treatment system is based on the comprehensive application of various technical means such as physical, chemical and biological methods. The uniformity of materials is improved through pretreatment. The effective separation of oil, water and residue is achieved by using solid-liquid separation technology. Then, through the oil recovery and wastewater treatment system, the recycling of oil and the standard treatment of wastewater are respectively realized. The waste residue is treated harmlessly to ensure the environmental friendliness of the entire treatment process.
     
    From drill cuttings recovery, solid-liquid separation to drying and volume reduction, and resource reuse, the processing system is modularly designed and flexibly combined to adapt to various working conditions and processing requirements. It can be applied to onshore drilling platforms and shale gas Wells. Offshore drilling platform Projects such as co-processing of waste from petrochemical enterprises. The application of the drilling waste treatment system has effectively reduced environmental pollution during the oilfield development process and improved the utilization efficiency of resources. The drilling waste treatment system, as an important environmental protection equipment in the field of petroleum exploration and development, its research and application are of great significance for promoting the sustainable development of the petroleum industry. In the future, with the continuous advancement of technology and increasingly strict environmental protection requirements, this field will embrace an even broader development prospect.

  • What factors affect the performance of the horizontal screw centrifuge?

     
    The horizontal screw centrifuge mainly consists of a drum, a screw, a differential system, a liquid level baffle, a drive system and a control system, etc. It is a dedicated solid-liquid separation equipment designed in accordance with the characteristics of petroleum drilling fluid. It can complete various processes such as feeding, centrifugal sedimentation and unloading at full speed. It is mainly used for recovering barite, removing fine solids, reducing the solid content of drilling fluid, controlling the density and viscosity of drilling fluid, ensuring the performance of drilling fluid and playing an important role in rapid drilling. The LW series centrifuge separates drilling suspensions based on the principle of centrifugal sedimentation. The suspension enters the drum through the liquid outlet hole in the screw conveyor via the feed pipe. Under the action of centrifugal force, solid particles are pushed to the inner wall of the drum and discharged from the small end of the drum through the blades on the screw conveyor. The liquid phase overflows through the overflow hole at the large end of the drum. This cycle is repeated continuously to achieve the purpose of continuous separation. The sedimentation centrifuge belongs to the category of horizontal screw centrifuges, and its full name is horizontal screw sedimentation centrifuge.

     

     

    Factors affecting the performance of horizontal screw centrifuges
     
    The application effect of the horizontal screw centrifuge is influenced by the mechanical part, which can be divided into adjustable factors and non-adjustable factors. The following is an explanation of each. First, by understanding its working principle, it can be effectively controlled during use
    The non-adjustable mechanical factors include: the diameter of the drum and its effective length. Semi-cone Angle of the drum. Pitch. Spiral type. The following classification is explained: Drum diameter and effective length: The larger the drum diameter, the longer the effective length, the larger the effective settlement area, and the greater the processing capacity. The semi-cone Angle of the drum: When the sediment settled on the inner side of the centrifuge drum is pushed towards the discharge port along the conical end of the drum, it is subjected to a downward sliding reflux force due to the effect of centrifugal force. The semi-cone Angle of the drum: A relatively important parameter in the design of centrifuges. In terms of clarification effect, the cone Angle should be as large as possible. In terms of slag conveying and dewatering effects, the cone Angle should be as small as possible. Pitch: that is, the distance between two adjacent helical blades, is a very important structural parameter and directly affects the success or failure of slag transportation. When the diameter of the helix is constant, the larger the pitch and the greater the helix Angle, the greater the chance that the material will get clogged between the helix blades. At the same time, a large pitch will reduce the number of turns of the helical blade, resulting in uneven material distribution at the conical end of the drum and causing increased machine vibration. Therefore, for difficult-to-separate materials such as activated sludge, the conveying of the residue is rather challenging, and the pitch should be smaller. Spiral type: According to the different ways of relative movement of liquid and solid within the drum, it is divided into counter-flow type and co-flow type. The feeding chamber of the counter-flow centrifuge is located in the middle of the screw, that is, near the boundary between the drying zone and the sedimentation zone, to ensure that the liquid phase has sufficient sedimentation distance, but the solid phase can only stay for the time it needs to pass through the conical part, so a relatively high centrifugal force is required. When materials enter the drum from here, the solid particles that have already settled in this area will float up again due to disturbance, and turbulence and additional vortices will also be generated, reducing the separation effect.
     
