KOSUN Pilling Tail Slurry TreatmentSystem is mainly used for large-volume centrifuge units, and is used with automatic dosing devices. The total processing capacity of the system is 200m3/h, and the whole process is automated. After separation, the solid phase meets the transport standard of the local environmental protection department, the liquid phase meets the recycling requirements, and the noise meets the city standard. The whole system is designed as a skid-mounted structure, which can be placed on the platform where the construction site is poured. The overall footprint is small, the operation and maintenance are convenient.
KOSUN Environmental black rhinoTail Slurry Treatment Flowchart:
Large solid impurities are separated from mud (sludge) by Hi-G dryer, and the filtrated liquid is dynamically mixed with the dosing system in pipelines through tee joint for flocculation and gel breaking. Pretreated mud is fed to centrifuge (or filter press). After solid-liquid separation by centrifuge, the collected solids can be directly transported by truck to the centralized treatment plant, or conveyed to the solids storage site by conveying equipment, and the clear liquid is uniformly collected and then discharged or recycled.
KOSUN is confident to help more subways in more markets around the world in bridges, tunnels, piling and other projects. To provide more customers with professional, high quality, high efficiency, cost-effective Tail Slurry TreatmentSystem and services.
KOSUN environmental River Sludge Disposal Technology covers pretreatment, washing and sieving, dewatering, tail water treatment, sediment stabilization, etc. When various materials are treated and reach the standard, the clean sand will backfill into the river channel, and the dewatered sediment will undergoes treatment. KOSUN Environmental sludge treatment technology includes such eight modules as pretreatment unit, desanding unit, desilting unit, dewatering unit, sewage treatment unit, clean water storage unit, solidification unit and chemicals unit.
In October 2017, KOSUN Environmental Black Rhino BRRD series equipment facilitated the local riverway dredging project in Yantai, Shandong. In the project, Black Rhino river channel sludge treatmentsystem, designed and manufactured by KOSUN Environmental, treated about 40,000m³ bottom mud polluted by medium and severe heavy metal and shortened the period of river regulation. A large amount of polluted river sand was backfilled into the river channel after being purified by the system, which effectively reduced the subsequent treatment cost of the project.
To meet the requirements of river dredging, KOSUN developed and equipped with customized decanter centrifuge. By this new technology, make the centrifuge adapt property changing of mud during the operation process, that makes the treatment more effective and perfect.( Customized Decanter Centrifuge for River Dredging)
Applications of customized decanter centrifuge for river dredging:
-River sediment disposal in cities and downtowns;
-Sediment disposal of urban landscape lakes and drinking water sources;
-Reservoir sediment disposal;
-River channel regulation and river sludge disposal technology.
Along with the economic development, people have higher requirements on living environment. There are numerous water environments in the polluted regions in China urgently needing to be remediated. Traditional dredging methods cannot meet the demands of people on environmental protection any longer, so the environmental dredge technology emerges at the right moment. In recent years, BRRD series Black Rhino environmental river dredging sludge treatment system, independently developed by KOSUN Environmental has been widely applied to environmental dredging field of rivers, lakes, reservoirs, etc. Moreover, we can customize the optimal integrated solution to river dredging sludge treatment system according to the field hydrogeological conditions.
In April 2018, during the construction of the subway in Guangdong, China, KOSUN 5 sets KD-500 Slurry Treatment Plant were used for the construction of the double-wheel trench cutter underground continuous wall. This system belongs to our high-end customized products. The maximum throughput can reach 500 cubic meters per hour, and the separation granularity can reach 30-40 microns. A larger amount of processing capacity and high quality slurry for reuse ensured the fast driving of the double-wheel trench cutter.
KOSUN environmental friendly KD series Slurry Treatment Plant consists of coarse screening module, sand removal module, mud removal module and tailings processing module. KOSUN black rhino Slurry Treatment Plant can meet the environmental protection requirements for urban construction and is widely used in urban rail transit construction, water conservancy and hydropower construction and municipal engineering.
