Drilling waste management,oil based mud treatment,drilling mud circulation system,drilling waste management companies

As the petrochemical industry advances, oily sludge treatment has become a critical intersection of environmental responsibility and sustainable growth. Traditional disposal methods like landfill or incineration are no longer viable due to escalating costs and strict regulations. KOSUN addresses this demand with its 1m³/h integrated oily sludge treatment system, a practical solution designed for high performance and cost optimization.

Chemical Hot Washing and Demulsification

The 1m³/h integrated oily sludge treatment system’s efficiency starts with chemical hot washing technology. Unlike conventional rinsing, this process uses specialized surfactants and cleaning agents under precise thermal regulation. This stage effectively breaks down emulsified structures and reduces the adhesion of crude oil to solid particles, ensuring a uniform feed for the subsequent centrifugal separation process.

Three-Phase Centrifugal Separation

Following the washing phase, the mixture enters a high-G force separation circuit utilizing decanter centrifuges and disc stack centrifuges. This achieves reliable three-phase separation results:

1. Oil Phase Recovery: The system recovers high-purity crude oil that can be redirected to refineries as feedstock, generating direct economic value.
2. Aqueous Phase Recirculation: Separated water is filtered and reintroduced into the closed-loop system, minimizing freshwater consumption and wastewater disposal needs.
3. Solid Phase Compliance: Processed solids exhibit oil content below 3%, meeting regulatory standards for landfill acceptance or construction reuse.

Economic Performance and ROI

A defining attribute of the KOSUN 1m³/h oily sludge treatment system is its ability to balance performance with favorable capital expenditure (CAPEX). By converting hazardous waste into marketable oil and reducing disposal volumes, the system ensures a rapid return on investment. Its compact footprint is ideal for mobile deployment or site-specific localized treatment in oilfields and storage terminals.

Versatile Industrial Applications

The KOSUN oily sludge treatment system is engineered for diverse feedstocks across the oil and gas value chain, including:

• Waste oil-based drilling muds and drill cuttings.
• Tank bottom sludge from storage terminals and transport vessels.
• Settled oily residues from wastewater treatment basins and refinery interceptors.

Adopting the KOSUN 1m³/h oily sludge treatment system represents a forward-looking commitment to both environmental compliance and profitability, aligning waste management practices with modern ESG goals.

In the energy service industry, equipment selection directly impacts Operating Expenditure (OPEX) and Non-Productive Time (NPT). The KOSUN MA Series Mud Agitator, recognized for its rigorous technical specifications, has become a preferred asset for global contractors seeking a high-performance drilling mud agitator.

Diverse Specifications for Precise Mud Mixer Matching

As shown in the technical specifications, KOSUN offers a complete lineup from MA40 (4kW) to MA220 (22kW). This wide power range ensures that for any tank system, clients can select the most efficient mud mixer, preventing unnecessary energy loss and power mismatch.

Flexible Configurations for Enhanced Mud Tank Agitator Efficiency

To eliminate dead zones, these agitators for mud tanks support customizable shaft lengths (up to 2100mm+) based on actual tank depth. Combined with single or double-layer impellers (up to 1000mm diameter), it effectively prevents the deposition of high-density solids across all levels as a reliable Mud Agitator.

Robust Structure for Secure Mud Tank Agitator Operation

Compact dimensions and a chassis weight of up to 738kg (MA220) ensure superior vibration damping for the mud tank agitator during high-load operations. With scientific 1:20/1:25 reduction ratios, the system delivers stable torque while significantly reducing mechanical wear and maintenance frequency.

Why Choose KOSUN as your Mud Agitator Partner

KOSUN provides more than just standalone hardware; we offer optimized mixing solutions backed by proven engineering logic. We ensure every cent of your investment is converted into actual drilling productivity, delivering a superior return on investment (ROI).

Check out our Mud Mixer to complete your drilling waste management setup.

In today’s era of increasing cost pressure in oil and gas development, the management of drilling fluid (mud) assets has become a critical factor determining project profitability. Drilling fluid costs typically account for 10% to 15% of the total drilling budget. A premium Solids Control System is not merely environmental equipment; it is the core profit center of the drilling site.

Expensive Mud Loss and Hidden Costs Induced by Harmful Solids Accumulation

During drilling operations, the mechanical shearing of rock cuttings leads to a large volume of ultra-fine particles entering the circulation. According to industry calculations by the International Association of Drilling Contractors (IADC), if these harmful solids are not promptly removed by an efficient Solids Control System, the density and viscosity of the mud will rise uncontrollably.

