As oil and gas exploration continues to advance into deep, ultra-deep, and complex operating conditions, the demands for drilling efficiency, safety, and environmental protection have significantly increased. As a crucial component of the overall drilling solid control system, the Liquid Mud Plant has become key infrastructure for ensuring a stable supply of drilling fluid, reducing operational costs, and enhancing environmental protection levels.

A Liquid Mud Plant is a specialized system for the storage, preparation (mixing), circulation, weighting, conditioning, and transportation of drilling fluid. It typically consists of several functional areas: drilling mud storage area (tank system), drilling mud preparation and weighting system, solid control and circulation treatment devices, pumping and transportation system, and automated monitoring and safety control systems. In onshore drilling, offshore platforms, centralized mud supply bases, and the production systems of oilfield service companies, the mud station acts as a “logistics center,” ensuring different well sites can obtain stable, high-quality drilling fluid on demand.

Core Functions of a Liquid Mud Plant

Drilling Fluid Storage: The mud station is equipped with multiple tanks of different capacities and functions for the segregated storage of water-based mud (WBM), oil-based mud (OBM), high-density mud, completion fluids, etc. These tanks typically feature: anti-corrosion inner walls, heating coils, level monitoring, overflow prevention and safety protection, and a movable or skid-mounted structure.

Drilling Fluid Preparation and Mixing: According to well condition requirements, the mud station can rapidly complete the large-scale pre-mixing and conditioning of drilling fluid, including: adding weighting agents (barite, hematite), adding chemical additives, maintaining rheological properties, and high-capacity shear mixing. An efficient preparation system can significantly reduce waiting time at the well site and improve operational efficiency.

Drilling Fluid Circulation and Solid Control: By configuring solid control equipment such as shale shakers, desanders, desilters, and centrifuges, the system achieves: solid phase control, solid-liquid separation, removal of suspended solids, and optimization and reuse of mud properties. This is of great significance for reducing drilling costs, extending equipment life, and minimizing waste discharge.

Drilling Fluid Pumping and Transportation: The mud station uses mud pumps, metering systems, and loading arms to transport the conditioned drilling fluid to: onshore well sites, offshore platforms, tank trucks, vessels, or supply boats. This ensures an efficient “on-call” supply capability.

Modern drilling operations have increasingly stringent requirements for mud performance, cost, and environmental protection. The Liquid Mud Plant maximizes the value of drilling fluid through efficient recovery and recycling, substantially reducing mud consumption and waste disposal costs. A completed mud station enables centralized supply and recycling of oil-based mud, effectively reducing total usage, which lowers construction costs while mitigating safety and environmental risks. The mud station adopts a centralized, large-scale treatment model, allowing for unified pollutant management, control of total discharge volume, reduction of environmental diffusion, and realization of green operations.

Furthermore, a single mud station construction can service multiple wells, resulting in less onsite equipment, a smaller footprint, and no waste accumulation, reducing environmental assessment pressure and construction costs from the source. It also lowers electrical load and lessens reliance on the drilling rig, making drilling operations safer and more efficient. By further optimizing the mud formulation ratio, the mud station can also enhance OBM performance, standardize operational procedures, ensure drilling quality, and provide reliable assurance for accelerating construction efficiency.

Currently, there are mainly three methods to address HDD mud problems: sedimentation, dilution, and mechanical removal.

Sedimentation: One or more mud pits are dug at the entry and exit points of the crossing. The returned mud is channeled into the pits. After a certain period of natural settling, the upper liquid phase is extracted for the mud circulation system, and the bottom solid phase is discarded. Advantages: Simple operation, low cost, low energy consumption; Disadvantages: Large footprint required, slow settling/separation speed, and the bottom solid phase is difficult to clear out.

Dilution: The mud returned from the crossing is collected in mud tanks, and then water, bentonite, and additives are added to adjust the mud properties required for the crossing, aiming to reduce the solid content of the mud. Advantages: Simple method, low cost; Disadvantages: Incomplete solid phase removal.

