mud recycling

The TBM construction and Pipe Jacking construction drilling will generate a lot of waste water slurry which contains big percentage of sand and stones. In order to accordance with environment protection regulations and save water, project operators have to separate the TBM drilling mud, to reduce the waste and reuse the water.

GN Solids Control can design and make full package of waste water slurry separation plants. The major separation equipment in GN slurry separation plant includes: shale shaker, desander, desilter, bottom drying shaker, etc… And there are accessory items for a one-stop turn-key solution: centrifugal pump for feeding desander / desilter mud cleaner, mud tank, electrical control system, etc.

The TBM construction and Pipe Jacking construction drilling are often took in urban areas, . In this case, the TBM drilling slurry separation usually requires compact design to suit for small working area. And the TBM drilling slurry separation need to reach high treatment efficiency to treat big volume slurry. GN Solids Control TBM Slurry Separation Plant is specially designed to meet the above demands. GN Solids Control TBM and Pipe Jacking drilling slurry separation system is with a very compact foundation by optimal designing. The TBM and pipe Jacking slurry treating system can work at different height levels.

In order to meet the different requirements of different clients and different projects, clients can choose more than a set GN Solids Control TBM Slurry Separation Plant and connect them by pipelines to use them as a big flow rate handling capacity. Plus, the combination of standard modular is for fast and easy assembly. Clients can choose different modules and select the quality they need to reach the flow rate they want to reach. GN Solids Control TMB and Pipe Jacking Slurry Separation Plant to move conveniently among different work sites.

GN Solids Control TBM and Pile Jacking Slurry Separation Plant advantages:
1) Full function compact package design for One -stop Turnkey Solutions
2) Modular, pre-assembled and small footprint units for easy and fast transportation from one location to another
3) 5-Phase Separation System for finer solids separation and to get more clear water

A set of GNMS-1000D mud recycling system and a 18 inch decanter centrifuge is ready for shipment. They will be shipped for a trenchless drilling project. GNMS-1000D is a Mud Treating & Recycling System. The mud cleaning system is designed and manufactured according to the needs and requirements of customers. GNMS-1000D mud recycling system is specially designed to treat the drilling mud in mining industry, piling machine, HDD (horizontal directional drilling) and other trenchless drilling activities. The treatment capacity of GNMS-1000D mud recyling system and cleaning system is up to 240m³/h.

1000GPM Mud Recycling Unit

A double deck shale shaker is used in the GNMS-1000D mud cleaning system. There are 2 sets of 10 inch desander cone assembly on top of the double deck shale shaker to use as a mud cleaner. The advantages of a single deck mud cleaner is that, it has the function of both shale shaker and cleaner and the footprint if small while with the compact design. The dirty mud will be fed to bottom shaker deck, which is mounted coarse shaker screen. The centrifugal pump is located on the tank slope to feed for the desander cleaner. Besides GNMS-1000D mud recycling system, GN Solids Control makes other capacity drilling mud cleaning system for trenchless drilling rigs: D Series Mud Recycling Models: 1) GNMS-200D mud cleaning system with handling Capacity: 200GPM, 50m3/h 2) GNMS-500D mud cleaning system with handling Capacity: 500GPM, 120m3/h 3) GNMS-1000D mud cleaning system with handling Capacity: 1000GPM, 240m3/h 4) Other models can be customized according to clients special request. GNLW452 is an economic standard decanter centrifuge. It is a 18 inch big bowl centrifuge. But the bowl diameter and bowl length ration is only 2. And the max. Bowl speed of the GNLW452 centrifuge is 2200RPM. It is a single motor decanter centrifuge with fixed speed control. VFD control is available if requested by clients. The centrifuge is widely used for trenchless drilling mud treatment, and oil & gas drilling mud barite recovery.

GN Solids Control is focusing on the full package of drilling mud processing system. As GN Solids Control makes full line drilling mud processing equipment. They know well about the equipment. GN Solids Control can offer professional proposal of drilling mud treatment system and mud mixing unit. All processing equipment and the tank volume should be match to each other.

For example, if the total shale capacity is max. 160m3/4 or 200m3/h, but the desilter and desilter capacity is 240m3/h. And feeding centrifugal pump and mixing pump are 55kw or above. The system is not reasonable. As the 1rst stage separation equipment, the shale shaker capacity should be bigger than the next step separation equipment. Otherwise, if the mud flow is big, the shale shaker will overflow. Or if the mud flow is small for the shale shaker to handle, but the desander and desilter pump are too big, it will cause pump suction air. And the hydrocyclone separation performance is not good in condition the feed flow is too small. The client need to increase shale shaker capacity, or decrease pump and mud cleaner capacity to suit for the mud pump capacity.

Every jobsite is different. Every client has his preferable. In order to offer a suitable mud system design to suit for the job site situation, as well as client’s special requirements. Below are some questions to let GN Solids Control knows more about clients request.

