GN Solids Control was firstly known as a manufacturer of drilling fluids recycling equipment that are used to remove the solids in the drilling fluids, thus the drilling fluids could be reused. In China, there are several this kinds of manufacturers who can fabricate the traditional solids control equipment like shale shaker, mud cleaner, agitator and mud tanks.
Keeping improving is one of GN’s features. In the past few years, GN has invested a lot on upgrading the traditional solids control equipment to make it easier for operation. Moreover, GN has developed many new products that keep GN a leader in the solids control industry. In the year of 2016, GN released the system for hydrocarbon recovery. It is an effective solution to treat the waste oily sludge.
Oil Sludge Recovery
GN’s hydrocarbon recovery system is a three phase separation system. It includes primary coarse solids separation shaker package, fine solids separation centrifuge package and oil & water separation package.
The working principle of GN hydrocarbon recovery system is to remove the solid particles step by step from the oil sludge. The high G force drying shaker unit is equipment with hot water spraying system for better washing performance, this process will remove most of the oil content on the solids.
Decanter centrifuge is equipped with chemical dosing system for fine solids separation after demulsification process. GN’s dosing system could be used in all kinds of dewatering system for ultra fine solids separation.
The liquid discharged from the decanter centrifuge flows into the oil water separator package. Here an inclined plate clarifier is installed for further removing the remaining silt in the liquid for clarifying the oil and water mixer. Then the liquid mixer flows into the micro bubble separation for oil and water separating.
GN’s hydrocarbon recovery system makes GN a real separation solution provider other than a solids control equipment manufacturer. GN would like to communicate with all the clients on this hydrocarbon recovery system.
Vertical rotating drilling rig is the normal machine used in piling project. During the drilling process, in order to protect the inner wall of the drilling hole and speed up the process, the operator always chooses to use drilling mud. Then here comes another problem how to reduce cost of the drilling mud thereby to reduce the cost of drilling. The solution is to use mud recycling system to make the drilling mud reusable.
The purpose of the mud recycling system is to remove the large size solid particles in the drilling mud by several separation machines. In regards to the mud recycling system for piling project, it could be a very compact design as separation process is not so complex as that for oil gas drilling. GN solids control is one of the most experienced separation solution providers who could provide the mud recycling system for almost all the industries will use it. GN already developed the standard mud recycling system especially for the piling project.
Strictly speaking, the mud recycling system used in piling should be called de-sanding unit as the drilling depth is normally shallow and most of the solid particles are sand. A de-sanding unit would be enough for processing the separation to get the expected reusable drilling mud.
GN’s de-sanding unit is a compact structure 2 steps separation system. The main equipment in this de-sanding
unit is combined with a 2 layers shaker and cyclone manifold. The double layers shaker is used for coarse solids separation by the under layers and the upper layer screen is for drying the slurry discharged from the cyclone unit. The tank under the shaker unit is used to store the drilling mud. One centrifugal pump is installed in the system for transferring the mud to the cyclone unit for sand separation.
This de-sanding unit could be connected with extra mud tank for larger capacity mud storage. The operators can also equip a jet mixing unit to make an self-contained mud recycling system for other drilling project like HDD and water drilling.
GN’s mud system is not only used in oil gas drilling but also in some other drilling projects. Therefore, GN developed the drilling mud recycling system for non-oil drilling like HDD, CBM and water well drilling.
One type of water well drilling is for the drilling water, while the other one type of water well drilling is for water re-injection to underground for keeping the pressure of oil layer for continuous oil producing.
Working principle of the mud recycling system for water well drilling is same as the mud system for oil gas drilling. Removing the cuttings, sand and silt in the drilling fluids to make the drilling fluids reusable is the purpose of the mud recycling system.
Compact Mud System
Shale shaker is always the first stage equipment for solids control; it could remove the coarse cuttings in the drilling fluids. Shale shaker is the only one equipment by separating the solids hundred percent by the size of the particles. The screen could remove out the solid particles larger than the wire mesh openings. By adjusting the G force and the shaker deck angle, the operator could adjust the dryness of the discharged solids.
