Author: desanderdesilter

As a manufacturer of decanter centrifuge and oil sludge treatment system, GN solids control can also produce three phase decanter centrifuge and three phase disc centrifuge, which can be used for oil sludge separation unit.
3 phase decanter centrifuge is a solids liquid liquid separation machine, in the complete oil sludge treatment process, one unit of 3 phase decanter centrifuge can replace the design of decanter centrifuge + 3 phase disc centrifuge. Both of the design can separate solids, water and oil, to get the dry solids for disposal or landfill, pure water can be sent to waste water treatment facility and recovered oil can be sold.

How to select the design with 3 phase decanter centrifuge or 3 phase disc centrifuge?
1)    When the user required treatment result is not high, they can accept more oil in the solids. The recovered oil is not so clean and more oil in the water, they can select the 3 phase decanter centrifuge. But if the recovered oil required with BS&W below 2% ~3%, then they should use 1 unit of decanter centrifuge plus 1 unit of 3 phase disc centrifuge. The benefit of 3 phase decanter centrifuge is that the easy maintenance and operation compared with disc centrifuge.
2)    When the budget is limit, one unit of 3 phase decanter centrifuge is with competitive price than one unit of decanter centrifuge and one unit of 3 phase disc centrifuge.

3)    Less power consumption, for 5m3/h oil sludge treatment system, the power consumption of 3 phase decanter centrifuge is 27.5KW, the power consumption of one unit of decanter centrifuge and one unit of 3 phase disc centrifuge is 66.5KW.
Both of the 3 phase decanter centrifuge and 3 phase disc centrifuge need to work with proper chemicals to archive better separation result.

As a manufacturer of solids control system and drilling waste management system manufacturer in China, GN solids control can also design and produce liquid mud plant, recently one set of 35000bbl liquid mud plant are shipping to port for our client– drilling fluids service company.

The technical configuration is as below:
Part 1: mud mixing system: 2 units of mud mixing tank with dust free hopper and mixing pump, mud agitator, mud gun, transfer pump, pipelines, electric control system, handrails, walkway.

Part 2: mud processing system, including 1 unit of GNZS594F linear motion shale shaker, 1 unit of GNLW452D middle speed decanter centrifuge, 1 unit of GNLW363C high speed decanter centrifuge, with decanter centrifuge feeding pump, mud agitator, mud gun, transfer pump with soft starter, pipelines, electric control system, handrails, walkway. The decanter centrifuge is made of anti-corrosion and wear-resistant material, the centrifuge bowl is made of duplex stainless steel 2205, the screw is made of stainless steel 316L, the screw is protected by tungsten carbide tiles, the solids distribution port and fluids distribution port is protected by tungsten carbide alloy. The bearing is SKF brand bearing for longer working life.

Part 3: storage system: including 70 units of 500bbl (80m3) vertical storage tank, total capacity is 35000bbl, with transfer pump and soft starter, pipelines, guardrails, walkway, stairs. The user will connect the pipelines with their existing pipeline from dock
Part 4: Dry Bulk Silos: for dry powder storage, such as Bulk Barite/Cement pressurized silos
Part 5: air supply system, including air compressor and its accessories.
Part 6: if required the system can be connected with drilling waste treatment system, such as vertical cuttings dryer, dewatering centrifuge, high G drying shaker, screw conveyor, etc.
We can design customized liquid mud plant as per client’s requirement, pls contact with GN solids control for more information.

Below is the photo of one set of drilling cuttings treatment system working at rig site for international oilfield service company, the customer is satisfied with the treatment result. It is used to treat the oil based drilling cuttings from primary shaker, we suggest the user to collect the drilling cuttings from desander, desilter and decanter centrifuge separately and send to oil sludge separation system in the factory to get pure water, recovered oil and solids for disposal. If not meet the disposal standard, it can be sent to Thermal desorption unit for further treatment.

The pre-condition to use the vertical cuttings dryer including that the drilling cuttings should be oil based drilling waste, and only from primary shaker; the drilling cuttings should not be accumulated for too long, the long it is collected, the hard to separate the oil from solids, which will influence the treatment result. The drilling cuttings should not be polluted by rain water and other water, which will increase the water content, the discharged solids will with more moisture.