    2. Adjustable mechanical factors include:

     

    drum speed, differential speed (differential ratio), liquid ring layer thickness, and process factors. The following is a classification explanation: Drum speed: The adjustment of drum speed is usually achieved through a variable frequency motor or a hydraulic motor. The greater the rotational speed, the greater the centrifugal force, which is conducive to increasing the solid content of the mud cake. However, if the rotational speed is too high, the sludge flocs will be destroyed, which will instead reduce the dewatering effect. At the same time, higher rotational speeds have higher requirements for materials, increase the wear and tear on the machine, and the power consumption, vibration and level will also increase accordingly. Differential velocity (differential ratio) directly affects the sludge discharge capacity, the dryness of the sludge cake and the quality of the filtrate. Increasing the differential velocity is beneficial for enhancing the sludge discharge capacity, but the dewatering time of the sediment will be shortened, and the moisture content of the sludge cake after dewatering will be high. At the same time, excessive differential velocity will increase the disturbance of the screw to the liquid pool in the clarification zone, and the quality of the filtrate will be relatively poor (commonly known as "backmixing"). The thickness of the liquid ring layer: The thickness of the liquid ring layer is an important parameter for equipment optimization, directly affecting the effective sedimentation volume of the centrifuge and the length of the drying zone (shore zone), and thereby influencing the treatment effect of sludge dewatering. Generally, it is achieved by manually adjusting the height of the liquid level baffles when the machine is shut down. During adjustment, it is necessary to ensure that the heights of all liquid level baffles are consistent; otherwise, it will cause severe vibration during the operation of the centrifuge. An increase in the thickness of the liquid ring layer will expand the sedimentation area, and the residence time of the material in the machine will also increase accordingly, improving the quality of the filtrate. However, at the same time, the length of the drying zone (shore zone) within the machine will shorten, resulting in a decrease in the dryness of the mud cake. On the contrary, reducing the thickness of the liquid ring layer can achieve a higher solid content in the mud cake, but it comes at the expense of the quality of the filtrate. Process factors: To improve the dewatering performance of sludge, an appropriate amount of organic high-molecular flocculants, such as polyacrylamide (PAM), should generally be uniformly added before mechanical dewatering to reduce the specific resistance of the sludge, making it easier to dewater after the separation of the solid and liquid phases of the sludge. The type of flocculant must be compatible with the characteristics of the sludge, as well as the type of equipment and operating conditions. In many cases, the reagents that perform well in the beaker test for flocculant selection do not have better performance in practical applications. A very important reason for this is that although the characteristics of the reagents to some extent meet the characteristics of the sludge, they cannot fully meet the operating conditions of the equipment.
     

    There are many factors that affect the dewatering efficiency of the horizontal screw centrifuge, and these factors interact with each other. Therefore, the treatment effect is the result of the combined action of the above-mentioned factors. The selection of the centrifuge should be based on the actual situation of the engineering project, and the adjustment of operating parameters should comprehensively consider factors such as the expected moisture content, solid content and economy of the dewatered mud cake as required by the disposal method of the dewatered mud cake.

  • Innovation and application of vertical cuttings spin dryrs, key equipment in the oil drilling industry

     
    Oil drilling, as a globally significant energy resource, faces numerous challenges during the extraction process. During the drilling process, a large amount of drilling cuttings are produced. These cuttings are usually mixed with drilling fluid. If not handled properly, it will not only cause waste of resources but also cause serious pollution to the environment. As an advanced solid-liquid separator, the vertical cuttings dryer plays a crucial role in the oil drilling industry. It can effectively process drilling cuttings, achieving the recycling and reuse of drilling fluids and the standard discharge of cuttings. It can effectively handle drilling cuttings, achieving the recycling of drilling fluid and the standard discharge of cuttings. With the continuous growth of global energy demand and increasingly strict environmental protection standards, it is of great practical significance to have a thorough understanding of the working principle and performance advantages of vertical cuttings dryers and their application in the oil drilling industry.

     

     

    I. Overview of Vertical Rock Cuttings Spin Dryer
     
    1. Working principle
     
    This equipment utilizes centrifugal force to achieve efficient separation of drilling cuttings and drilling fluid. During operation, the drill cuttings mixture enters the high-speed rotating drum. Under the action of centrifugal force, the denser cuttings are thrown towards the drum wall and scraped off by the scraper, while the drilling fluid accumulates towards the center and is discharged from the overflow outlet. This method features high separation efficiency and large processing capacity, which can meet the rapid and precise demands of solid-liquid separation in the oil drilling industry.
     