To maintain mud performance, operators are often forced to adopt the “dilution method”—discharging portions of high-sand-content mud and injecting large volumes of new fluid. This primitive approach leads to massive waste of expensive barite, polymer additives, and base oils. Research data suggests that for every 10% decrease in solids control efficiency, mud material expenditures for a single deep-well project increase by more than 15%. Furthermore, tool wear and pump damage caused by harmful solids significantly drive up spare parts replacement costs, creating a massive hidden economic burden.

Resource Recovery Mechanisms of High Efficiency Solids Control Systems for Project ROI

A scientifically configured Solids Control System achieves closed-loop circulation and resource recovery through physical separation, directly enhancing the Project’s Return on Investment (ROI). According to the American Petroleum Institute (API) specifications, efficient solids control workflows can recover over 85% of the base mud.

Through the synergistic operation of high-efficiency shale shakers and high-speed centrifuges, the system precisely controls the solids content in the mud. This not only reduces the cost of preparing new mud but, more importantly, significantly decreases the total volume of waste mud for disposal. Under increasingly strict environmental policies, the costs of waste transportation and third-party disposal have become non-negligible expenditures. An efficient Solids Control System achieves “reduction at the source,” transforming expensive waste into recyclable resources, thereby ensuring operational compliance while lowering Operating Expenses (OPEX).

KOSUN Expert Performance in OBM Drilling Waste Management System for Deep Recovery

As a leading global expert in solids control, KOSUN has been deeply rooted in the industry since 1992. Addressing the specific needs of Oil-Based Mud (OBM) recovery and “Zero Discharge” requirements, the KOSUN OBM Drilling Waste Management System demonstrates exceptional economic value. This system integrates high-efficiency Vertical Cuttings Dryers and high-speed Decanter Centrifuges, specifically designed to treat wet cuttings discharged from shale shakers.

The KOSUN Vertical Cuttings Dryer utilizes powerful centrifugal force to reduce the Oil on Cuttings (OOC) to below 5%. This means that expensive base oil, which would otherwise be discharged with waste, is extracted and recycled back into the Solids Control System for reuse. This deep liquid phase recovery capability, combined with a highly modular and compact design, not only saves customers massive expenditures on mud raw materials but also significantly reduces logistics costs for rig moves and waste transport. With over thirty years of field experience, KOSUN is empowering global partners to maximize profits through its expert-level processing technology.

In drilling operations, treating gas-cut mud caused by well kicks is a critical link in ensuring well control safety and maintaining mud performance. The drilling fluid vacuum degasser manufactured by KOSUN provides a reliable gas treatment solution for construction sites through its mature negative-pressure separation process and compact structural layout. 

Negative Pressure Self-Priming Structure of the Vacuum Degasser 

The KOSUN Vacuum Degasser adopts the industry-mainstream self-priming structure. Its core principle involves using a vacuum pump to extract gas from a sealed separation vessel, creating a significant pressure differential. Driven by atmospheric pressure, the mud automatically enters the vessel through the suction pipeline without the need for an additional centrifugal feeding pump. This compact layout reduces investment in auxiliary equipment and simplifies pipeline connections. It is particularly suitable for space-constrained operating environments, effectively minimizing potential system failure points. 

Eliminating Corrosion Hazards and Reducing Maintenance Costs 

Upon entering the vessel, the mud is sprayed and agitated by a high-speed rotating impeller. In a low-pressure environment, bubbles within the mud are rapidly ruptured, achieving swift separation of free gases. Through efficient degassing, this drilling fluid vacuum degasser eliminates cavitation damage to mud pump liners, pistons, and centrifuge bearings caused by gas intrusion. Simultaneously, the separated gas enters a water-gas separator; certain harmful gases are dissolved in water for treatment, while the rest are discharged safely. This process reduces the corrosion of pipelines and metal tanks by acidic gases, directly lowering repair and maintenance costs. 

Compact Design Optimizing Tank Surface Space Utilization 

To meet the strict requirements for equipment footprint at modern well sites, the KOSUN Vacuum Degasser has been structurally optimized. The overall design is compact, occupying minimal space. On the mud tank surface, this streamlined layout leaves more room for other solids control equipment while making lifting, transportation, and onsite installation more convenient and efficient. 