The high G drying shaker with the function to reduce the solids content, to get the better treatment result, we suggest client to use big screen opening of the screen basket, but by this way, some of the fine solids will be remained in the fluids, if the solids content is too high, the decanter centrifuge will be blocked and it is wear very fast, so we add a high G drying shaker  between them, no need extra feeding pump, just through flow by gravity, it will increase the separation efficiency of the whole drilling cuttings treatment system.
The decanter centrifuge is the last step treatment to separate the fine solids from the mud, the fluids can be reused to prepare for new drilling fluids and reused by the drilling rig.

Recently one batch of linear motion shale shaker, mud cleaner, decanter centrifuge are ready for shipment to oilfield service company. They are used to treat the used drilling fluids and recycle them to prepare for new drilling fluids, the new drilling fluids will be reused for drilling rig. As one of the solids control equipments and system manufacturer in China, GN solids control can produce complete line solids control equipments, including linear motion shale shaker, elliptical motion shale shaker, mud cleaner, desander, desilter, vacuum degasser, decanter centrifuge, mud agitator, centrifugal pump, mud gas separator, vertical cuttings dryer, mixing hopper, shaker screens, screw pump, screw conveyor, etc.

The single layer shaker screen with 4pcs panel shaker screens with 2.73m2 screen area, the equipped shaker screen is composite material frame shaker screen for longer working life and better separation performance. The mud cleaner with same model bottom shaker, the client can stock the wear parts convenient, the desander cone and desilter cone are installed with 1500gpm treating capacity. The cone is made of 100% polyurethane for better abrasion resistance. We can provide mud cleaner feeding pump – centrifugal pump, complete with pump head, explosion proof motor, pump skid, pump control panel, coupler with cover, etc.

The GNLW454ET-VFD decanter centrifuge is a high ratio 18 inch bowl decanter centrifuge with VFD control panel. The bowl diameter is 18 inch, the bowl length is 74.5 inch, the designed capacity is 400gpm, the typical treating capacity is 300gpm, The max bowl speed is 3500rpm, typical bowl speed is 0~3200rpm. Max G force is 3084G, typical G force is 0~ 2578G. The screw is protected by tungsten carbide tiles, the fluids distribution port and solids discharged port is protected by tungsten carbide alloy. Normally we use screw pump as decanter centrifuge to adjust the flow rate easily.

GN solids control design and produce 240m3/h, 360m3/h, 500m3/h TBM Slurry Separation Plant, which is suitable for big TBM project. The features of GNTBM slurry separation plant:

1.    Compact design, module design, integrated design, small footprint, easy transportation
2.    Customized design, can change our design as per client’s requirement
3.    5 phase separation, the discharged solids is much drier, and the fluids is more clean
By assembly different modules, we can provide more different treating capacity system.
Basic model:

GNTBM-240 ( 240m3/h)
GNTBM-360 ( 360m3/h)
GNTBM-500 ( 500m3/h)
Assembled model:
GNTBM-800 ( 800m3/h)
GNTBM-1000 ( 1000m3/h)
GNTBM-1500 ( 2000m3/h)
GNTBM-2000 ( 800m3/h)
GNTBM-2500 ( 2500m3/h)
GNTBM-3000 ( 3000m3/h)
Recently one set of 360m3/h TBM slurry separation plant are ready for shipment to pipe jacking engineering company. The technical configuration is as below:
1.    Coarse solids separation shaker : GNZKR-1230, 1 set
2    Double deck mud cleaner :GNZY705E-Y3S16N, 1 set
the bottom shale shaker is a double deck shale shaker, with 3 ea of 10 inch desander cone and 16ea of 4 inch desilter cone , the total treating capacity is 360m3/h. the screen area is 4m3. The vibration strength is max 7.5G ( adjustable)
3 Desander feeding pump is GNSB8X6-14/12J, desilter feeding pump is GNSB8X6-14/12J.
4.    The system frame is 6058 x 2438x2891mm, with fluids catching tank, during transportation, the coarse solids separation shaker will be disassembled.
The 5 phase separation process including:

Pre-treatment : coarse solids separation, to separate the big solids, stones, sand
Desander cone separation, the separation cut point is 45 microns
Desilter cone separation: the separation cut point is 20 microns
Mixing: the collected fluids will be used to prepare for new fluids to be reused.
Decanter centrifuge: the separation cut point is 2~5 microns
If you need a customized solution for TBM slurry separation plant, pls contact with GN solids control.