    2. Structure
     
    Vertical cuttings spin dryers are typically composed of rollers, scrapers, drive units, frames and control systems. The drum is the core component of the equipment. Its material is generally made of high-strength and wear-resistant materials to withstand the huge centrifugal force and rock debris wear during high-speed rotation. The scraper is installed inside the drum. Its function is to promptly scrape off the rock debris adhering to the inner wall of the drum, ensuring the normal operation of the equipment and the separation effect. The drive unit provides power for the rotation of the drum. Generally, high-performance motors and transmission systems are adopted to achieve smooth and high-speed rotation of the drum. The frame plays a role in supporting and fixing each component, ensuring the stability of the equipment during operation. The control system is used to control the start-up, stop, speed regulation and other operating parameters of the equipment, to achieve the automatic and intelligent operation of the equipment, and to improve the operational efficiency and reliability of the equipment.
     
    3. Performance characteristics
     
    Efficient solid-liquid separation
    The vertical cuttings spin dryer has excellent solid-liquid separation capabilities and can effectively separate drilling fluid from drilling cuttings. This equipment was designed and manufactured with full consideration of the harsh environment and high-load operation requirements of oil drilling operations. It adopts high-quality materials and advanced manufacturing processes to ensure high reliability and stability. In practical applications, many oil drilling enterprises have reported that the vertical cuttings spin dryer can still maintain a good working condition after continuous operation for thousands of hours, providing a strong guarantee for the smooth progress of drilling operations. Easy to operate and maintain

     

     

    Ii. The Key Role of Vertical Cuttings Dryers in the Oil Drilling Industry
     
     
    Reduce waste emissions
     
    During the process of oil drilling, a large amount of drilling cuttings and waste drilling fluid are directly discharged without effective treatment, which will cause serious pollution to the surrounding environment. Vertical cuttings dryers can effectively separate drilling fluids from cuttings, reduce the water and oil content of cuttings, and thereby decrease the overall waste discharge. The oil content of the processed rock cuttings can be as low as less than 5%, meeting international environmental protection standards and significantly reducing the risk of pollution to soil, water and other environments.
     
    2. Reduce pollution to soil and water
     
    The traditional methods for handling drilling waste are prone to causing harmful substances to seep into the soil and water bodies, resulting in long-term damage to the ecological environment. The vertical cuttings dryer separates harmful substances from cuttings in drilling fluid through efficient solid-liquid separation, preventing these substances from causing damage to soil and water. The vertical cuttings dryer effectively separates harmful substances in the drilling fluid from the cuttings through solid-liquid separation, avoiding direct pollution to the soil and water. Meanwhile, the recovered drilling fluid can be reused after further processing, reducing the usage of new drilling fluid and indirectly lowering the potential pollution risk to the environment.
     
     
    3. Recovery and reuse of drilling fluid
     
    Drilling fluid is an important consumable in oil drilling operations, and its cost accounts for a large proportion of the total drilling cost. Vertical cuttings dryers can effectively recover drilling fluid from drilling cuttings. After appropriate treatment, the drilling fluid can be reused in drilling operations. Generally speaking, a large amount of drilling fluid can be recovered by using this kind of equipment, and the recovery rate can reach a certain percentage.
     
    4. Ensure the continuity of drilling operations
     
    In drilling operations, if drilling cuttings are not dealt with in a timely manner, they will accumulate, affecting the normal operation of drilling equipment and even causing safety accidents. The vertical cuttings dryer can continuously and stably process drilling cuttings, ensuring the continuity of drilling operations. The vertical cuttings dryer provides continuous and stable cuttings treatment, ensuring the continuity of drilling operations. The high reliability and stability of the equipment enable it to maintain a good working condition for a relatively long time, reducing the downtime caused by equipment failures.
    Vertical cuttings spin dryers play a crucial role in the oil drilling industry. It not only complies with increasingly strict environmental protection regulations, reducing waste emissions and pollution to soil and water, but also effectively lowers costs through the recycling and reuse of drilling fluids and the reduction of waste treatment costs. Meanwhile, its rapid processing of drilling cuttings ensures the continuity of drilling operations, which can significantly improve drilling efficiency, reduce flammable and explosive substances, lower the risk of equipment failure, and enhance overall operational safety.

  • Hot washing process of oil sludge: A key technology for environmental protection and resource regeneration in oil fields

    The rapid development of the petroleum industry has brought about a thorny problem: oily sludge. These black pollutants produced during the processes of oil extraction, transportation and refining contain a large amount of toxic and harmful substances. They not only damage the structure and ecological functions of the soil, but also may pollute groundwater and threaten human health.
     