Mechanical Removal: This method uses a solids control system to separate the solid phase. A solids control system refers to a setup composed of shale shakers, desanders, desilters, desander cleaners, desilter cleaners, horizontal decanter centrifuges, and circulating large tanks, configured according to specific solids control requirements. In most cases, mechanical removal is the most effective and economical method.

As can be seen, the most effective and feasible means of treating mud currently is mechanical removal. For example, the Horizontal Directional Drilling (HDD) Mud Recycling System produced by Xi’an KOSUN Machinery is an effective mechanical removal solution for solving mud pollution.

The KOSUN Machinery Horizontal Directional Drilling (HDD) Mud Recycling System uses a multi-stage purification process of “shale shaker + desander + desilter” to efficiently separate solid particles from the mud, achieving over 90% mud recycling and reuse. Specifically, the shale shaker can remove solid particles >1.5mm, the desander can remove solid particles from 0.074mm to 1.5mm, and the desilter can remove solid particles from 0.02mm to 0.074mm. After treatment, the suspended solids in the separated wastewater are ≤50mg/L, allowing it to be directly reused in construction or discharged in compliance with standards; the dried cuttings can be made into road base materials or green planting soil, truly achieving “zero mud pollution discharge”. The system has also passed ISO14001 environmental certification, adapting to strict environmental protection policies.

In addition, the KOSUN Machinery Horizontal Directional Drilling (HDD) Mud Recycling System features a compact design that significantly reduces the required footprint, allowing it to function fully even in space-constrained construction environments.

The core value of the KOSUN Machinery Horizontal Directional Drilling (HDD) Mud Recycling System lies in transforming mud from a “polluting waste” into a “recyclable resource.” Through breakthroughs in environmental compliance, cost optimization, and efficiency improvement, the system not only provides a compliant solution for HDD construction but also promotes the green transformation of the trenchless industry.

With the continuous expansion of urban underground space development, trenchless construction technologies such as pipe jacking, horizontal directional drilling (HDD), and large-cross-section rectangular passages have become important methods in municipal engineering. During these construction processes, the stability of mud circulation and the environmental compliance of mud treatment directly affect project quality, construction efficiency, and overall cost. Kosun, leveraging years of experience in manufacturing solid control equipment, introduces professional mud recycling systems for the trenchless industry, helping construction parties improve drilling efficiency, reduce mud loss, and minimize waste slurry discharge, thereby achieving true energy saving and environmental protection.

In pipe jacking projects, especially for large diameters and ultra-long distances, the requirements for mud performance are more stringent. The Kosun mud recycling system can continuously maintain stable mud density and viscosity, balance earth pressure during jacking, reduce formation disturbance, minimize pipeline resistance, and ensure smoother propulsion operations. Simultaneously, multi-stage separation equipment within the system, including shale shakers, desanders, desilters, and centrifuges, effectively separates drill cuttings, increases the reuse rate of the mud, substantially reduces bentonite consumption, and saves significant costs for construction parties.

In the field of horizontal directional drilling (HDD), the HDD mud recycling system designed by Kosun features high-efficiency circulation capabilities, providing clean and stable mud for pilot drilling and reaming operations. This significantly reduces drill string torque and wear, ensuring a stable borehole trajectory. With reduced solids content in the mud, the resistance during pipeline pullback also decreases, leading to a higher success rate for long-distance, large-curvature crossing projects. By minimizing waste slurry discharge, Kosun equipment also helps construction enterprises easily meet environmental compliance requirements.

In the construction of large-cross-section rectangular underground passages, the system likewise achieves high-flow-rate circulation and efficient solid control, preventing mud sedimentation, maintaining excavation face stability, and reducing impact on surface facilities. The combination of mechanized construction and a stable mud system makes tunnel propulsion more efficient and controllable.

The HDD mud recycling system designed by Xi’an Kosun fully integrates the characteristics of directional crossing construction, consolidating equipment such as shale shakers, desanders, desilters, decanter centrifuges, and mud tanks. Utilizing mechanical grading, screening, and solid-liquid separation principles, it achieves high-efficiency purification and recycling of the mud. The treated mud can be directly reused in crossing construction, saving construction costs while reducing waste mud discharge and minimizing environmental impact. Concurrently, Kosun’s systems can be flexibly configured according to different project demands, ensuring stable and efficient mud treatment whether for urban construction or complex terrain operations.