3 phase disc centrifuge and 3 phase decanter centrifuge is 2 equipments normally used for oily water separation, both of them have their advantages and disadvantages.
The comparison is as below:
Both of the 3 phase disc centrifuge and 3 phase centrifuge are for light liquid, heavy liquid, and solids separation, just one is vertical centrifuge, the other one is horizontal centrifuge.
The working principal is different:

3 phase Disc centrifuge: the oily water is feed into the disc centrifuge, under the centrifugal force, the material pass through the disc bundle separation intervals, the light liquid and heavy liquid are discharged by the lower centrifugal pump and the upper centrifugal pump respectively, the solids is discharged regularly.
3 phase decanter centrifuge: when the oil sludge is feed to the centrifuge inlet pipe and enter into high speed bowl, the material rotates synchronously with the bowl.The centrifugal force became less from outside to inside. The solids are pushed by the screw conveyor, the water is discharged from the nozzle in the upper, the oil is discharged from the bottom nozzle .

The disc centrifuge can be applied for materials with fine solids and with less solids content, so the material to be feed to disc centrifuge is very strict limited, the solids content should be less than 3% and the particle size is no more than 1mm, so normally we will use a decanter centrifuge before the disc centrifuge, to reduce the solids content and separate the big solids from the oily water/ oil sludge. So the cost of the proposal with a decanter centrifuge and a disc centrifuge will be definitely higher than 3 phase decanter centrifuge, but the treatment result will be always better, it can meet the requirement for oil recovery, solids disposal safely and water to be sent to waste water treatment.

As a waste sludge dewatering equipments manufacturer in China, GN solids control can produce a range of sludge dewatering equipments for our clients applied for different industries. Such as dewatering centrifuge, screw press dewatering machine, chemical doing unit. Recently one batch of waste sludge treatment equipments are ready for shipment to our environmental company customer.

Dewatering centrifuge unit with chemical doing unit is the most popular dewatering equipments for waste sludge treatment, like oil sludge treatment, construction waste sludge treatment, industrial waste sludge treatment. It is consist of one unit of dewatering centrifuge with VFD control panel, one unit of centrifuge feeding pump, one set of fluids collection tank, one unit of chemical dosing unit, sometimes it is installed on the skid of mud tank, sometimes it is in a separate skid or installed inside a 20ft container for sun/water proof and convenient operation. The waste sludge and prepared chemicals are mixed inside the centrifuge feed pipe, sometimes we will install Static mixer before that for their better mixing, then the mixture sludge will flow to centrifuge and treated as solids and liquid. If the user need further treatment like fluids with fluids, such as oil and water, we will use 3 phase decanter centrifuge or 3 phase disc centrifuge to treat the fluids to get pure oil and relatively pure water.

The screw press machine is introduced as sludge extrusion dewatering equipment, compared with filter press and dewatering centrifuge, it has its own advantages and disadvantages. For energy saving, decanter centrifuge is the highest engery consumption, ,and screw press is the lowest, for cost issue, filter press is the highest, decanter centrifuge in middle and screw press is the cheapest. For treating capacity, decanter centrifuge is high with better treatment result, the screw press is lower, for operation cost, screw press is the lowest.

As a HDD mud reclaimer manufacturer in China, GN solids control can design and produce the solids-liquid separation solution for HDD, CBM, TBM, Piling, etc works. Recently we shipped one batch of mud reclaimer eqiupments to our HDD company client, including:

2 units of GNMS-500D desander unit: this is an economic configuration mud recycling unit, with 1 unit of double deck shale shaker plus desander cone, 1 unit of centrifugal pump as desander feeding pump, 1 unit of fluids catching tank to collect the discharged fluids from coarse solids separation screen layer in the bottom, the centrifugal pump suck the mud from this catching tank to desander cone, the separation cut point is 45 microns, the clean fluids from desander cone will flow to mud mixing tank through pipelines, and the solids will drop on the top layer screen of the dual deck shale shaker for drying and recycling.