Dual-Purpose Functionality: Serving as a High-Power Mud Agitator 

The KOSUN drilling fluid vacuum degasser was designed with integrated utilization in mind. Under non-gas-cut conditions, due to its powerful internal circulating and spraying capabilities, the Vacuum Degasser can also function as a high-power drilling mud agitator. By continuously circulating the mud within the tank, it effectively prevents the settling of solid particles and ensures stable mud properties, achieving multi-functional value for a single unit across different working conditions. KOSUN focuses on enhancing product durability and field applicability. Through rigorous negative-pressure degassing processes and stable power performance, we are committed to providing global customers with solids control equipment that meets industry standards and delivers significant economic benefits. 

With global oil and gas environmental regulations becoming increasingly stringent—targets like “Zero Discharge” and “Cuttings Containment” in the North Sea, Gulf of Mexico, and China are now mandatory—building an efficient Drilling Waste Management (DWM) system is essential. In this complex closed-loop process, the centrifugal sand pump

, responsible for efficient slurry transfer, is the core equipment ensuring continuous operation and regulatory compliance.

Centrifugal Sand Pump Ensures Stability of the Environmental Treatment Chain

A cuttings management system must pump oil-based or water-based cuttings from collection points to vertical dryers, thermal desorption units, or stabilization units. This is a high-wear, high-load continuous process. Any failure—especially in the centrifugal sand pump—can interrupt the entire workflow, leading to severe environmental non-compliance risks and financial penalties.

The KOSUN centrifugal sand pump is engineered for these harsh environments. Its heavy-duty horizontal design focuses on reliability under extreme conditions. The rugged construction and specialized wear-resistant carbide mechanical seals ensure long-term stability when conveying highly abrasive and viscous materials, significantly reducing downtime for maintenance.

Core Technology: How the Centrifugal Sand Pump Supports Green Drilling

The design features of a high-quality centrifugal sand pump directly serve environmental goals:

Efficient Transfer Capability: It ensures cuttings are moved from the rig site to processing equipment without delay or accumulation, preventing secondary pollution. Thanks to unique closed impeller and back vane designs, this centrifugal sand pump offers higher head and consistent efficiency.

Corrosion and Wear Resistance: By utilizing specialized materials to handle the erosive challenges of different base muds (OBM or WBM), the centrifugal sand pump maintains performance over long-term use, meeting the strictest environmental operational standards.

Expanding the Application Scenarios of the Centrifugal Sand Pump

Beyond waste management, the centrifugal sand pump plays a versatile role across the entire drilling fluid circulation system:

Feeding Solids Control Equipment: It serves as a stable feeding pump for desanders and desilters hydrocyclones.

Mud Charging and Mixing: The centrifugal sand pump can be used as a pre-charging (supercharging) pump for main mud pumps to prevent cavitation, or in conjunction with jet mixing devices for rapid mud preparation.

Long-Distance Transfer: With its high-head design, this centrifugal sand pump easily handles mud transfer between different tank areas and long-distance conveyance tasks within the well site.

KOSUN centrifugal sand pumps, specifically designed for oilfield applications, provide the reliability and durability needed for safe, compliant, and sustainable drilling. They are the cornerstone for oilfield enterprises to fulfill social responsibilities while enhancing operational efficiency.

In modern mining operations, traditional wet tailings disposal is increasingly being replaced by mechanical dewatering due to land scarcity, safety risks, and environmental regulations. As a specialist in solid-liquid separation, KOSUN offers the integrated Tailings Management System, leveraging decanter centrifuge technology to achieve effective tailings reduction and resource recovery.

Industry Challenges in Traditional Disposal

• Safety & Environmental Risks: Wet storage poses seepage risks and potential dam stability issues, creating long-term environmental liabilities.
• Cost Pressures: The construction, maintenance, and land acquisition for large-scale tailings ponds involve significant capital expenditure and complex regulatory approvals.
• Resource Loss: Large volumes of process water remain trapped in tailings ponds, leading to high fresh water consumption and waste.