Choosing Kosun’s mud treatment solution not only means improved construction efficiency but also guarantees construction safety and environmental friendliness. With years of technological accumulation and a comprehensive after-sales service system, Kosun assists various directional crossing projects in smooth progression, facilitating the upgrade of mud treatment from traditional methods to mechanized and intelligent solutions, providing robust assurance for urban infrastructure development.

In horizontal directional drilling (HDD) projects, the stability of the drilling fluid (mud) often determines whether construction can proceed smoothly. With the widespread application of trenchless technology in urban pipe networks, power lines, communication engineering, and long-distance transmission projects, high-quality mud circulation and drilling mud processing equipment are no longer optional accessories. They have become core conditions for ensuring project efficiency and meeting environmental standards. For years, Xi’an Kosun has specialized in the research and development of mud treatment systems and solids control equipment, verifying the critical role of their mud recycling systems in practical construction through numerous domestic and international crossing projects.

Optimizing Drilling Efficiency with Advanced Mud Systems

During directional drilling, mud lubricates tools, carries cuttings, and stabilizes the borehole. Declining mud performance leads to issues like increased torque, borehole collapse, and equipment wear. Xi’an Kosun’s mud recycling system uses multi-stage processes including shale shakers, hydrocyclone assemblies, and centrifugal separation to remove cuttings, sand, and fines, keeping the mud within ideal performance. Benefits include smoother drilling, reduced torque, extended tool life, and less downtime for mud changes. Efficient drilling fluid recycling is vital for successful HDD.

Cost Savings and Sustainable Waste Management

The mud recycling system reduces drilling mud materials and disposal costs. Without solids control equipment, daily mud replenishment is needed, which is costly and requires material storage and transport. The system separates solids for reuse, cutting raw material waste. Separated solids have low water content, simplifying centralized treatment and reducing environmental impact through solids management and waste minimization.

Meeting Stringent Environmental Compliance Standards

With stricter environmental rules, discharging waste mud is risky. Xi’an Kosun’s mud recycling system ensures clean mud circulation and less waste, helping projects pass environmental tests and giving companies an edge in bidding. This is why these mud recycling systems are used in urban gas, heating, power, and communication pipeline projects and are recognized internationally.

The Strategic Choice for Project Success

Selecting a dependable mud recycling system supports a construction method that is safe, environmentally responsible, cost-effective, and stable. Xi’an Kosun provides proven mud treatment solutions based on extensive experience. Effective mud recycling is crucial for successful projects.

In oil drilling operations, the cleanliness of drilling fluid directly affects drilling efficiency, wellbore stability, and equipment lifespan. As drilling depth and complexity continue to increase, traditional desanders and desilters alone are often insufficient to meet the requirements for efficient purification. The mud cleaner, which integrates both desanding and desilting functions into a single unit, has become an indispensable component in modern solids control systems. Leveraging its in-depth research in drilling fluid solids control technology, Xi’an Kosun has accumulated extensive experience in the design, manufacturing, and application of cleaners, providing reliable purification solutions for global oil and gas drilling projects.

The primary function of a mud cleaner is to further remove medium-to-fine particles that shale shakers are unable to separate, typically with particle sizes between 20 and 74 microns. If these fine solids are not removed promptly, they can increase drilling fluid viscosity, cause density fluctuations, and consequently raise drill torque, accelerate wear, or even lead to stuck pipes and wellbore collapse, creating serious safety risks. By combining centrifugal separation with screening, the cleaner efficiently removes solid particles without altering mud properties, maintaining smooth flow and stability in the drilling fluid circulation system.

During operation, pre-treated drilling fluid first enters the hydrocyclone separation unit of the cleaner. The high-speed rotation generates centrifugal force, which forces the heavier solids outward. The separated upper liquid layer then passes through a fine mesh screen for secondary filtration, ensuring that the discharged fluid is even cleaner. Xi’an Kosun’s drilling fluid cleaners feature an optimized fluid dynamics design, with low flow resistance, high separation efficiency, and stable overall operation. Even under high solid-loading conditions, the equipment maintains continuous, high-efficiency purification.