De-sander and de-silter could be called hydrocyclone unit. Same as the decanter centrifuge, hydrocyclone separates solid and liquid by using centrifugal force. Density difference is the main factor should be considered if the hydrocyclone unit would be applied.
Mud system for water well drilling is designed compact structure. As per the treating capacity, the corresponding equipment with same capacity would be installed in the system. For different drilling depth, the nos. of the mud tanks are various in different mud system.
Not all the shale shaker, de-sander or de-silter would be used in one mud system. GN ever made a mud recycling for a water well drilling project. The main equipment includes shale shaker and de-silter unit, no de-sander involved as the de-silter cyclone could fully hold function of the de-sander unit.
Besides mud recycling system for water well drilling, GN also developed other separation solutions. Any question, please contact with GN freely.
In past couple years, besides the petroleum industry, GN also tried expanding the business to some other fields. The big bowl decanter centrifuge and dosing system are two of the main equipment that widely used in environmental protection for waste water treatment. The decanter centrifuge is used to remove the solid particles in the waste water, used together with the dosing system; the treated water could be discharged directly with national standard for environmental protection.
By now, GN has already developed he big bowl decanter centrifuge for dewatering process. A very popular model GNLW553 in GN’s production line is the unit with 22 inch bowl diameter. The bowl length is over 3 times of the diameter. This is not the largest model GN can make. In near future, GN’s decanter centrifuge especially used for water treatment will be released. The model series would be 454 and even 554.
GN’s decanter centrifuge is VFD available for main motor, back motor and the feeding pump. All the electric components used come from worldwide famous brand. Operator could set the RPM on the HMI panel and monitor the machine running conditions.
The dosing system is designed containerized with all the components are installed inside the container. GN has both 20 feet and 40 feet model. Clients could choose high configuration that including automatic dosing system and acid/alkali mixing tank or simple polymer mixing tank.
The cured flocculation polymer is fed to the waste water and then the ultra fine solids will be gathered to become large size blocks for easy separation by the centrifuge.
Features of GN Waste Water Decanter Centrifuge
1. Speed adjustable as per treated waste water condition
2. Humanized HMI operation for easy operation and reducing of manpower
3. Low consumption on polymer and energy comparing with filter press
4. Considerable protection for solids discharge port and scroll for longer lifetime
GN will release more models of decanter centrifuge for environmental protection waste water treatment. Any questions, please feel free to contact GN know.
Mud system will not work if there are no mud tanks. In the mud recycling system, the tanks are used to store the drilling mud to be a base where the solids control equipment to be installed. Normally, more than one mud tanks
will be used in the oil drilling mud system. For different purpose, the design of the mud tank is different, especially the inner structure of the mud tanks.
There are mainly 3 types of mud tanks recycling tank, intermediate tank and premixing tank. Then what are the different among these 3 types of mud tank?
The recycling tank is where to install the primary shakers and degasser unit, and also the de-sanding and de-silting unit. Each of equipment needs a compartment in the mud tank. As the recycled drilling mud is treated by the solids control equipment one by one. After treatment by each of the equipment, the drilling fluids will be cleaner than before. Thus the drilling fluids cannot be mixed. The wall between two compartments always has an overflow port for balance of the drilling mud in the tank.
Mud Tank System
For the tank to install the de-sander and de-silter unit, inner structure of the mud tank would be much complex as there are pipes for centrifugal pump to such the drilling fluids from inside of the tank and transfer to the cyclone for further treatment. Operator has to know which pipe is for de-sander and which pipe is the desilter.
On the mud tanks for installing the solids control equipment on, there always have the walkways and handrails. The walkways provide enough space for the operator to walk around the equipment for operation and maintenance. Intermediate tank is a type buffering tank, part of this tank is for mud recycling, and other parts are used for mud storage. Operators can easily tell how many compartment in this tank.
The premixing tank is used to mix drilling fluids. It always is connected with the jet mixer unit. The mixing pumps suck liquid from mud tank and send liquid back again with added mud materials from the hopper. Thus the pump should be able to suck the drilling mud from anywhere in the mud tank used for mixing and storage.