Core Features of the KOSUN Tailings Management System

• High-Efficiency Solid-Liquid Separation: The system utilizes a decanter centrifuge to generate high centrifugal force, effectively capturing ultra-fine particles from the slurry. The resulting solid cakes have low moisture content, making them suitable for dry stacking or backfilling.
• Closed-Loop Water Recycling: The recovered liquid (centrate) features low total suspended solids (TSS) and can be directly reused in the mineral processing circuit. This closed-loop approach reduces fresh water intake and minimizes wastewater treatment costs.
• Operational Adaptability: Designed to handle diverse tailings types (e.g., gold, copper, iron), the system allows for precise adjustment of bowl speed and differential speed to maintain stable performance despite fluctuations in slurry concentration or feed rate.
• High Degree of Automation: The integrated control system monitors operational parameters in real-time, reducing the need for manual intervention while optimizing energy consumption.

Systematic Process Flow

• Homogenization & Buffering: Tailings slurry enters a buffer tank to homogenize concentration and regulate flow, ensuring a steady feed to the downstream equipment.
• Pre-treatment: Scalping screens remove oversized debris and coarse particles to protect the centrifuge from abnormal wear.
• Core Dewatering: The slurry is fed into the decanter centrifuge, where solids and liquids are separated and discharged through dedicated outlets.
• Resource Output: The solid phase meets environmental standards for transport or stacking, while the clear liquid is recycled back into the production line.

Conclusion

The KOSUN Tailings Slurry Management System transforms “waste slurry” into “reusable resources.” By mitigating safety hazards and enabling water recycling, the system provides a mature technical pathway for mining companies to achieve green transitions and operational cost-efficiency.

In industries such as petroleum refining, oilfield exploration, and oil storage, the treatment of oily sludge has always been a significant environmental issue. This hazardous waste occupies valuable land and poses risks to ecosystems. Responding to global sustainable development goals, KOSUN has innovatively launched its independently developed 1m³/h oily sludge treatment system. Integrating high efficiency, environmental protection, and resource recovery, it provides a comprehensive solution for the treatment of oily waste.

Oily Sludge Treatment System Achieving Efficient Three-Phase Separation

The system employs advanced chemical thermal washing technology to achieve thorough separation and recovery of oil, water, and solids:

• Enables the recovery of reusable crude oil from sludge;
• Produces water with oil content as low as 200mg/L, suitable for reuse;
• Yields solid residues with oil content below 2%, meeting disposal standards.

Oily Sludge Treatment System Delivering Excellent Cost Efficiency

Compared with traditional treatment methods, KOSUN’s 1m³/h oily sludge integrated treatment system offers both economic and environmental advantages. Its modular integrated design lowers initial investment costs, while the efficient processing capacity meets the operational needs of small and medium-sized enterprises.

Oily Sludge Treatment System Suitable for Multiple Industry Applications

The system is suitable for various oily waste treatment scenarios, including:

• Petroleum and petrochemical plants;
• Oilfield production sites;
• Oil storage and transportation facilities.

Oily Sludge Treatment System Driving Industrial Green Transformation

Through efficient separation and resource recovery technology, KOSUN’s oily sludge treatment system advances the sustainable management of sludge, supporting the green transformation of industries and setting new standards for environmentally friendly waste treatment.

In the 2026 energy landscape, where low-carbon and high-efficiency operations are paramount, traditional mud management is rapidly shifting toward centralized and professionalized models. KOSUN’s Liquid Mud Plant (LMP)—a comprehensive 1,000m³+ scale solution—has emerged as a game-changer for oil & gas drilling, Horizontal Directional Drilling (HDD), and tunneling projects.

I. Multi-Scenario Application: High-Standard Solutions

The KOSUN Mud Station is engineered for versatility. It provides stable oil-based and water-based mud supply for oil and gas drilling, efficient bentonite slurry treatment for HDD projects, and consistent mud performance for piling and tunneling, ensuring superior borehole quality across all sectors.

II. Technical Highlights: Solids Control Meets Intelligence

• High-Efficiency Purification: Integrated multi-stage modules (shale shakers, desander/desilter, and high-speed centrifuges) rapidly remove harmful solids. This significantly extends the lifespan of expensive drilling fluids and protected downhole tools.
• Zero-Leakage Design: The fully enclosed system eliminates spills and leaks, protecting soil and groundwater while ensuring 100% compliance with strict environmental regulations.
• Automation & Smart Monitoring: Automated dosing and mixing systems, managed via a central control panel, allow real-time monitoring of density, viscosity, and sand content, reducing labor costs and human error.