Compared with single-function devices, drilling fluid cleaners offer significant advantages, including a compact structure, strong processing capacity, and ease of maintenance. They can substantially reduce the load on downstream centrifuges, decrease the overall energy consumption of the mud treatment system, and extend the service life of drilling fluid, ultimately lowering drilling costs at the source. By incorporating a modular design concept, Xi’an Kosun ensures that cleaners can flexibly integrate with different solids control system layouts, whether for onshore drilling or offshore platforms, providing easy installation, commissioning, and maintenance.

In addition, Xi’an Kosun has carried out comprehensive optimizations in material selection and manufacturing processes. The main body of the equipment is made of wear- and corrosion-resistant steel, while the hydrocyclones are constructed from high-performance polymer polyurethane, offering excellent impact resistance and extended wear life. The screen section uses high-strength stainless steel composite screens, ensuring long-term screening accuracy and stability. Some models are also equipped with intelligent monitoring systems, which can real-time monitor pressure, flow, and vibration, providing operators with accurate data support and further enhancing system safety and automation.

The stable operation of drilling fluid cleaners not only improves mud circulation purification efficiency but also effectively protects the wellbore, reduces drill bit wear, and extends equipment lifespan, thereby increasing drilling efficiency while lowering costs. With over 30 years of industry experience, Xi’an Kosun adheres to the philosophy of “quality as the foundation, innovation as the guide”, continuously optimizing product performance and improving after-sales services to provide efficient, environmentally friendly, and cost-effective drilling fluid cleaning solutions for global oilfield clients.

Looking forward, Xi’an Kosun will continue to focus on innovation in solids control technologies, helping the oil drilling industry move toward safer, more efficient, and greener operations.

In the mud circulation systems of oil drilling, the fluid treatment processes of chemical production, and even the wastewater purification workflows of the environmental industry, harmful gases hidden within fluids remain an “invisible hazard” that threatens production efficiency, product quality, and operational safety. As a core device for solving this issue, choosing the right vertical degasser not only significantly improves fluid purity but also ensures the stable operation of the entire production line.

Faced with a wide range of vertical degasser products on the market, how can enterprises make the right selection? With years of deep expertise and hands-on experience in industrial fluid treatment, Xi’an Kosun has summarized the key factors for accurate equipment selection.

The first step in selecting a vertical degasser is to align it closely with your actual fluid-handling requirements. Xi’an Kosun recommends first determining the maximum circulation capacity of your fluid (in cubic meters per hour or gallons per minute) to ensure that the degasser’s processing capability fully meets, or slightly exceeds, the real operational demand.

The drive motor, serving as the power source of a vertical degasser, directly affects the equipment’s operational stability and energy efficiency. Xi’an Kosun exercises strict quality control in motor selection, precisely matching the motor power to the degasser’s processing capacity for each model. This ensures sufficient power without overloading, while avoiding unnecessary energy waste caused by oversized motors.

Notably, Xi’an Kosun uses high-quality motors from leading industry brands, which feature low noise, excellent stability, and high energy efficiency. Over long-term operation, these advantages help significantly reduce energy consumption and overall operating costs for enterprises.

The layout of industrial sites is often complex and varied, making ease of installation an important factor when selecting equipment. Xi’an Kosun fully considers this requirement from the very beginning of its design process. The company’s vertical degassers feature a modular structure with a compact footprint and well-optimized layout, allowing for seamless integration into existing production systems. They can also be easily adapted to different site configurations, significantly reducing installation difficulty and construction time, enabling the equipment to be put into operation quickly and efficiently.

From demand matching to core components, from power systems to intelligent configurations, and from site adaptability to operational reliability, every selection detail impacts a company’s productivity and safety. As a specialized manufacturer dedicated to the R&D and production of industrial fluid treatment equipment, Xi’an Kosun remains customer-oriented, leveraging technological innovation and strict quality control to provide the oil drilling, chemical, and environmental protection industries with more efficient, durable, and intelligent vertical degasser solutions.