    The traditional incineration and landfill treatment methods are not only inefficient but may also cause secondary pollution. Facing the increasingly severe environmental protection situation, oilfield enterprises urgently need an efficient, environmentally friendly and economical solution.
     
    The hot washing process of oil sludge is an efficient and environmentally friendly technology for treating oil sludge. It achieves the reduction, harmless treatment and resource utilization of oil sludge by heating, washing and separating the oil sludge, thus separating the oil, water and solid substances in the oil sludge.

     


     

    The hot washing process flow of oil sludge mainly includes the following steps:
     
    1. Vibrating screen pretreatment: Screen the oil sludge to be treated to remove large particle waste. At the same time, add spray water to make the oil sludge more moist, which is convenient for subsequent treatment.
    2. Mixing tank treatment: Put the sieved oil sludge into the mixing tank, add hot water and chemicals, and stir thoroughly. The agent can play a role in emulsifying, dispersing and dissolving the oil in the oil sludge, while hot water can increase the temperature of the oil sludge and accelerate the separation of the oil.
    3. Sedimentation tank separation: Put the stirred oil sludge into the sedimentation tank for sedimentation separation. During the sedimentation process, the oil in the sludge will float to the water surface, forming floating oil, while water and solid substances will settle at the bottom of the tank. Floating oil can be transported through pipelines to waste oil tanks for recycling and reuse, while water can be transported through pipelines to water tanks for recycling and reuse.
    4. Centrifuge separation: Place the sediment at the bottom of the sedimentation tank into a centrifuge for centrifugal separation. During the centrifugation process, water and solid substances in the sediment will be separated. The water can be transported through pipelines to the water tank for recycling, while the solid substances will be discharged and treated as waste residue.


     

    The hot washing process of oil sludge has the following advantages:
     
    1. Environmentally friendly and pollution-free: The entire treatment process does not produce waste gas, wastewater or waste residue, and will not cause secondary pollution to the environment.
    2. High resource utilization rate: The oil in the oil sludge can be recovered and reused, and at the same time, water and solid substances can be recycled, which improves the utilization rate of resources.
    3. Low processing cost: Compared with traditional oil sludge treatment methods, the oil sludge hot washing process has a lower processing cost and a higher cost performance.
    The hot washing process of oil sludge is an efficient, environmentally friendly, resource-efficient and low-cost oil sludge treatment technology. It can effectively solve the problem of oil sludge pollution and contribute to the sustainable development of the petroleum industry.

  • How does the oily sludge treatment equipment achieve efficient separation of oil, sludge and sand in three phases?

    Oil sludge is also known as oily sludge, oil mud sand, fallen oil sludge, etc. During the drilling process, when the drilling rig is replaced and casing is extracted, oily sludge is carried out and left around the well site. This oily sludge is wrapped with various mud, sand and other impurities. It cannot be dealt with on site in time and is temporarily piled up at the well site. As it accumulates more and more, it is produced. The oily sludge comes from deep within the drilling formation and contains a large amount of toxic substances with a foul smell such as benzene series, phenols, anthracene and pyrene. If oily sludge is not treated, it will not only damage the soil and pollute the environment, but also cause a waste of resources.


     

     

    1- The generation and hazards of oily sludge (oil mud sand)
     
    The generation of oily sludge (oil mud sand) :
     
    Oily sludge is an oily solid waste produced in the processes of oil extraction, transportation, refining and oily wastewater treatment. It is one of the main pollution sources in the production process of oilfield enterprises. There are many types and complex properties of oily sludge. The sludge produced during crude oil extraction mainly comes from the surface treatment system. The oily sludge generated during the oil production wastewater treatment process, along with the flocs formed by the water purifying agents added in the wastewater purification treatment, corrosion products and scale of equipment and pipelines, bacteria (corpses), etc., constitute the sludge. When oil storage tanks in petrochemical enterprises store oil products, a small amount of mechanical impurities, sand particles, soil, heavy metal salts, as well as heavy oil components such as paraffin and asphaltene in the oil products deposit at the bottom of the tanks, forming tank bottom sludge.
     
     
    The hazards of oily sludge (oil mud sand) :
     
    Oily sludge contains a large amount of toxic substances with a foul smell such as benzene series, phenols, anthracene and pyrene. If oily sludge is not treated, it will seriously pollute the soil and the environment. On the other hand, if oily sludge is not collected in time, it will cause a waste of resources. The oil content in sludge is generally between 10% and 50%, and the water content is between 10% and 60%. Oily sludge is rich in crude oil. If crude oil is separated and extracted from it, the water content of the crude oil is below 4%, which meets the crude oil recovery standards and can be recycled and utilized by crude oil recovery plants and refineries to achieve economic value.
     