In addition, the unique second and third-level separation switching technology of KOSUN’s Green Slurry Treatment Plant makes it easy to handle the construction requirements of different strata. Whether it is river construction or urban infrastructure construction, the construction of subway tunnels or underground pipe corridors, KOSUN can provide customers with the best comprehensive solution for sludge treatment.
Piling desander/desander for Piling is the best solution of Mud sludge treatment in Bored Pile Construction.
How to process slurry of bored pile construction? This is a difficult problem in the construction of bored piles. The conventional mud treatment solution of bored pile is in the process of drilling, using shaker screen to separate and filter the small gravel, sand and other solid particles from the mud. Then the mud is discharged to the sink and precipitated fully. The sediment is carried to the evaporating pool by the excavator. Until the natural dehydration solidifies, the sediment is transported to the storage yard. This slurry treatment methods is feasible for small pile foundation. If there is a large quantity of pile base and the amount of mud,it is not applicable.
How to process slurry of bored pile construction? There are two solutions:1. The mud is pumped into the tanker and then is delivered to the designated place. The mud need to cover a large area, so the cost is very high. 2. First, the mud is dewatering by the mud and water dewatering equipment Piling desander/desander for Piling , the water can be used again and the mud can be carried to make bricks.
KOSUN recommend the second pile mud treatment solution. Using special mud and water separation equipment Piling desander/desander for Piling to solve the problem of large quantity of pile foundation and huge amount of mud.
KOSUN Piling desander/desander for Piling working principle:
The Piling desander/desander for Piling used of vibrating screen and cyclone desander sieve filtration principle, under the action of vibration force at high speed, large size sludge were filtered, and the clean water separated from sludge back to the mud recovery tank, the waste slurry will be discharge d form shaker and transported by the loading vehicle , the filtered water will be reuse again.
EPB TBM waste mud treatment system is the equipment who is supported the Earth Pressure Balance Shields to treat the mud which is produced when constructing. So called Earth Pressure Balance Shields (EPB) turn the excavated material into a soil paste that is used as pliable, plastic support medium. This makes it possible to balance the pressure conditions at the tunnel face, avoids uncontrolled inflow of soil into the machine and creates the conditions for rapid tunnelling with minimum settlement.
The special feature of Earth Pressure Balance Shields is that they use the excavated soil directly as support medium. This method is the first choice in cohesive soils with high clay and silt contents and low water permeability. A rotating cutting wheel equipped with tools is pressed onto the tunnel face and excavates the material. The soil enters the excavation chamber through openings, where it mixes with the soil paste already there. Mixing arms on the cutting wheel and bulkhead mix the paste until it has the required texture. The bulkhead transfers the pressure of the thrust cylinders to the pliable soil paste. When the pressure of the soil paste in the excavation chamber equals the pressure of the surrounding soil and groundwater, the necessary balance has been achieved.
KOSUN EPB TBM waste mud treatment system is the most advanced technolog ical products in the world. It can meet the environ mental requirements on urban construction and processing. It can aso save construction costs, reduce mud emissions and reduce environmental pollution. It is an economical, efficient and environment-friendly necessary construction equipment.The market demand of environ mental EPB TBM waste mud treatment system will be increasing.
Anaerobic three stages: hydrolysis, fermentation, methane production.
1, large investment, high operating costs, safety issues.
2, sludge need to preheat and consume a lot of heat.
3, produce a large amount of biogas residue, need to deal with again.
4, methane gas is difficult to incorporate into the municipal pipe network.
5, the northern winter can not run.
Second, sludge aerobic composting
Using straw and other excipients to reduce the water content of sludge to 60%, increase the gap to achieve the required CN ratio, continue to add oxygen, by 25-30 days of fermentation humus. To stabilize,and then can be used as landscaping and land improvement disposal.
