Introduction to Solids Control in Drilling Operations
The KOSUN Solids Control System is an integrated solution designed to remove drilled solids, maintain optimal drilling fluid properties, and reduce environmental impact in oil & gas operations. As a leading manufacturer with 30+ years of experience, KOSUN delivers reliable solids control equipment for both onshore and offshore applications.
This comprehensive guide covers:
✔ Core components of KOSUN solids control system
✔ How the 5-stage purification process works
✔ Key benefits over conventional systems
✔ Industry applications and case studies
5-Stage Solids Control Process by KOSUN
1. Shale Shakers (Primary Removal)
- Function: Remove large cuttings (74+ μm)
- KOSUN Advantage:
- Linear/elliptical motion models
- API-compliant screen design
- 20-30% higher throughput than industry average
2. Desanders & Desilters (Secondary Removal)
- Particle Removal Range:
- Desanders: 45-74 μm
- Desilters: 15-44 μm
- KOSUN Technology:
- Hydrocyclone clusters with wear-resistant liners
- Optimized cone geometry for 98% separation efficiency
3. Decanter Centrifuges (Fine Solids Removal)
- Critical for:
- Weighted mud recovery
- Colloidal solids (<15 μm) removal
- KOSUN Models Feature:
- Variable frequency drive (VFD) control
- G-force up to 3,200 × g
- 30% lower power consumption
4. Degassers (Gas Removal)
- Handles:
- Entrained gases (H₂S, CH₄)
- Foam suppression
- KOSUN Vacuum Degasser:
- 99% gas removal efficiency
- Integrated with mud gas separator
5. Centrifugal Pumps & Mud Tanks
- Closed-Loop System:
- 500-3,000 GPM capacity range
- Corrosion-resistant steel construction
- Customizable tank configurations
Industry Applications
Oil & Gas Drilling
- Reduces drilling fluid costs by 40-60%
- Improves ROP by maintaining optimal mud weight
HDD (Horizontal Directional Drilling)
- Compact skid-mounted units
- Meets urban environmental regulations
CBM & Shale Gas Operations
- Handles high clay content formations
- Recovers 85%+ of expensive synthetic mud
KOSUN vs Conventional Systems
| Parameter | KOSUN System | Standard Systems |
|---|---|---|
| Solids Removal Efficiency | 95-98% | 80-90% |
| Fluid Recovery Rate | 90%+ | 70-80% |
| Power Consumption | 15-20% lower | Industry average |
| Footprint | Modular compact design | Bulky layout |
| Automation Level | IoT-enabled monitoring | Manual controls |
6 Key Advantages of Choosing KOSUN
- Proven Reliability: 3,000+ installations worldwide
- Custom Engineering: Site-specific solutions for:
- Arctic conditions (-50°C)
- Desert operations (50°C+)
- Offshore platforms
- Cost Savings:
- 30% reduction in waste disposal costs
- 50% longer equipment lifespan
- Environmental Compliance:
- Meets API RP 13C standards
- Reduces drilling waste volume by 60%
- Smart Monitoring:
- Real-time solids analysis
- Predictive maintenance alerts
- Global Support:
- 24/7 technical assistance
- Local spare parts warehouses
Case Study: North Sea Offshore Project
Challenge: High-pressure well with expensive synthetic-based mud
KOSUN Solution:
- Customized 5-stage system with:
- Dual-motion shale shakers
- High-G centrifuges
Results:
✔ 92% drilling fluid recovery
✔ $2.8M saved in mud costs
✔ Zero environmental incidents
How to Select the Right System
Consider these factors:
- Well Parameters: Depth, formation type, mud weight
- Flow Rate Requirements: 500-5,000 GPM options
- Mobility Needs: Skid-mounted vs trailer-mounted
- Automation Level: Basic vs smart IoT systems
- Future Expansion: Modular design capabilities