    Current situation of oily sludge (oil mud sand) treatment:
    Oily sludge is generally a stable suspended emulsion system composed of oil-in-water (o/w), water-in-oil (w/o), and suspended solids. It has poor dewatering effect, and the composition and physical properties of the sludge are affected by factors such as the quality of the wastewater, treatment process, and chemicals added. Due to the significant differences in oil sludge and oil content, as well as the inconsistent conditions of each unit, it is difficult to formulate standardized equipment, making the treatment highly challenging.
     
    2- The treatment process of oily sludge by Xi 'an Kosun
    Xi 'an Kosun Manufacturing, based on the characteristics of oily sludge, relying on the technical advantages of the integrated solid-liquid separation solution and combining years of research and application experience in oilfield solid-liquid separation equipment systems, has launched this economical and efficient "oily sludge treatment solution".


     

     


    Flowchart of the treatment process for oily sludge

     

    The first step: Through the sorting equipment, the stones, weeds, tree roots and other impurities in the oily sludge are sorted out.
    Step 2: Through heating tank equipment, stirring equipment, and dosing equipment, by taking advantage of the physical property of different specific graviums between oil and water, water, oil, silt, etc. are fully stratified through water temperature, chemicals, and stirring. Oil, with a lower specific gravity, adheres to the top layer; water, with a lower specific gravity, follows in the middle layer; and silt, with a higher specific gravity, settles at the bottom layer.
    Step 3: Utilize three-phase separation equipment. This step can also be achieved through oil-water separation equipment and sludge-water separation equipment, etc. The aim is to achieve the three-phase separation of water, oil and sludge, as well as the reuse of crude oil and water. The slurry water enters the slurry water treatment equipment. The water can be reused in the heating tank or further processed through the water treatment equipment.
     
    3- Composition of Xi 'an Kosun Oily Sludge Treatment System
     
    Xi 'an Kosun has designed and configured a complete set of integrated oily sludge treatment systems based on the "Oily Sludge Treatment Plan". It features flexible equipment selection, flexible configuration, low investment and high output. The Xi 'an Kosun oily sludge treatment system consists of: oil sludge pretreatment equipment, oil sludge sand screening equipment, dosing system, oil-water separation equipment, sludge-water separation equipment and other types of equipment.

     

    Oily sludge treatment system
     

    4- Xi 'an Kosun Oily Sludge Treatment System Case
     
    In terms of the treatment of oil mud and oil-based mud in oil fields, Xi 'an Kosun has designed and produced a number of integrated solutions for oil field projects in domestic regions such as Gansu, Inner Mongolia, Xinjiang, and Sichuan, as well as in international countries like Kuwait, Russia, and Uzbekistan. As a professional equipment manufacturer specializing in the treatment of oilfield oil mud and sand, oily sludge, oil sludge and oil mud, we can design integrated solutions for our customers based on the specific conditions of each oilfield, and provide dedicated oily sludge treatment equipment and systems, truly achieving low-cost, large-scale and resourceful treatment of oilfield oil mud and sand, oil sludge and other pollution sources. Welcome to consult. We will serve you wholeheartedly!

     

  • Water-based mud waste treatment system

     
    Against the backdrop of the continuous growth of global energy demand and increasingly strict environmental protection requirements, the oil drilling industry is facing unprecedented environmental challenges and transformation opportunities. As an indispensable component of drilling engineering, water-based mud, after fulfilling its functions such as wall protection, slag-carrying and cooling, often turns into difficult-to-handle waste, becoming a long-standing and intractable problem plaguing the industry. With nearly three decades of technological accumulation and innovative breakthroughs, Xi 'an KOSUN has successfully developed a series of efficient and intelligent water-based mud waste treatment systems, addressing industry pain points and providing cost-effective green solutions for global drilling enterprises.


     


     

    Water-based mud, as the most commonly used circulating medium in drilling engineering, often becomes a difficult-to-handle waste after fulfilling important functions such as protecting the borehole wall, cooling the drill bit, and carrying rock cuttings due to the mixture of a large amount of drill cuttings, chemical additives, and formation materials. The traditional treatment methods are confronted with multiple predicaments: direct discharge will pollute soil and water sources and endanger the ecological environment; Simple landfill, however, occupies a large amount of land resources and poses a long-term risk of seepage. However, the natural sedimentation method is inefficient and cannot meet the high-intensity operation requirements of modern drilling engineering.
    Meanwhile, the drilling industry itself is also confronted with cost pressure and efficiency challenges. The traditional mud treatment methods often require a large amount of human and material resources, have a long treatment cycle, and affect the overall project progress. However, untreated mud cannot be recycled, leading to the continuous input of new materials and significantly increasing operating costs. How to meet environmental protection requirements while improving processing efficiency and reducing overall costs has become an urgent problem for drilling enterprises to solve.



