Drilling Waste Management

Drilling cuttings solidification or stabilization unit is for the final treatment of drilling cuttings or waste sludge after the drying treatment. It is especially used to treat the drill cuttings treated by GN vertical cuttings dryer, and GN high G drying shale shaker, or decanter centrifuges.

A full package of GN Drilling Cuttings Solidification Unit is finished for production and inspected by international famous third party inspection company. The full package of GN Drilling Cuttings Solidification Unit is made for an Africa client. It will be dispatched to the sea port for exporting to the Africa client to complete his waste management processing system.

Drilling Cuttings Solidification Unit can use lime as curing agent, flyash and Cement kiln dust as filler to do the solidification. This apply to solidifying the inorganic pollutant, like Petroleum refining sludge, Heavy metal sludge, oxidizing material, waste acid etc. The curing agent and filler is easy to get; operation is easier and cheaper than cement solidification.
Drilling Cuttings Solidification Unit is composed of waste cuttings transfer system, mixing system, solidifying system, electrical control system, lighting etc. It can be used for transferring, mixing, agitating and solidifying of the waste cuttings.

GN Solidification unit is composed of Auger skip feeder unit, Single axis continuous Rotary mixer, variable speed control screw conveyor, electrical control system and ladder, walkway, handrails etc. GN Solidification unit is with compact design, reasonable layout; it is convenient for assembly & disassembly.

Besides Drilling Cuttings Solidification Unit, GN Solids Control design and makes all the full line solids control and drilling waste management equipment before the Drilling Cuttings Solidification Unit, like the solids control shale shaker, mud cleaner, desander, desilter, vacuum degasser, various decanter centrifuge, vertical cuttings dryer, high G drying shaker, various sizes and lengths screw conveyor, solids and sludge vacuum transfer pump, chemical dosing dewatering unit, oil sludge treatment system, thermal desorption unit, etc…

This week, a package of oil sludge treatment system was departed to an oil field service company in China. The unit will be used to recovery oil sludge from oil base drilling cuttings. The oil sludge treatment system including below items:
1) 2 phase decanter centrifuge. Material fed to 2 phase decanter centrifuge must be with solids content Less 20% and Particle Size less than 20mm.
2) 3 phase disc centrifuge. The solid phase material entering the three phase disc separator usually shall be reduced the solid content to less than 3% and the solid particles to less than 400 micrometers by the decanter centrifuge, then the three-phase disc separator can achieve the best effect.

3) Transfer pumps
4) Dewatering chemical dosing system with dosing pumps and automatic control system
5) Transfer tank and holding tanks for mud recovery and mud transfer.

The project is for processing oil and solid wastes in sludge storage tanks. After the oily sludge wastes have been pre-treated. After the oil sludge wastes have been treated by sieving, sand washing, demulsify, and finely screened, they have now achieved reductions and preliminary separation. After that, the oily sludge will be treated for three-phase separation.

Two phase decanter centrifuge and three phase disc centrifuge is used in the three phase separation process. After three phase centrifuge separation, the final outputs are soil, oil and water.

Chemical dosing system is used before 2 phase and 3 phase centrifuge separation to help for the removal of as more fine solids as possible.

Besides 2 phase decanter centrifuge, 3 phase disc centrifuge and chemical dosing sytem, GN Solids Control also offers other oil sludge treatment and transfer equipment, like 3 phase decanter centrifuge, high G drying shale shaker, mud cleaner, Vertical cuttings dryer, Drilling Cuttings Solidification Unit, Thermal Desorption Unit (TDU), oil water separator, sludge vacuum pump, screw conveyor, etc…

Recently, GN Solid Control has completed the design and manufacture of a set of oil sludge treatment system for an oil field environmental protection company in China. Since the oil sludge treatment system was launched on the market, it has been widely concerned by customers no matter in China or outside of China, and the feedback from the on-site operation of the market is good. More and more oil field environmental protection contractors inquire and order the system as an important solution to reduce the content of harmful substances in oil sludge efficiently and economically.

