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Mud Tank: Essential Component for Efficient Drilling Operations

In the field of drilling operations, efficiency, accuracy, and safety are of utmost importance. The mud tank is one of the key components to ensure the smooth operation of the drilling platform. In this paper, we discuss the significance, function, and characteristics of oil rig mud tanks and reveal the importance of mud tanks for drilling rigs in the oil and gas industry. KOSUN offers high-performance mud tanks engineered for reliable drilling fluid management in demanding environments.

Understanding the Mud Tank System

Mud tanks are specialized containers for the storage and circulation of drilling fluids (also known as drilling mud) during drilling operations. These tanks are designed to withstand the rigors of the drilling site and facilitate the management of drilling fluids throughout the drilling process.

The drilling mud tank is the main storage container for drilling fluids, which can hold the large amount of mud required for drilling operations. It also helps in the mixing and blending of drilling fluids to ensure the uniformity and consistency of mud composition. Mud tanks contain mechanisms for separating solids, such as linear motion shale shakers and decanter centrifuges , to maintain the quality and performance of drilling mud. In addition, some advanced mud tank systems include heating and cooling elements to regulate the temperature of the drilling fluid, optimize its performance, and improve drilling efficiency.

Internal Structure of a Drilling Mud Tank

A drilling mud tank is composed of a tank body, mixing device, discharge port, and feed port.

  1. Tank Body

The body of the mud tank is a sealed container, usually made of welded steel plates. The tank has different shapes such as round, oval, or square, and the size also varies according to the specific use needs. The inner wall of the tank is generally treated with anti-corrosion to prevent the corrosion of the mud on the tank.

  1. Mixing Device

A mixing device is provided inside the mud tank for mixing mud to keep it in a uniform mixing state. The stirring device is usually composed of a motor, a reducer, and a stirrer. The motor transmits power through the reducer to the agitator, which rotates the mud to keep the solids suspended and prevent them from settling at the bottom of the tank.

  1. Discharge and Feed Ports

The mud tank is provided with a discharge port and a feed port for the discharge and entry of mud. The discharge port is usually located at the bottom of the tank and drains the mud through a pipe to the next treatment unit. The feed port is usually located at the top of the tank, and the fresh mud is injected into the tank through the pipe. The location and size of the discharge and feed ports are determined according to the specific design requirements in order to achieve effective mud flow and handling.

We usually add a sand pump beside the tank to provide power to transport mud, and sometimes we have a jet mud mixer to mix the mud.

Conclusion

In the dynamic world of drilling operations, mud tanks are an indispensable asset, providing the necessary infrastructure to effectively manage drilling fluids. From storage and mixing to separation and temperature control, drilling rig mud tanks play a multifaceted role in ensuring the success and safety of drilling operations. With the development of drilling technology, the importance of well-designed and reliable solids control equipment has increased, and it is the backbone of the oil and gas industry as it seeks energy exploration and production. KOSUN is committed to providing high-performance mud tanks and expert support to help customers achieve their operational goals.

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Cuttings Dryer: Working Principle and Core Functions for Drilling Waste Management

In modern petroleum drilling engineering, as environmental regulations become increasingly stringent, the effective treatment of oily drill cuttings has become a focal point of the industry. As the core equipment of the Drilling Waste Management System, the cuttings dryer has become the key to achieving mud recovery and waste reduction through its superior solid-liquid separation performance. KOSUN offers advanced cuttings dryers engineered for high-efficiency solids control in demanding drilling environments.

Definition and Application Scenarios of the Cuttings Dryer

A cuttings dryer (also commonly referred to as a vertical dryer or drill cuttings dryer) is primarily used to treat cuttings generated during drilling processes using Oil-Based Mud (OBM) or Synthetic-Based Mud (SBM). Its core objective is to strip and recover the liquid adhering to the surface of the cuttings using the immense centrifugal force generated by high-speed rotation. This process achieves solid-liquid separation, resulting in drier solids and a significantly reduced oil content on the waste. KOSUN’s cuttings dryers are designed for maximum fluid recovery and minimal waste volume.

Detailed Working Principle of the Cuttings Dryer

Feeding and Acceleration Phase

Oily drill cuttings are fed into the top inlet of the cuttings dryer via conveying equipment (such as a Screw Conveyor ). Upon entering the equipment, the cuttings drop into the center of the high-speed rotating basket (screen).

High G-Force Centrifugal Separation Phase

The rotor (containing the screen basket) rotates at high speeds, generating a centrifugal force (G-force) typically ranging from 300G to 900G . Under this intense force, the oil-based liquid adhering to the solid surfaces passes through the screen gaps and enters the liquid collection tank, while solid particles larger than the screen gaps are retained on the inner side of the screen.

Mechanical Scraping and Assisted Discharge Phase

To prevent solids from accumulating and clogging the inner walls of the screen, the cuttings dryer is designed with internal rotating flights (scrapers). There is a slight speed differential between the scrapers and the screen basket. This controlled differential operation scrapes the dried solids off the screen, allowing them to move toward the discharge outlet at the bottom of the equipment under the influence of gravity.