     

    Xi 'an Kosun has a profound understanding of industry demands. Through continuous technological innovation, it has successfully developed a modular, intelligent and efficient water-based mud waste treatment system. The system scientifically processes the cuttings and waste drilling fluid generated during drilling through a series of precise procedures such as collection, transmission, dosing and stirring, gel breaking and destabilization, and solid-liquid separation. Our technology not only meets the strictest environmental protection standards, but also converts waste into reusable resources, truly realizing the circular economy model of "turning waste into treasure".
    Precise solid-liquid separation: By using advanced equipment such as vibrating screens and mud cleaners, the solid and liquid phases in the mud can be efficiently separated based on the differences in particle size and density. The solid-phase control accuracy can reach ≤5μm, ensuring the precision of the separation effect and laying a solid foundation for subsequent processing.
    Resource recycling: After the separated liquid phase undergoes deep purification treatment and meets environmental protection standards, part of it can be directly reused in the preparation of drilling fluid, achieving the recycling of water resources and significantly reducing the cost of new slurry preparation.


     

    Overall, the water-based slurry waste treatment process is a comprehensive systematic project, which requires close cooperation among multiple links to achieve the best treatment effect. Through scientific processing procedures, we can not only effectively reduce the impact of mud on the environment, but also achieve resource recycling and reuse, thereby promoting sustainable development.
     

  • What are the features of the VD series vacuum degasser of Kosun Machinery?

    A vacuum degasser is a professional device that efficiently separates dissolved gases in liquids through the principle of physical pressure reduction. The core working principle is to use a vacuum pump to create a negative pressure environment in a closed tank, causing the bubbles in the liquid to expand and burst due to a sudden drop in pressure. The escaping gas is then drawn away by the vacuum pump, and the purified liquid is discharged through a liquid discharge device. This process can achieve a degassing efficiency of 95% to 99%, becoming a key equipment for ensuring process safety and energy efficiency in fields such as oil drilling, chemical and pharmaceutical engineering, and HVAC.


     

     

    Among the numerous vacuum degassing devices in the market, the VD series vacuum degassing devices produced by Xi 'an kosun Machinery are gradually becoming the choice of more customers due to their superior quality and better degassing efficiency.
     
    The VD series vacuum degasser of Kosun Machinery is a new type of specialized equipment used for treating gas-invaded drilling mud. It can quickly remove various gases that have invaded the drilling mud and plays a very important role in restoring the specific gravity of the mud and stabilizing its performance. The VD series vacuum degasser of Kosun Machinery can also be used as a high-power agitator and is suitable for matching with various slurry circulation purification systems.

     


     

    Advantages of Kosun Machinery's VD series vacuum degasser
    1. High-efficiency degassing: ≥95% degassing efficiency, capable of quickly removing gases from gas-invaded mud, restoring the mud's specific gravity, and stabilizing its performance;
    2. Diverse functions: It can be used as a high-power stirrer;
    3. Energy conservation and environmental protection: Under the same processing capacity, the required power consumption is less than that of similar products.
    4. Economical and durable: Made of high-quality steel and motors, it has a longer service life and a lower failure rate.
    5. Superior structure: Compact design, smaller floor space, unique structural design directly disdischarge the treated slurry, no need to be equipped with high-power centrifugal pumps.
     
    The VD series vacuum degasser of Kosun Machinery has been sold to nearly 30 countries and regions around the world. Its technological maturity and global project verification have been recognized by customers, making it a benchmark equipment for gas-liquid separation in the field of oil and gas drilling. If you also have the need to use the Kosun Machinery VD series vacuum degasser.

     

  • The ＂golden pair＂ in the mud solid control system: the classification coordination mechanism of the desander and the centrifuge

    In the slurry solid control system, after the vibrating screen completes the separation of coarse particles, the coordinated action of the desander and the centrifuge becomes the key link to achieve precise classification of solid particles. Through different separation principles and classification treatments, the solid particles in the mud are efficiently separated by particle size, which not only ensures the stable performance of the drilling fluid but also significantly improves the utilization rate of resources and environmental benefits.
     