If you are still unsure about which vertical degasser best suits your needs, contact Xi’an Kosun today. Our professional technical team will provide one-on-one selection guidance, helping you choose with confidence and operate with peace of mind.

The vacuum degasser is a specialized solids control device used in oil and gas drilling to handle gas-contaminated drilling fluid. It is also known as a negative-pressure degasser or drilling fluid degasser.

In petroleum and natural gas drilling operations, gas intrusion into the drilling fluid is one of the critical factors affecting well control safety and operational efficiency. The vacuum degasser can rapidly remove various gases that have entered the drilling fluid, playing a vital role in restoring mud density and stabilizing mud properties. It is therefore an indispensable technical device for ensuring the safety of drilling operations.

1. Working Principle

The vacuum degasser operates based on Henry’s Law, which states that the solubility of a gas in a liquid is directly proportional to its partial pressure. The device establishes and maintains a negative-pressure environment within a sealed container, reducing the partial pressure of dissolved gases and forcing the gases to come out of the drilling fluid.

The working process can be divided into three key steps:

Establishing the Vacuum Environment:

A vacuum pump or ejector pump creates and maintains a stable negative-pressure state inside the degasser tank. This vacuum serves as the driving force for the entire separation process.

Gas–Liquid Separation Process:

Gas-contaminated drilling fluid is sucked into the tank under vacuum. It passes over specially designed umbrella plates or baffles, which spread the fluid into thin liquid films. During this process, dissolved gases rapidly come out of solution and expand, achieving efficient separation.

Orderly Discharge:

The separated gases are safely vented through the vacuum system, while the purified drilling fluid returns to the circulation system, restoring its density and regaining its functional properties.

2. Key Points for Selecting a Vacuum Degasser

Clarify Production Requirements

The first step in selecting a vacuum degasser model is to fully understand the specific production requirements. Key factors to consider include the characteristics of the drilling fluid, required processing capacity, and working environment conditions. Different production scenarios place varying demands on equipment performance, and accurate requirement analysis forms the foundation for proper selection.

Processing Capacity

Processing capacity is a decisive parameter for selection, referring to the cubic meters of drilling fluid the equipment can treat per hour. The rated capacity should exceed the maximum expected drilling fluid circulation rate and include a sufficient safety margin. Inadequate capacity may result in incomplete degassing, which can compromise well control safety.

Consider the Working Pressure Range

The working pressure range is an important factor affecting degassing efficiency. Different production processes have specific pressure requirements, and the selected equipment must be capable of operating within this range. Proper pressure settings are critical to achieving effective gas removal.

Evaluate Equipment Reliability

Focus on stability and durability during selection. Stable equipment ensures continuous and reliable operation, while durable equipment maintains performance over long-term use. Both factors directly impact production efficiency and operating costs.

Refer to Actual Application Feedback

Before finalizing a model, it is advisable to review its performance in real-world applications. Examining how the equipment operates under similar conditions and considering user feedback provides valuable insights to guide selection.

Recommended Selection Process:

Analyze well conditions → Determine processing requirements → Choose performance parameters → Optimize power configuration → Verify equipment quality

3. Engineering Application Value Analysis

In drilling engineering projects, deploying a vacuum degasser offers clear technical and economic benefits:

Enhancing Safety Levels: Serves as an active well-control measure, providing an additional reliable technical barrier for drilling operations.

Ensuring Operational Continuity: Reduces non-productive time caused by gas-contaminated drilling fluid, thereby improving overall drilling efficiency.

Optimizing Lifecycle Costs: Compared to potential costs from well-control incidents and production losses, investing in the equipment offers significant cost-effectiveness. The use of energy-saving technologies, such as ejector pumps, can further reduce operational energy consumption.

Conclusion

In drilling operations under deep, ultra-deep, and complex geological conditions, the vacuum degasser has evolved from an auxiliary device into a core piece of equipment for well-control safety. Its rigorous technical principles, reliable engineering design, and clear application value make it an indispensable component of modern drilling fluid purification systems.