1) what is the rig horse power of the system for, or what is the mud pump horse power or capacity? The whole mud system handle capacity should suit to the mud pump capacity.
2) What is the total tank volume the client prefer?
3) How many tanks the client prefer?
4) What is the max. Tank size (L × W × H) the client can accept to suit for their local shipping regulations?
5) What processing equipment they prefer to equip inside the system? Shale shaker, mud cleaner, desilter, desilter, mud cleaner, vacuum degasser, decanter centrifuge, etc..Which processing equipment they want?
6) What is the Voltage and hz for the mud system?
7) What is the explosion proof standard, CNEX, ATEX, or international IECEx standard?
8) Additional requirement and any special requirements if there, like do they want trip tank, pill tank, water tank, etc…

GN Solids Control is one of the well-known International Brand for drilling Mud Solids Control System & Drilling Waste Management system. GN Solids Control offers the one stop solution for Solids Control treatment of oil gas drilling, CBM drilling, HDD, and water well drilling as well as the construction drilling mud treatment etc.

Nearly all drilling mud processing equipment containers shaker screen separation. Replacement shaker screen is a major wearing spare parts for drilling mud system. And it is a big and continue cost. GN Solids Control is specialized in high quality replacement shaker screen for various popular shaker models. GN Solids Control has his own R&D department for shale shaker screens. Clients can also contact GN Solids Control to make customized shaker screen.

Most solids control equipment manufacturer only make some kinds of processing equipment. Like some companies make shale shaker, mud cleaner and agitators, but they are not capacity to make decanter centrifuge or cuttings dryers. Some companies are only capacity to make centrifuges for various industries, they cannot make solids control separation equipment, like shale shaker, mud cleaner, degasser, etc…While some companies are only make pumps, they cannot make separation equipment. And there are some companies only make mud tanks, they are not capacity to make solids control separation equipment by themselves.

GN Solids Control is focusing on full line solids control equipment for various drilling mud. GN Solids Control is specialized in drilling mud liquid and solids separation. All the separation equipment are made by GN Solids Control. In this case, GN Solids Control knows more about the separation equipment, and can offer more reasonable proposal.

Furthermore, electrical control system is another essential point for separation equipment, especially VFD smart control panels for decanter centrifuges. GN Solids Control has his own electrical control department. GN Solids Control electrical engineering business department has comprehensive ability to provide solution for explosion-proof electrical control. GN is able to provide the electric control system, explosion-proof electrical enclosure design and development, fabrication, site installation, program debugging, and other services.

GN Explosion Proof Certification: GN Solids Control electrical control products have been certified by China National standard CNEx, International standard IECEx and European standard ATEX certificate, which enable GN’s products to meet high level market requirements.

GN Solids Control made a small liquid and solids separation system. The small system is customized for an Europe company per clients request. The client asked for a small recycling unit with cleaning capacity of about 12-15 m³ / hour. The client wants a small single centrifuge in the small recycling system.

GN Solids Control customized a compact system which is composed of a small size shale shaker and a mini size decanter centrifuge. The shale shaker and decanter centrifuge are located on a mud tank together with a centrifuge feeding pump and electric control cabinet for the whole system. Tank size for the whole system is 3900Lx2250Wx1300H (mm) for easy movement. It is a small capacity recycling system with turn-key solution. All connections inside the system are included.

The Shale shaker separator model is GNZS752F-MDZF. It is a 2-panel small size shale shaker with small footprint.

The Decanter centrifuge model is GNLW223D-VFD. It is a 9” baby centrifuge for fine solids separation. The Cut point of GNLW223D-VFD centrifuge is 2 ~ 5 microns.

The color, brand and logo are all customized per client’s request. GN Solids Control is capable to make other customized system per clients job site situation. Clients can contact GN Solids Control sales engineer to get customized solutions.

Besides the small mud recycling system, GN Solids Control makes various sizes of Mud Recycling System for HDD, water well drilling, Trenchless, Piling and TBM activities.

The major applications of GN mud recycling system covers below field, but not only limited to below:
1) Trenchless HDD Project
2) Bored Pile Project
3) Micro TBM (Tunnel Boring Machine)
4) Diamond Drilling, Water Well Drilling etc

Below are some Mud Recycling desanding plant Models GN can make:
D Series Mud Recycling Models:
1)GNMS-200D Capacity: 200GPM, 50m3/h
2)GNMS-500D Capacity: 500GPM, 120m3/h
3)GNMS-1000D Capacity: 1000GPM, 240m3/h
4)Other models should be customized per clients’ request

Some sets of 500GPM mud desander plant will be ready for shipment in the coming week. They are ordered by a China domestic client for their trenchless drilling machines. The mode of these 500GPM mud desander plant is GNMS-500D. It is a very compact desandind plant to treat drilling mud from trenchless drilling well. The GNMS-500D desanding plants are customized with clients color and brand.

There is a double deck mud cleaner used in the system. The dirt drilling mud from trenchless well will be fed to the bottom deck of the double deck desander mud cleaner. As there are high sand contend and even rocks from the trenchless drilling well, PU screens or metal frame screen with bigger screen opening will be used for the bottom deck for screen separation. After the screening separation, the rocks and sands bigger than the screen opening will be 100% removed from the system, the liquid phase will pass the screen and fall down to the mud tank.