The oil sludge treatment system has two separation principles: chemical dosing and physical separation after heating. GN oil sludge separation system is composed of several modules with different functions to gradually recover water and oil from the sludge. The following is a brief introduction of the system:

1) Sludge vacuum transfer pump module – the sludge from oil-based mud drilling cuttings has high viscosity and high sludge content, which requires a powerful and efficient conveying device to suck the sludge out of the mud pit and feed to the oil sludge treatment system. GN sludge vacuum pump is a fully pneumatic pump with no electrical components and does not produce any sparks in use. it is especially suitable for oil and gas explosion-proof environment. With 85Kpa vacuum, the viscous sludge can be sucked and discharged to other place far away.

2) Pre-mixing module – before the sludge is fed into the separation module, the material needs to be homogeneously mixed to more than 80% of the liquid content. At the same time, in order to enhance the separation effect of oil and mud, it is necessary to add chemicals in the process of homogeneous mixing.

3) Separation module – GN Solid Control uses different separation equipment to separate oil and water from the sludge step by step. High G force shale shaker, 2-phase decanter centrifuge and 3-phase disc centrifuge are used in the Separation module.

Solids and sludge vacuum pump is a popular feeding pump for GN oily sludge treatment system.

GN Solids Control makes different sizes vacuum pump for drill cuttings, solids and sludge transfer. GN vacuum pumps are 100% driven by air, without electrical parts. The pumps can be used for hazardous areas for zone 1 and zone 2 applications. And there are no rotating parts on the pump. It makes the vacuum sludge and solids transfer pump is easy for operation and maintenance.

So many clients are wondering will the air compressor included in GN Solids Control supply scope? How they can get the air source? The vacuum sludge and solids transfer pump can be fed air from other air suppliers, like from the rigs, or supplied with a separate air compressor.
From GN Solids Control proposal, the air compressor is excluded. If clients want the specification of the air compressor, they can contact GN sales team to ask for recommendations.

But as GN Solids Control is not the manufacturer for air compressor. GN Solids Control will suggest the clients to contact air compressor suppliers directly and buy the air compressor by themselves.

Besides the air compressor, clients will also need a heating system for the oily sludge treatment system to heat up the sludge to 70 C degrees? The heating system can be Electrical or by a heat exchanger. Clients can use the hot water boiler to heat up by steam, or they can use hot oil boilers. GN Solids Control already equip the heating lines inside the tank of the oil sludge treatment system, clients can feed it with hot steam or hot oil. The volume of the hot heat depends on the ambient temperature. Clients will need to offer the minimum Ambient temperature for their operation to calculate the size of the boiler for them. Water treatment unit is excluded in GN supply scope of the standard oily sludge treatment system.

Recently, a client ask GN questions about the operation of the big size GN Sludge and solids vacuum transfer pump GNSP40B. The client want to know what is the flow rate of the air supply to GN Sludge and solids vacuum pump? No indication of airflow, clients are just looking at the outlet pressure on the main compressor display to increase the air supply flow rate above 20M3/min will make the pump more powerful.

Below is the communications between GN Solids Control and the client.
The client has been testing the vacuum pump to remove soft sand , and noticed the following situation:
1) Suction pressure is reduced when the status turns into loading (On Auto mode )
2) Continues airflow from the discharge while it is sucking.
3) When the section line is extended to 40 m, the efficiency dramatically reduced.
The client want GN Solids Control could clarify the above.

GN Solids Control replied that,
1) It is right that the air flow goes out from the discharge hose while suction. So this moving air will produce high vacuum by the jet pack. That’s the working principle.
2) The minimum requirement for air supply to feed to the 40 pump is 17M3/hour with pressure 0.8 – 0.9 mpa. What is your air supply now? Clients replied that the pressure while sucking is 0.5 mpa and while unloading increase to 0.8 mpa…. Please advise how to increase the supply pressure while sucking?

GN Solids Control asked the client: Do you have an air storage tank between the air compressor and the pump? And what’s the volume of the Air tank? Clients replied that, there is no air storage tank available, the air is going direct to the pump
GN Solids Control expressed that; it will improve the pump performance a lot
to have air flow rate above 20m3/min Minimum needs to be 17m3/min
Also you need to have an air tank to work as buffer tank to connect to the pump.
By doing above you can make the pump working more properly.
3) 40 meters for water is fine but for solids suction is too long. It’s better to keep less than 12 meters. But as the discharge pressure is high. GN Solids Control suggests the client to reduce the suction hose to less than 12m, but they can have much longer hose for discharge.
4) The longer of suction hose, the longer of the suction time should be set. While leaving factory. GN Solids Control sets 10 Seconds for suction and 10 seconds for discharge. Clients can adjust the suction and discharging time according to job site situation.