As its application continues to expand, the vacuum degasser has surpassed the role of a single-function device, becoming a strategic element for ensuring drilling safety and enhancing operational efficiency. From conventional oil and gas exploration to unconventional resources such as geothermal and coalbed methane drilling, its ability to efficiently remove dissolved gases and stabilize drilling mud has become increasingly prominent.

Therefore, selecting a technically mature and reliable model based on specific operating conditions, and integrating it scientifically into the system, is not only a critical step in risk management and efficiency optimization for drilling projects, but also a key foundation for safe control of high-risk drilling operations and maximizing economic benefits.

In industrial fields such as oil drilling, shale gas development and mine exploration, the performance of drilling fluid (also known as mud) directly affects drilling efficiency, downhole safety and operation costs. The solids control system is precisely the core support system that ensures the continuous and stable operation of drilling fluid. As a professional enterprise deeply engaged in solid control equipment and system solutions, Xi ‘an Kosun, with years of industry experience, not only has a profound understanding of the technical essence of solid control systems, but also can tailor efficient and reliable solid control solutions for customers in different scenarios, helping the industry achieve green and efficient drilling operations. ​

In simple terms, a solids control system is a comprehensive equipment system that removes solid impurities (such as cuttings, sand grains, colloidal particles, etc.) from drilling fluid through classification separation and purification treatment, while recovering useful components (such as weighting agents, chemical treatment agents). During the drilling process, the drill bit breaks the formation rock, generating a large amount of cuttings. These cuttings circulate back to the surface with the drilling fluid. If not removed in time, it will lead to an increase in the viscosity and abnormal density of the drilling fluid, not only increasing the drilling torque and energy consumption, but also may cause safety hazards such as well gushing and well leakage, and even damage the drilling equipment. The core function of the solids control system is to “purify” the drilling fluid returning to the surface through scientific technological processes and professional equipment, restoring its performance to a state that meets the drilling requirements, achieving recycling and reuse. This not only reduces the waste of drilling fluid and lowers operation costs but also avoids environmental pollution caused by discarded drilling fluid, which is in line with the modern industrial green development concept.

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A complete fixed control system is not merely the simple superposition of a single device, but is composed of multiple core devices and auxiliary facilities with complementary functions working in coordination. This is also the focus of Xi ‘an Kosun in system design and integration. From the perspective of the process, the drilling fluid first enters the vibrating screen, which serves as the “first line of defense”. Through the high-frequency vibrating screen, large rock cuttings with a particle size greater than 75μm are filtered out, initially reducing the solid content. Subsequently, the drilling fluid containing medium and fine particles enters the desander, where the sand impurities ranging from 44 to 75μm are removed by cyclone separation technology. Then, the desilter comes into play, focusing on handling fine solid phases ranging from 15 to 44μm, further enhancing the cleanliness of the drilling fluid. For ultrafine particles with a particle size less than 15μm and colloidal substances, a horizontal screw centrifuge is used to deeply separate them through the centrifugal force generated by high-speed rotation, and at the same time, valuable weighting materials such as barite are recovered. All kinds of equipment work closely together to form a complete closed loop of “hierarchical purification – recycling”. ​

In scenarios such as sludge dewatering and industrial wastewater treatment in the environmental protection field, solid control systems also play a significant role. Xi ‘an Kosun can customize dedicated solid control solutions based on the composition characteristics of different types of wastewater and sludge. Through equipment such as horizontal screw centrifuges, it can achieve efficient solid-liquid separation, helping environmental protection enterprises improve treatment efficiency and meet discharge standards.

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With the continuous improvement of the industry’s requirements for drilling efficiency, safety and environmental protection, the importance of solids control systems has become increasingly prominent. As a professional service provider in the solid control field, Xi ‘an Kosun has always closely followed the technological development trend and constantly innovated its products and solutions. From single equipment supply to complete system integration, from the initial scheme design to the later operation and maintenance services, Xi ‘an Kosun provides customers with “one-stop” solid control services, helping them achieve efficient, safe and green production in drilling operations.