Therefore, in the mixing tank, there are two groups of pipelines, one for sucking, and the other one is for sending liquid back. Mug agitators and mud guns are always installed on the mixing tank.
Though, the inner structure of the above tanks is different, the outer dimension and design are always the same for purpose of easy transportation and assembling.
Two weeks ago, GN Solids Control completed one set 40 feet water based drilling waste treatment system that is used for oilfield waste management service. Water based drilling waste is coming from the drilling projects where
use the water based drilling fluids to cool down the drill bit, protect the drilling well wall and take out the drilling cuttings.
The main equipment included in this 40 feet water based drilling waste treatment system are as follows:
1) High G force dryer shakers used to further drying the cuttings discharged from the primary solids control equipment, wide open deck design allows the feeding of waste easily
2) Dosing System for mixing chemicals that will fed to the centrifuge for flocculation process
3) High speed Decanter Centrifuge for liquid and solids separation
4) Mud Tank unit under the shaker to collect the liquid going through the shaker screens
5) Screw Pump transfer the fluids to decanter centrifuge for polishing
Drilling Waste Management System
Working diagram of the 40 feet water based drilling waste management system
The drilling waste, always coarse drilling cuttings, was fed to dryer shaker for further drying, and then the screw pump will transfer the drilling fluids with ultra fine solids to the decanter centrifuge (It is also dewatering centrifuge). In the meanwhile, the chemical dosing system mixes polymer, once the polymer solution is cured. The diaphragm pump transfers the polymer to the dewatering centrifuge. The ultra fine solids will get together once meet with the polymer, which will help the centrifuge to separate the solids. The drilling waste management system for separating the ultra solids in waster based drilling fluids is also called dewatering system.
Equipment features of the 40 feet water based drilling waste management system
GN’s high G force dryer shaker has up to 8 G force. with 4 panels composite material screen, the Dryer shaker has an excellent separation and drying performance.
GN high speed decanter centrifuge and feeding screw pump are VFD driven and controlled by PLC. The operators could set the suitable parameters to treat different kinds of drilling fluids.
Besides the drilling waste management system for water based mud, GN also developed the equipment for oil based mud. Even the oily sludge treatment solution is one of GN’s main businesses. GN’s system for drilling waste management has many performance cases that will prove GN equipment quality and availability. This is why customers choose GN Solids Control.
Solids control is one of the main jobs where GN’s centrifuge could be used. Now the latest design of GN decanter centrifuge is the C version with premier configuration.
By the end of this year, 2 of GN premier decanter centrifuge caught up the last ship to Latin America for the solids control job there. Below are the main features of this premier model.
Solids Control Decanter Centrifuge
- High level material used for the rotating parts. The bowl is the core part of the centrifuge unit; the separation is process when the bowl is rotating. GN uses duplex stainless steel 2205 to make the bowl with centrifugal casting technology. The evenly material distribution ensures the excellent balance performance when rotating. Inside the bowl the scroll is made of SS316L which is much better than the other China suppliers who are using SS304.
- All around protection is put on the parts that will bear a lasting friction coming from the solids. The scroll is protected by 4mm thick tungsten carbide tiles that are replaceable for longer lifetime. The outlet port of liquid speeding up cone on the scroll is covered with ceramic liner. The same ceramic liner is also installed at the solids discharge port on the bowl. To prevent the building up of solids in the collection box, the tungsten material scrapers are fixed on the bowl to protect the bowl from wearing.
- To ensure the treating capacity, GN makes the slurry feeding direction and solids delivery direction same. This will speed up the solids delivering in the bowl. On the scroll blade, there are several openings allow the liquid passing through for large flow rate.
GN premier decanter centrifuge is also widely used in waste management like the waste cuttings treatment and the oily sludge recovery project. For safety consideration, GN premier decanter centrifuge is equipped with DNV lifting certified skid for transportation.
GN now is gradually known as a separation solution provider who not only has the business to provide equipment for drilling cuttings separation from drilling fluids, but also for recovery the oil in the oily sludge. After couple years research, GN developed a 4 stages separation system that could effectively recover the oil from the oily sludge coming from oil based drilling waste, refineries waste and crude oil tank cleaning slurry.