A centrifugal pump on the tank slop will suck and transfer the shale shaker recovered drilling mud to the 10’’ desander hydrau cyclone for desanding separation. The cuttings point of 10’’ desander hydrau cyclone is 57 microns. The clean drilling mud separated from 10’’ desander hydrau cyclone will flow to trenchless drilling rig well, or goes to storage tank. Hydrau cyclone is not a 100% separation device, there will be some percentage of usable clean mud be discharged together with sands.

As the 10’’ desander hydrau cyclone unit is mounted on top of the double deck shale shaker. The discharged dirty mud will be separated again by the upper deck screens to further recovery the usable drilling fluids. There are pressure while the dirty mud discharged from 10’’ desander hydrau cyclone, if they falls down to the screen surface directly, the mud will damage the shaker screens very soon. In order to protection screen and extend the life time. GN Solids Control equips small hopper under the 10’’ desander hydrau cyclone for damping.

Last week, several packages of Mud Cleaning System were shipped to Chinese sea port. The mud cleaning systems will be sailed to North America to service their mud cleaning projects. The project the client will do is that, they collect various kinds of waste mud and waste water from rigs or from construction field. The client transports the waste mud and waste water by vacuum trucks, and treat them together to reduce the waste material, and recover solids and waste for reuse. It is high standard mud cleaning system to suit for North America standard.

The features of the mud cleaning system are that, its design is very compact for small foot print. Several mud separation shale shakers and dewatering centrifuge unit are equipped in the system for better separation performance.

1) First separation is by double deck coarse shale shaker to remove the big size solids from the waste mud and waste water. The top of the shale shaker is covered by metal boards to avoid mud leakage during shale shaker vibration.

2) After the double deck coarse shale shaker, next separation is taken by a single deck high G force shale shaker. The same design as the double deck shale shaker, the top of the single deck shale shaker is covered by metal boards to avoid mud leakage during shale shaker vibration.

3) A package of dewatering centrifuge unit.

As there are still many fine solids particles inside the recovered water from shale shakers, a dewater unit is used in the system for chemical dosing. It is used together with a high speed big bowl decanter centrifuge for fine solids separation.
The mud cleaning systems can recovery as more sands from the waste water. Regarding the waste mud from hydraulic excavation drilling, the recovery liquid phase is usable mud for reuse. The separated sands can be used for construction material.

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.

gn-de-sanding-unit-piling

De-sanding Unit

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.

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.

shale-shaker

Shale Shaker

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
solids.
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.

Normally, the drilling mud recycling system is consisting of mud recycling tank skid and mud mixing tank skid. On
the mud recycling tank skid, the solids control equipment like shakers, mud cleaner, and even decanter centrifuge unit will be installed for removing the cuttings and useless solid particles in the drilling fluids. After several times recycling, the useful mud materials will loss together with the cuttings, and then the mud engineer need add new mud materials into the drilling fluids to maintain the proper mud property for the drilling job. The mud mixing unit is the equipment used for adding the mud materials into the fluids.

gn-mud-mixer-unit-1

Mud Mixing Hopper

What is the Function and Principle of the Mud Mixing Unit
The mud mixing unit is always installed at end of the mixing tank. Before starting the drilling, the driller need have sufficient drilling mud to keep a continuous drilling. Thus at the first, the mud mixing unit is used to make the drilling mud by mixing clean water and mud materials. With the drilling going on, once the mud property is not proper for the drilling process, new mud materials like barite or other polymers need to be added into the drilling fluids. The mud mixing unit is sucking the drilling mud from the mixing tank, and then pump the mud together with materials back again into the mixing tank. Normally, the mud agitators would be equipped on the mixing tank for fully blending.

What Components are Included in the Mud Mixing Unit
1. Centrifugal Pump – the inlet of the pump is connected with the mixing tank for sucking the drilling mud from tank. And the outlet is connecting with pipe manifold that will transfer the mud to the hopper unit. As this pump is fixed with the mixing hopper, it is also called mixing pump. This pump is driven by an electric motor via direct shaft connection. By higher efficiency shearing purpose, GN will used belt driving for a shearing pump.

gn-mud-mixer-unit-2

Mixing Hopper Bag Breaker

2. Mud Hopper – GN’s mud hopper is Ventri type connected with the pipe manifold via a T pipe. The mud materials will be added into the hopper and then immediately sucked into the drilling fluids as there is a vacuum produced by the high speed flow. For the hopper, GN uses the material of stainless steel for better anti corrosion performance and long life time. Inside the hopper, there is a bad beaker for quickly adding of powders. On the pipe manifold, there is a pressure gauge for the operator to inspect the working pressure of the mixing pump.
3. Control Panel – GN’s mud mixing unit is equipped with explosion proof control panel for application in Zone 1. The operation of the control is easy for only three buttons on the panel. One on, one off and one for emergency stop, accordingly, the signal lights is installed to reflect the operation.

GN’s mud mixing unit could be installed both at the end of the mixing tank or separately mounted on a small skid. This mud mixing unit can also be designed as a dual hopper dual pump type for larger capacity or in case one of them is broken down.