From energy development to mining, and then to construction and environmental protection treatment, Xi ‘an Kosun’s solids control systems always take scene requirements as the core. Through technological innovation and customized services, they provide efficient and reliable solids control support for customers in various industries. In the future, Xi ‘an Kosun will continue to focus on the field of solids control technology, providing more advanced systems and better services to safeguard the high-quality development of industries such as oil drilling.

Mud Recycling System Treatment Process: Efficient, Eco-Friendly Drilling Waste Management

In modern drilling operations, managing drilling mud waste is both an environmental obligation and a cost-saving opportunity. A mud recycling system treatment process ensures sustainable reuse of drilling fluids while minimizing environmental impact. This article explores how advanced mud recycling systems work, their benefits, and why they’re essential for compliant, efficient drilling operations.

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How Does a Mud Recycling System Work?

The mud recycling treatment process involves multiple stages to separate, clean, and reuse drilling fluids:

1. Solid-Liquid Separation

• Shale Shakers: Remove large cuttings (≥75μm) from drilling mud via vibration screening.
• Decanter Centrifuges: Further separate fine solids (5–10μm) using centrifugal force.
• Key Benefit: Extends mud lifespan, reduces disposal costs.

2. Chemical Treatment & Stabilization

• Polymer Flocculants: Bind ultrafine particles for easier removal.
• pH Adjustment: Optimizes mud properties for reuse.
• Key Benefit: Maintains mud viscosity and lubricity.

3. Dewatering (Optional)

• Filter Presses: Reduce moisture content in separated solids for landfill compliance.
• Evaporation Pits: Natural drying for arid climates.

4. Clean Mud Reintroduction

• Recycled fluids are reinjected into the active mud system.
• Key Benefit: Cuts fresh mud consumption by up to 70%.

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Why Invest in a Mud Recycling Treatment System?

✅ Cost Savings

• Reduce fresh mud purchases by 50–80%.
• Lower waste transportation/disposal fees.

✅ Environmental Compliance

• Meets EPA, OSHA, and regional drilling waste regulations.
• Minimizes groundwater contamination risks.

✅ Operational Efficiency

• Fewer drilling interruptions for mud replacement.
• Consistent fluid properties enhance ROP (Rate of Penetration).

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Industry Applications

• Oil & Gas Drilling (Onshore/Offshore)
• HDD (Horizontal Directional Drilling)
• Geothermal Well Construction
• Mining & Tunneling Projects

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Choosing the Right Mud Recycling System

Consider these factors:

• Throughput Capacity (50–500 m³/h systems available)
• Automation Level (Manual vs. PLC-controlled)
• Mobility (Skid-mounted, trailer, or modular designs)

Pro Tip: Look for ISO 9001/14001-certified suppliers with field-proven

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FAQs About Mud Recycling Systems

Q: How much waste can a recycling system reduce?
A: Up to 90% of drilling waste volume through solids removal and reuse.

Q: What’s the ROI of a mud recycling unit?
A: Typically 6–18 months via mud cost savings and reduced disposal fees.

Q: Can it handle oil-based mud (OBM)?
A: Yes, but requires additional thermal or chemical treatment modules.

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Conclusion

A mud recycling system treatment process transforms drilling waste from a liability into a resource. By investing in this technology, operators achieve:

• Lower costs
• Regulatory compliance
• Smaller environmental footprint

Ready to upgrade your drilling waste management?
 Contact KOSUN for a free consultation on customized mud recycling solutions!

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

1. Proven Reliability: 3,000+ installations worldwide
2. Custom Engineering: Site-specific solutions for:
   • Arctic conditions (-50°C)
   • Desert operations (50°C+)
   • Offshore platforms
3. Cost Savings:
   • 30% reduction in waste disposal costs
   • 50% longer equipment lifespan
4. Environmental Compliance:
   • Meets API RP 13C standards
   • Reduces drilling waste volume by 60%
5. Smart Monitoring:
   • Real-time solids analysis
   • Predictive maintenance alerts
6. 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:

1. Well Parameters: Depth, formation type, mud weight
2. Flow Rate Requirements: 500-5,000 GPM options
3. Mobility Needs: Skid-mounted vs trailer-mounted
4. Automation Level: Basic vs smart IoT systems
5. Future Expansion: Modular design capabilities