Vertical cuttings dryer is a major separation machine for oil base mud drilling cuttings treatment. The VG dryer is used to further treat and recover drilling cuttings discharged from shale shaker, and in some cases, the cuttings from mud cleaner. The Vertical cuttings dryer cannot be used to treat drilling cuttings discharged from decanter centrifuge. As the solids discharged from decanter centrifuge is something like soil. The vertical cuttings dryer is equipped with screen basket with bigger opening like 0.25mm, 0.35mm and 0.5 mm. The centrifuge discharge is too fine. They will all pass the VG dryer screen basket. There are nothing can be recovered.

The control panel of the vertical cutting dryer must have connection between the main drive motor and the oil pump. So that when the main drive motor is turned on before the oil pump, it cannot be started. If there were not connections between the main drive motor and the oil pump, the VG dryer main motor can be started before or after the oil pump running, there may be no lubrication oil for cooling down while the main drive motor is running. It will make damage to the vertical cuttings dryer. The situation must be taken into consideration because this situation may be lead to damage the bearing or rotor due to Stopped or failure oil pump or leakage or drop of oil pressure .

These situation is abnormal, because according to the operating procedures must be start on the oil pump in the first until the oil pressure reaches 15-25 psi, after 5 minutes of running the oil pump go to start on the main drive to ensure that oil reached to all rotating parts , bearing .

Where is supposed if happened any drop in oil pressure or failure in oil pump the main drive shut off before happens any failure in bearing or rotor. ( for protection the unit)

2019 ADIPEC petroleum exhibition is coming on 11-14 November 2019 in Abu Dhabi National Exhibition Centre. ADIPEC is the largest petroleum exhibition in middleeast. It is also one of the largest petroleum exhibitions in the world. Most of the petroleum related companies in middle east, Affrica, Europe South America, North America, and Asia will come for the big events.

Below is the equipment GN Solids Control will take for the ADIPEC oil show. Visitors can check GN products quality on the booth and talk more details with GN engineers and sales team.

1) 9 inch mini decanter centrifuge
It is the smallest decanter centrifuge model made by GN Solids Control. GN Solids Control also makes popular size 14 inch and big bowl centrifuge 18 inch, 22 inch and the huge bowl centrifuge 30 inch.

2) Screen vacuum unit c/w with shale shaker
Screen vacuum unit is used together with shale shaker. The unit is fixed underneath the first screen of shaker deck. Screen vacuum technology is new technology that few company can make. It is GN Solids Control new products launched last year in 2018. If clients have interest, they can ask for more information. Clients can also visit GN website to check the jobsite video.


3) Solids and sludge vacuum transfer pump.
The vacuum pumps has wide application in oil field. GN Solids Control has 3 sizes vacuum pumps. The smallest pump can be used for cuttings/sludge transfer and use as a vacuum cleaner.
The vacuum pump can be used for long distance cuttings transfer, and then feed to cutting skips.

There are 2 feeding design from vacuum pump to skips:
a. The Rotaring feeder can be controlled by sensors, while a skip is full, it will feed to another skip.
b. The Triple skip station is controlled by valves.



4) Replacement screens for the popular shaker models

This week, a full package of compact oily sludge separation system was finished from GN factory in Beijing China. The compact design fast movable oily sludge treatment system is purchased by a reputable Environmental Solutions Company from China domestic market.

There are 3-stage separation equipment included in the oily sludge treatment system.

1) There is a 2-panel small footprint shale shaker equipped in the system for coarse solids separation. The model is GNZS752. As mostly, the oily waste come out from different sources and it is mixture of different wastes. There may be big size solids in side. The big sides solids may block or even broken the centrifuges. The small size shale shaker is used to remove the possible big size solids in the sludge.

2) There are 2 centrifuges in the oily sludge treatment system. The first centrifuge we call it decanter centrifuge. The decanter centrifuge model is GNLW224, it is a 2-phase separation centrifuge. The 2-phase decanter centrifuge is help to remove solids or soil from liquid mixture. The 9 inch centrifuge is a min size decanter centrifuge. The bowl diameter is only 9 inch, but the bowl length and diameter ration is up to 4. The longer ration can help to get cleaner liquid. It is the smallest centrifuge from GN Solids Control for industry separation.

