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.