1, sludge muddy instability, heavy metal is difficult to stabilize, can only be used as landscaping fertilizer.
2, the composting process produces a lot of odor, which may pollute the surrounding environment.
3, adding a large amount of straw and other conditioning agents, continuous oxygen supply, operating costs 200 yuan / t or more.
Third, sludge incineration power generation
Core equipment is incinerator, the main equipment is the tower, the bottom of the perforated plate, the plate placed on the hot carrier sand burning bed, tower lined with refractory material, the gas from the bottom access, after the sludge into the boiling fluidized state of combustion .
1, large investment, serious corrosion of the boiler, high maintenance costs.
2, high operating costs.
3, a greater impact on exhaust emissions, easy to produce dioxin and other harmful gases.
Fourth, sludge sanitary landfill
Landfill is mainly mixed with rubbish and the landfill site is constructed with the cost of 50-60 yuan / t. It is easy to pollute the water source, the atmosphere and occupy a large area. At present, the land resources used for landfill in our country are tense, Mud landfill will soon be no way out.
Fifth, rotary kiln drying
Using coal or natural gas and other energy to dry sludge dehydration.
1, energy consumption, high operating costs.
2, high temperature drying easy to produce odor.
3, the drying process of dust control requirements, there are security risks.
Six, box filter secondary pressure
The sludge diluted about 90%, after adding pharmaceuticals, secondary pressure filtration.
1, moisture content can only be 75-65%.
2, adding a large number of agents to increase the dry weight of sludge, operating costs higher.
3, the limitations of sludge reuse increased.
Seven, curing agent stability
In the original sludge by adding lime and other curing agent, chemical reaction with the sludge release a lot of heat, reducing water content.
1, add a lot of lime, aluminum-based materials, sludge increment.
2, sludge can not be used again.
3, higher operating costs.
So if relying on a single process, it would be difficult to meet the sludge treatment and disposal requirements. For different regions and different types of sludge, taking into account the climate, regional characteristics, the conditions of the construction site, the combination of a variety of techniques in order to achieve the best results. (Editor:Kosun Lily.Wang)
During Non-excavation directional drilling, due to the diameter of a large hole, such as West-East Gas Pipeline and Jining pipeline project, with a diameter of 1016mm steel pipe, in the reaming stage, the amount of mud is very large.( mud purification recovery)
Usually, the non-excavation drill is through the open system, in the general through, the amount of mud are more than 3000 cubic meters, and some even reach 10,000 cubic meters. The amount of mud is large, not only increases the cost of mud and land acquisition, the more serious problem is that after the completion of waste mud if not effective treatment, pollution of farmland and water will cause ecological problems.
With the enhancement of environmental awareness, it is imperative to develop and use mud purification and recovery equipment.
The slurry purification and recovery unit can carry out solid phase treatment of the returned slurry and then recycle it, on the one hand, reducing the amount of mud, reducing the pollution to the environment and reducing the amount of waste disposal. On the other hand, the recovered mud is ” maturity Mud “, the performance is relatively stable,it can reduce the performance instability caused by underground accidents, to ensure the smooth progress of the project.
Recent years, with the requirement of high working efficiency in drilling industry, a new system has been designed and developed in some big solid control manufacturer, and the system is called “solid control system”. Kosun as the leading original manufacturer of solid control equipment and drilling waste management unit, the “solid control system” is not a problem for us.How to understand solid control system? As the professional solid control system manufacturer, we have our own understanding about this system.
Introduction of the Main Equipment for Solid Control System:
The first main equipment for solid control system should be the vacuum degasser,We could analytics from the function of vacuum degasser. Generally speaking, horizontal vacuum degasser will be used to separate the gas from the drilling solids. What’s the reason to do like that? Because we should do everything to prevent any dangerous elements in oil & gas drilling fields. That’s why we should put the vacuum degasser as the first role.