III. Strategic Value: Maximum Economic Returns

Investing in a KOSUN Liquid Mud Plant LMP is a strategic move that delivers clear financial benefits:

1. Cost Savings: With mud recovery rates exceeding 90%, procurement of barite and bentonite is drastically reduced.
2. Waste Reduction: Advanced solid-liquid separation minimizes waste volume, slashing expensive disposal and transportation fees.
3. Operational Excellence: Stable mud properties maintain wellbore stability and cooling, boosting the Rate of Penetration (ROP) and minimizing non-productive time (NPT).

Conclusion
KOSUN is more than an equipment manufacturer; we are your strategic partner in mud management. By choosing the KOSUN Liquid Mud Plant, you achieve “Green Construction” goals while gaining a competitive edge through lower costs and guaranteed engineering quality.

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In modern deep drilling—whether for oil, gas, or geothermal energy—high formation temperatures are a critical challenge. As depth increases, circulating mud temperatures surge, leading to fluid degradation, equipment failure, and safety hazards. A professional Drilling Fluid Cooling System is no longer optional; it is essential for safe and efficient operations.

Why is Mud Cooling System Mandatory?

High temperatures create a cascade of operational risks:

• Property Degradation: High heat breaks down chemical additives and polymers, causing uncontrolled fluid rheology.
• Equipment Damage: Excessive heat accelerates wear on shale shaker screens, centrifuge seals, and downhole tools.
• Safety Risks: Overheated mud increases wellbore instability and worsens the working environment for the crew.

How It Works: Precision Heat Exchange

The system operates on the principle of thermal exchange. High-temperature mud passes through a Heat Exchanger (plate or coaxial), transferring heat to a cooling medium (air, water, or refrigerant).

• Key Components: Heat exchanger, refrigeration/cooling unit, circulation pumps, and an intelligent control system for real-time temperature monitoring.

Tailored Mud Cooling Solutions

Depending on the environment, different configurations are utilized:

• Air-Cooled Systems: Ideal for water-scarce regions.
• Water-Cooled Systems: High-efficiency cooling using towers or external water sources.
• Integrated/Hybrid Systems: Combines both technologies for maximum flexibility.

Summary

The drilling fluid cooling system is a vital safeguard for deep-well integrity. By preserving mud properties and extending equipment life, it ensures the success of complex drilling projects.

Partner with an industry expert like KOSUN to get a customized, energy-efficient cooling solution tailored to your specific rig site challenges.

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Currently, stringent environmental regulations and rising operational costs make efficient Oil-Based Mud (OBM) management critical. An advanced OBM Drilling Waste Treatment System provides a “closed-loop” solution that ensures regulatory compliance while significantly recovering valuable drilling fluids.

Ensuring Environmental Compliance

Modern OBM treatment systems utilize a “treat-while-drilling” approach to achieve Zero Discharge.

• Oil Content Control: Systems can reduce oil on cuttings (OOC) to ≤5%, meeting international standards for safe disposal or resource reuse (e.g., road paving).
• Eco-Protection: Closed-loop processing prevents soil and groundwater contamination, eliminating the legal risks of illegal disposal.

Maximizing Economic Benefits

Oil-based mud is a high-value asset. Our system utilizes Vertical Cuttings Dryers (VCD) and Decanter Centrifuges to turn waste into profit.

• 90%+ Recovery Rate: Efficiently recovers base oil for immediate reuse in mud formulation, drastically cutting material costs.
• Volume Reduction: Lowering oil and liquid content reduces waste volume, leading to significant savings in transportation and third-party disposal fees.
• Footprint Optimization: Eliminates the need for traditional mud pits, simplifying site layout and accelerating rig moves.

Technical Reliability and Efficiency

Designed for high-density, high-solids OBM, our modular systems are built for continuous heavy-load operations.

• Core Components: High-quality screw conveyors, cuttings dryers, and centrifuges ensure stable performance in harsh environments.
• High Throughput: Processing speeds are synchronized with drilling progress to ensure no operational downtime.
• Customization: Skid-mounted and modular designs allow for rapid deployment and flexible configuration based on well-site requirements.

Advanced Operation and Maintenance

• Automation: PLC-integrated control systems monitor torque, temperature, and runtime in real-time with automatic safety alarms.
• Easy Relocation: Modular assembly ensures fast installation and seamless transition between well sites.
• Low Upkeep: Wear-resistant components and dedicated technical support minimize long-term maintenance expenses.

Conclusion

The OBM Drilling Waste Treatment System is a vital investment for sustainable oil and gas operations. By integrating mature technology with automated control, companies can achieve peak economic efficiency while fulfilling their 2026 environmental mandates.