To be frank, GN’s 4-stage oily sludge treatment system is consisting of 4 modules. These 4 modules could be combined freely as per different sludge conditions or outputs. Now let’s see what is the 4-stage oil sludge treatment system.
Waste Oil Recovery System
The first stage is the high G force drying shaker with washing tank. The high G force drying shaker is located on a slurry tank. With a hopper type feeder, the oily sludge could be fed to the shaker easily. Up to 8 G force could effectively remove the coarse material in the sludge. The shaker unit could be equipped with hot water spraying system for better demulsification. To prevent the oily sludge spraying out of the shaker deck, this shaker will have a top cover. Continue reading »
Recently, GN developed a new product that can be used in the oil tanks cleaning system for the water recycling. Operator use high pressure water, sometimes warm water, to flush the oil storage tank for tank cleaning. This work needs lots of clean water. If the water could be recovered and reused, then a great of money could be saved.
Main part of GN water recycling system
1. Tank cleaning machine – this is a machine that can produce high pressure to drive the water for flushing the inner wall of oil tank. At this time, this unit is outsourced by clients.
2. Clean water buffer tank – this tank is used to store the clean water, also the recycled water is flow back to this tank.
3. Solids remover – the dirty water contents water, oil and solid particles. In order to remove the solids in the mixture, GN designed 2 steps solids remover. First step is de-silter cyclone unit, and the second step is inclined plate clarifier.
4. Pumping system – this system is consisting of pump for water transferring, slurry transferring and settlement sludge discharging pump.
5. Electric control – this unit control all the pumps in the system.
Water Recycling System
Working principle of tank cleaning water recycling system
1. Clean water will be first fill into the buffer tank; the water transferring pump will feed the water to the high pressure tank cleaning machine for tank flushing.
2. The dirty water is transferred by the second pump to the de-silter cyclone for first step solids removing. A strainer will be installed between the oil tank and pump to filter the large size solids for protection of pump and cyclone.
3. The liquid overflow out of the cyclone will flow into the inclined plate clarifier; the special structure will speed up the solids settlement towards the bottom of the clarifier. The upper layer liquid will overflow back to water buffer tank for reuse.
4. The sludge discharged from the cyclone and bottom of the inclined plate clarifier will be collected in a small cuttings box.
All equipment in GN’s water recycling system for tank cleaning is installed on one skid with length same as 20 feet container. So it could be delivered easily by a flat bed trailer from one site to another.
Shale shaker is very common equipment used in the drilling mud recycling system. Its function is the first stage for remove the coarse solids in the drilling mud. Sometimes, we may see the double layers shale shakers are installed in the mud system. Below we would like to share some information on how the double layers shale shaker works in the mud recycling system.
Some mud system may has limitation on the footprint, thus, the operators would like to equip a shale shaker with high treating capacity but compact structure. The double layer shaker no doubt is the ideal choice.
For shale shaker application – when the unit is used as primary shale shaker, it is located at the very beginning of the mud system. As we know, the shale shaker unit has buffer box for mud feeding into the shaker unit. The mud overflow out from the buffer box would flow into the upper shaker screen panels with coarse screen for larger size solids separation. The lower screen panels would be much finer for small solids separation. Double layer shale shaker will have a relative larger capacity; in the meanwhile, it can remove out smaller
For Mud Cleaner application – Shale shaker can also be used as underflow drying shaker by combining with hydro cyclone unit. This type mud cleaner functioned as both shale shaker and cyclone unit. The lower screen with coarse mesh is for larger solids separation, and the upper screen with fine mesh is for drying the slurry discharged from the cyclone.
GN now has main two models of double layers shale shaker. One is coming from the shaker model of GNZS703. Its deformation GNZS706 double layer is for larger capacity shaker and GNZS705 for mud cleaner unit. The other is GNZS752; it can be upgraded to GNZS753 double layers. These double layer shale shakers are widely used in GN’s compact design mud recycling/de-sanding unit for area limitation project.