1 unit of mud mixing tank, the tank capacity and mixing capacity can be customized according to your requirement, we can add one or 2 mixing hopper with 1 or 2 mixing pump to meet your requirement from 200gpm mixing unit to 1400gpm mud mixing capacity. For this project, we make 2 units of venturi hopper with 2 units of mixing pump installed on the skid of one side.

1 unit of double deck shale shaker, normally it is used to separate the coarse solids from the drilling fluids, with 2ea of 2.5HP vibration motor produced high G force, the total screen area is up to 4.63m2, it increase the treating capacity compared with single deck shale shaker and it can treat the mud much cleaner. Both of the top layer shaker screen and bottom layer shaker screen are made of composite material frame shaker screen to ensure the separation performance.

Recently one set of oil based drilling waste management system are ready for shipment to our client in China. The technical configuration is as below:
（1）1 set of GNCD930F vertical cuttings dryer with telescopic skid, with 900rpm speed and max G force is up to 420G
(2) 1 set of GNLW363C-VFD decanter centrifuge installed on the fluids catching tank, and screw pump as feeding pump
(3) skid assy and mud tank, the

The working process is as below:
When the drilling waste management system is installed on the rig site, the drilling cuttings will be collected by screw conveyor directly and automatically transfer to the vertical cuttings dryer for treatment. When the drilling waste management system is installed in the waste facility, probably they will use forklift with a hopper to receive the waste and dump into the collection hopper, which is connected with a screw conveyor inlet port, the drilling waste will be transferred to vertical cutting dryer feeding port automatically through its discharge port; Another way is that the client use the excavator to pick up the drilling waste and sent to the collection hopper, the collection hopper should be big enough to receive the oil based drilling cuttings.

When the drilling waste is water based drilling cuttings or mixture of oil based mud and water based mud, they can not use this system to treat the drilling cuttings. For water based mud drilling waste treatment, we normally user high G drying shaker to separate the big solids firstly, and the fluids are treat by dewatering centrifuge with chemical dosing system. For mixture drilling waste which is collected from offshore drilling rig, they can not be separately collected, we will suggest oil sludge separation unit, we have 1~2 m3/h, 5m3/h, 15 m3/h oil sludge treatment unit for option.

The three phase decanter centrifuge can be used for oil tank bottom cleaning sludge treatment, relatively, we can use 1 unit of 2 phase decanter centrifuge with 1 unit of disc separator to instead of it. How to select it?

3 phase decanter centrifuge, the cost is cheaper compared with using 1 unit of decanter centrifuge plus 1 unit of disc separator. But for the treatment result , 1 unit of decanter centrifuge + 1 unit of disc centrifuge is better, also the application range is also much wide than 3 phase decanter centrifuge.
To ensure the separation process of 3 phase decanter centrifuge, the user should confirm that the solids content is less than 10%, and the oil content is higher than 10%, otherwise the separation result will not be good, as the high content solids will block the screw easily, and the less oil will lead the liquid – liquid separation very difficult.

The 2 phase decanter centrifuge can separate the solids with liquid efficiently by using with chemical dosing unit, the prepared chemicals are feed to decanter centrifuge , at the same time, the decanter centrifuge feeding pump also feed the sludge to decanter centrifuge, they mixed well in the feed tube , so that the suspend solids will be accumulated well and will be easily separated out of the fluids, only left very few fine solids( less than 3%) and the solids size is very small, then it will be feed to disc separator, for oil and water separation.
We have 3 models of 3 phase tricanter for option, GNSX-350 with designed capacity 5m3/h, the lubrication method is by grease, GNSX-450 with designed capacity 10m3/h, GNSX-520 with designed capacity 15 m3/h, which the lubrication method is by oil pump. For more information, pls contact with GN solids control.