           

     

    I. Working Principles of Desander and Centrifuge
     
    Desander: Separation of medium particles under centrifugal force field
     
    Working principle: The solid-containing slurry enters the cyclone in a tangential direction. Under the centrifugal force field generated by high-speed rotation, the denser solid particles (76-47μm) are thrown towards the wall of the cyclone and discharged downward along the cone, while the liquid phase and fine particles are discharged from the central overflow pipe.
    Technical features: Processing capacity 50-200m³/h, separation efficiency depends on the feed slurry pressure (0.2-0.4MPa), cyclone diameter (8-12 inches), and sand discharge port size (1/4-1/2 inch).
     
    Centrifuge: Fine separation through ultra-high-speed rotation
     
    Working principle: The slurry enters the high-speed rotating drum (3000-5000 RPM), generating a strong centrifugal force to separate ultrafine particles (<15μm) from weighting agents such as barite. The liquid phase is discharged through the overflow port, and the solid phase is conveyed to the slag discharge port by the screw conveyor.
    Technical advantages: The separation accuracy can reach 5μm, the barite recovery rate exceeds 90%, and the material loss is significantly reduced.


     

     

    Ii. Synergistic Mechanism: "Classification – purification – circulation" in a trinity
     
    Classification treatment: The desander serves as the pretreatment unit
    The desander prioritizes the separation of medium particles larger than 74μm, which can reduce the processing load of the centrifuge by 30-50%. Data from a certain shale gas project shows that the processing capacity of the centrifuge after pretreatment has dropped from 150m³/h to 80m³/h, and the service life of the equipment has been extended by 20%.
     
    Deep purification: The centrifuge achieves fine control

     

    After being treated by the desander, the solid content of the mud was reduced to below 8%. The centrifuge further reduced the content of particles smaller than 15μm from 12% to within 5%, significantly improving the rheological properties of the drilling fluid.


     


     

    Resource recycling: A win-win situation for economic benefits and environmental protection
    The collaborative system can achieve a barite recovery rate of over 90%, and the moisture content of rock cuttings after dehydration is less than 30%. It can comprehensively reduce the cost of mud by 25-40% and cut the discharge of hazardous waste by more than 40%.
     
    Iii. Equipment Selection and Maintenance Guide
     
    Selection suggestions
    Desander: Polyurethane wear-resistant cyclone is preferred, and the processing capacity should cover the maximum drilling displacement (120%).
    Centrifuge: Select the dual-motor drive model based on the density of the slurry. The material of the drum needs to be corrosion-resistant
     
    Key points of maintenance
    Daily inspection: Cyclone wear condition, centrifuge vibration value
    Regular maintenance: Lubricate the bearings weekly and replace the seals monthly
    Anti-clogging measures: Install 100 front-mounted filters and configure an automatic backwashing device
     
    Hierarchical collaboration doubles efficiency
    The collaborative effect of the desander and the centrifuge is essentially an art of balancing "efficiency and precision". The former rapidly separates medium-sized particles through centrifugal force, while the latter achieves ultrafine purification through ultra-high-speed rotation. Both are indispensable. In the modern drilling field that pursues cost reduction, efficiency improvement and green low-carbon development, optimizing the collaborative mechanism of this "golden pair" will inject continuous vitality into the mud solid control system.

  • An efficient and environmentally friendly solution for the resource utilization of oily sludge

     
    With increasingly strict global environmental protection regulations, the efficient treatment of oily sludge has become an important issue in the petrochemical industry. As a major oil-producing region in the world, the Middle East generates a large amount of oily sludge during the processes of oil extraction, transportation, storage and refining. The main sources include drilling mud and crude oil separation residues from oilfield exploitation, bottom sludge from storage tanks in refineries, waste residue from oil pipelines, and contaminated soil due to leakage. According to statistics, the Middle East generates over several million tons of oily sludge every year. If not properly treated, it will seriously threaten the ecological environment.
    The hazards of oily sludge: Oil sludge has a complex composition and contains pollutants such as petroleum hydrocarbons, heavy metals, and toxic organic substances. If it is directly landfilled or piled up, it will lead to soil pollution, groundwater pollution, air pollution, cological risks, etc.


     

     

    The Xi 'an KOSUN oily sludge treatment system adopts advanced cleaning and separation technology, with a processing capacity of 50 tons per hour and an annual processing capacity of 200,000 tons. It achieves efficient separation of oil, water and solid phase, meeting the dual demands of environmental protection and resource recovery. The main components of oil sludge include sand (65%), soil (5%), coke (7%), and oil (23%). The treatment objective is to achieve a solid oil content of no more than 2%, facilitating subsequent biodegradation, water phase reuse, reducing fresh water consumption, oil phase recovery, and enhancing resource utilization.