3) The second centrifuge inside the oily sludge treatment system is disc centrifuge. It is also called 3-phase centrifuge. As the name mean, the disc centrifuge can separation oil, water and soil.

Many people may wonder: in case the disc centrifuge can separate and get oil, water and soil. While you add 2-phase decanter centrifuge inside the system? Really, the 2-phase decanter centrifuge is surely not to increase the cost. The disc centrifuge can only allow liquid mixture with liquid content less than 3%. Otherwise, it will damage the centrifuge. While the decanter centrifuge can allow liquid with solids content up to 15% ~ 20%. Decanter centrifuge is a necessary as pre-separation before disc centrifuge.

Thermal desorption unit is normally known as TDU. It is a kind of Ultimate equipment for oily waste management. The Thermal desorption unit (TDU) is a High-tech products, few company has the capability and technology to make it.

GN Thermal Desorption Unit is an ex-situ, non-incineration technology. It is designed to separate hydrocarbons from various matrices including oilfield drilling cuttings waste, oil based drill cuttings, oily contaminated soil, oil sludge and sand, filter-cake, tank and tanker bottoms, organic-based hazardous waste and contaminated soil in a non-oxidizing atmosphere without destroying the hydrocarbons. The TDU technology has been used extensively for waste management, the main function is for recovery of the oil from the waste material as a sellable product throughout the world.
Many clients showed great interest on the design of GN Thermal desorption unit (TDU) technology. There are mainly 2 designs developed by GN Solids Control.

From 2015 to June, 2016, GN Solids Control have been working on the design of the drum type TDU. But GN stopped that project after 2016. After that GN Solids Control shift to design the screw type TDU from July, 2016. So now, GN Solids Control does not make drum type Thermal desorption unit (TDU).

GN Solids Control latest design on is similar to TPS, but not TPS, TPS is a single screw in one tube, with different tubes.

GN Solids Control design is as following:
1) One tube, two auger system for self cleaning, it’s better than the single tube system.
2) Temperature can go up to 700 C degree which suits the drilling cuttings and oil sludge to recovery oil and water.
3) GN Solids Control have a dust removing unit before condensing, so it makes it easier for oil water, solids separation.
GN Solids Control already have the major components, like tube material, burners, air lock valves and Fin-Fan coolers etc in the factory to shorten the manufacturing time.

For any questions, please contact GN Solids Control sales team for support.

GN Solids Control made an oil-based drilling cuttings treatment system for a CNPC company. GN Solids Control made and designed and system per client’s job site situation. So it can suit for the clients’ situation well. Clients are happy with the performance of the OBM treatment system. Both the team leader and job site workers are satisfied with the system, and they said that, after applying GN waste management system. They can recovery more usable drilling mud. Their drilling waste and their drilling cost are both reduced. And they can save cost and manpower on the waste material shipment.

The oil based mud treatment system made for CNPC is a complete package. It is a skid mounted cuttings drying system with processing equipment, mud and cuttings transfer equipment, and electric control system.

Below is the major equipment included in the skid mounted oil based mud cuttings drying system:

Firstly, there is a vertical cutting dryer. The vertical cuttings dryer is mounted on a separate skid. VG dryer is also called VG centrifuge, it is the major equipment to treat the oil based mud and cuttings discharged from shale shaker. GN high quality vertical centrifuge can reduce the oil on cuttings to as low as 3% ~ 5%. In many countries and regions, less than 3~5% OOC can be discharged directly. Even not, it is already very dry like powders. It is easy for movement and for next process treatment.

Secondly, there is a 14 inch decanter centrifuge in the oil base mud cuttings drying system. The decanter centrifuge is used after the vertical centrifuge to reduce the mud weight. Enable the recovered mud qualified for drilling activity.

3 sets screw conveyors are equipped in the system. One screw conveyor is located under the shale shaker to collect drilling cuttings discharged from shale shakers. Another screw conveyor is located inclined to transfer the cuttings from shale shaker and feed to the vertical cuttings dryer. The 3rd screw conveyor is inclined and under the vertical cuttings dryer. It is used to transfer the drying cuttings from VG dryer to the cuttings containers.