The second one should be mud cleaner. KOSUN MD Series Mud Cleaner is the second stage separation equipment for drilling fluids, which deals with the mud being treated by the first grade separation equipment. The barite will be recovered and cuttings which are bigger than barite will be removed. Then the barite in the underflow will flow into circulation tanks through the screens when the weighted mud passes while the particles that are bigger than mesh will be removed.
The third equipment, we think it should be shale shaker (with necessary steel frame shaker screen). Actually, after the drilling solids have been transported and fed into vacuum degasser and mud cleaner, the third step is going with shale shaker. Commonly, we still need to be transported the solids onto the shale shaker, or we could say onto the surface of shaker screen. The equipment of transporting we should use is centrifugal sand pump or screw pump; and we may use shear pump to cut the drilling solids into small one if they are in big size. With the different design of the shaker screen’s mesh, we could get the drilling solids separated in different sizes.
The fourth equipment should be the decanter centrifuge. KOSUN DC Series Decanter Centrifuge is used to separate suspended solids ≥2μm in diameter and treat the drilling mud and fluids. It is especially effective when used in oilfield service industry, industrial service industry and especially in environmentally sensitive areas. This type of centrifuge is high in recovery rate, effective in solids control and remarkable in the reduction of cost spent on drilling mud resupplying and management. It is a very sophisticated dynamic balancing machine, able to operate stably with the whirling speed ranging from 0 to 3900 and generate centrifugal force of 3000G. In solid control system, decanter centrifuge has been popularly used, which is also the popular one for drilling waste management. In this step, we could not only get the result of separating, but also we could separate the oil from the drilling solids, even if the oil is just a little part.
Of course, the whole equipment must be mounted on the top of drilling mud tank, which is a kind of basic equipment for both solid control system and drilling waste management (vertical cutting dryer is the core equipment for this system), but it is a kind of powerful equipment.
KOSUN was founded in Xi’an China in 1992. Up to now, KOSUN has formed a strategic layout integrating three centers and two industries. The Production, R&D and Domestic Sales Center is located in Xi’an China, the Overseas Project Management Center and International Trade Center in Beijing China and the Oilfield Services and Oilfield Engineering Center in Aktobe Kazakhstan in Central Asia. The two industries are traditional oil drilling solids control equipment manufacturing industry and integrated oil & gas drilling waste management service industry respectively. Kosun- Solid Control System Company
Mixing and Grouting Plants or Mixing and Grouting unit（Mixing and Grouting Plants stations）are used in separation step during different projections, such as soil nails, tie-backs, soil mixing, jet grouting, grout compaction, vertical tie downs and injection grouting. Slurry obtained from field is not in its pure form.
It is usually mixed with particles and different liquids. Thus separation of these component in mixing and grounting plants is necessary. Kosun made system also give App end and PC control end to easily control the whole running.
For detailed phares in mixing and grouting plants(mixing and grouting units),the Separation of projection mud is done by the system which is an physical speparation flow.
Mixing and grounting stations
This Separation process is carried out by passing the slurry through an Separation. Mixing is brought in contact with the slurry at this time. High proportions of solids is scattered by shakers.
This process can be modified for extraction of specific slurry to increase its effectiveness. Extraction of other heavier slurry is up to 100% with use of this process. However for lighter solids, it is not an ideal process.
Mixing and grounting units
By the end of this process in mixing and grouting plants, 90 – 95 % of mud is obtained from the slurry stream. Move over, some energy is used to convert slurry from complex components into resuable slurry from by centrifuging it.
This decreases the cost associated with extraction of ethane from effluent. Thus separation of slurry from solids in mixing and grounting plants not only makes them pure and clean for use but also helps in obtaining valuable solids itself.
Fully understanding of the above detailed information will be hard, its a little bit different with TBM Separation plants or mine tailings treatment plants, but the real application case of the mixing and grounting plants is increasing the numbers day by day, some companies like Kosun from China have paid their attention on the related mechanics research. The performance is good, but still many progress can be achieved in the recent time. in the recent time.