     


     

    The processing technology involves the raw materials being uniformly conveyed to the sand washing machine through the feeding hopper of the feeding mechanism, the feeder, and the belt conveyor. At the same time, chemicals are added and high-temperature hot water is used for stirring and cleaning. The large particle materials after cleaning enter the vibrating screen for dewatering and screening, while the other oily materials are conveyed to the next processing equipment for sand and mud removal and separation. After the mud and sand are processed, the materials enter the centrifuge for oil and water separation. Meanwhile, the boiler heats the water tank to keep the system water at a certain temperature all the time, ensuring that the oil sludge treatment is efficient, environmentally friendly and energy-saving.

     

           

     

                                                                       Solid phase of vibrating screen                                           Centrifuge solid phase                                          Solid phase in a spin dryer

    The technical advantages enable it to efficiently handle a processing capacity of 50 tons per hour, meeting the demand for large-scale oil sludge disposal. The solid oil content is ≤2%, satisfying environmental protection emission standards. It features a high oil recovery rate, water recycling, reducing operating costs. The high-temperature hot water circulation system is energy-saving and environmentally friendly, reducing energy waste and conforming to the concept of green production.
     
    An efficient and environmentally friendly solution for the resource utilization of oily sludge is applicable to the treatment of oily sludge in industries such as oil extraction, refining and chemical processing, and storage and transportation, especially suitable for the disposal of high-sand-content oil sludge in the Middle East. The project not only solved the problem of oil sludge pollution, but also achieved "turning waste into treasure", promoting the development of a circular economy.
     


     

  • Drilling Fluid Purification Pioneer: The Application of shale shaker in Solid Phase Control

     
    In the entire process of drilling mud treatment, the drilling fluid shale shaker, as the "first line of defense for purification", plays an irreplaceable and crucial role. As the core equipment at the very front end of the solid-phase control system, it can quickly remove a large amount of drill cuttings generated during the drilling process with its efficient solid-liquid separation capability, laying a solid foundation for the subsequent mud purification treatment and directly affecting the efficiency and economy of the drilling operation.
     

         

     

    The working principle of the drilling fluid vibrating screen is based on the synergistic effect of mechanical vibration and screen filtration. The motor drives the exciter to rotate at high speed through a belt drive, generating a directional excitation force that drives the screen box to perform regular reciprocating vibration. When the mud carrying drill cuttings is evenly distributed on the screen surface from the slurry inlet, under the effect of vibration, the liquid phase and fine solid particles in the mud pass through the pores of the screen and enter the lower equipment, while the drill cuttings with a particle size larger than the screen holes are effectively discharged along the inclined direction of the screen surface and fall into the slag discharge trough to complete the separation. The mesh size and material selection of the screen should be flexibly adjusted according to the actual drilling geological conditions. In soft strata, 40-80 mesh screens are usually chosen to ensure processing capacity, while in hard rock strata, 100-200 mesh screens are used to improve separation accuracy. ​
     
    Engineering practice shows that the separation efficiency of the drilling fluid vibrating screen directly determines the reuse rate of the mud. In deep well drilling operations, the comprehensive cost of one cubic meter of mud per cycle can reach 3,000 to 5,000 yuan. If the separation effect of the vibrating screen is poor, a large amount of drill cuttings remaining in the mud will lead to deterioration of rheological properties, not only significantly increasing the energy consumption of the mud pump, but also may cause complex downhole situations such as wellbore diameter reduction.


    1. Sieve frame; 2. Base; 3.AWD Angle adjustment system; 4. Sieve tensioning system; 5. Feeding box; 6. Vibration isolation device; 7. Vibrating motor; 8. Electrical system; 9. Locking device

     

    The coordinated cooperation between the drilling fluid vibrating screen and the subsequent solid control equipment is particularly crucial. When the mud that has been initially purified by the vibrating screen enters the secondary treatment equipment such as the desander and desilter, since the large drill cuttings have been effectively removed, these devices can focus more on dealing with fine particle impurities, avoiding the decline in treatment efficiency caused by screen blockage.
     
    As the primary step in the purification of drilling mud, the stable and efficient operation of the drilling fluid vibrating screen is an important foundation for ensuring drilling safety and enhancing economic benefits. Its technological development has always been continuously advanced around the major direction of "efficient separation and energy conservation and environmental protection". In the future intelligent drilling system, this key equipment will continue to play an irreplaceable fundamental role, providing a solid guarantee for the safe and efficient implementation of drilling projects.