Liquid Recovery and Purification Phase

The expelled liquid phase (mud containing a small amount of fine particles) is discharged through the liquid outlet. Typically, this recovered liquid is sent to a downstream Decanter Centrifuge for further purification. Once ultra-fine particles are removed, the liquid is finally reintroduced into the active mud system for reuse.

Key Technical Parameters Affecting Cuttings Dryer Efficiency

To achieve optimal treatment results under the latest environmental standards, the following parameters are critical:

  • Screen Gap: Typically selected based on the geological formation and lithology.
  • Centrifugal Force: Higher rotational speeds yield greater centrifugal force and better dehydration; however, this places higher demands on the equipment’s dynamic balance and wear resistance.
  • Scraper Wear Resistance: Since drill cuttings are highly abrasive, high-performance cuttings dryer scrapers are usually reinforced with tungsten carbide or other hard alloys to extend their service life.

KOSUN’s cuttings dryers are engineered with durable materials and precision components for long-term reliability in abrasive drilling environments.

Conclusion

Through efficient physical separation, the cuttings dryer not only solves environmental discharge challenges in oilfield operations but also saves drilling contractors significant material costs through high-ratio mud recovery. KOSUN is committed to providing high-performance cuttings dryers and expert support to help customers achieve their operational and environmental goals.

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Sludge Treatment: 1m³/h Oily Sludge System for Efficient Waste Management

Sludge treatment is a critical process for industries dealing with oily waste. On-site sludge treatment saves time and money, reduces waste, and makes it much easier to recycle vital resources. Anyone working in industries such as petrochemicals, oil refining, or steel manufacturing will know all about the problems associated with sludge waste and the legal responsibilities they have when it comes to handling hazardous waste. However, on-site separation facilities work across a range of other industries as well, such as shipping, food and beverages, and wastewater treatment.

KOSUN Machinery has developed the 1m³/h Oily Sludge Treatment System — an efficient sludge treatment solution specifically designed for the harmless and resourceful treatment of various types of oily sludge. The core of the system adopts advanced chemical hot washing technology, which can maximize the recovery of crude oil from the complex sludge mixture and realize the recycling of water resources and the standard treatment of solid-phase residue. With its significant cost advantage in investment and excellent treatment efficiency, the system has become an ideal choice for sludge treatment in petroleum and petrochemical industries, oilfield exploitation, and oil storage and transportation.

Application Scope of the 1m³/h Sludge Treatment System

The 1m³/h Oily Sludge Treatment System is designed to handle a wide range of oily sludge sources, including:

Landing sludge from oil field operations and equipment leakage

Waste oil-based mud and drill cuttings produced during the drilling process

Oil residue and sludge produced during the cleaning of oil storage tanks and transport tanks

Sediment deposited in oily wastewater sedimentation tanks and catchment pits

Processing Effect of the Sludge Treatment System

After being processed by this sludge treatment system, all phase products can reach industry-leading standards, achieving efficient separation and purification of the “oil, water and solid” three phases:

The oil content of the solid-phase residue is less than 2% , which is far lower than the national general hazardous waste landfill standard. This creates favorable conditions for subsequent advanced disposal (such as pyrolysis, incineration, and biodegradation), significantly reducing disposal costs.

The oil content in the liquid-phase effluent is as low as 200 mg/L , and the water quality is clear. It can be reused in the system’s own cleaning or hot washing process, achieving the internal circulation of water resources within the factory and saving the consumption of fresh water and the cost of wastewater discharge.

Core Process of the Sludge Treatment System
  1. Chemical Hot Washing Process: By adding a specially formulated surfactant and cleaning agent at an appropriate heating temperature, the stable “water-oil-solid” emulsified structure in the oil sludge is disrupted, effectively reducing the adhesion force between the oil phase and the solid phase particles, allowing the crude oil to be fully stripped and released.
  2. Multi-Stage Centrifugal Separation Process: The mixture after hot washing enters high-efficiency multi-stage centrifugal units (such as decanter centrifuges and disc centrifuges). By precisely controlling the centrifugal force field, the fine separation of oil, water, and solid is achieved:

Light phase: The recovered crude oil has a relatively high purity and can be directly sold to refineries as raw materials, generating considerable economic benefits.

Middle phase: The separated water phase can be reused after simple treatment in the system to form a closed loop.

Heavy phase: Solid residues with extremely low oil content, meeting environmental protection requirements.

System Advantages of the 1m³/h Sludge Treatment System
  1. Maximizing Resource Recovery: High crude oil recovery rate, turning waste into treasure, directly generating economic benefits.
  2. Stable and Reliable Treatment Effect: Ensuring that solid residue and effluent quality consistently meet or exceed design standards.
  3. Mature Process with Controllable Costs: Energy consumption and chemical costs are controllable. The recycling of water significantly reduces water consumption and sewage discharge fees.
  4. High Return on Investment: Compared with incineration, pyrolysis, and other high-temperature and high-pressure processes, the system offers a high return on investment. Combined with oil sales income, the investment payback period is short.
  5. Reduction, Harmlessness, and Resource Utilization: The entire sludge treatment process achieves reduction, harmlessness, and resource utilization, helping enterprises achieve environmental protection goals.
Destination of the Final Product
  1. Recovered Oil： If the quality is good, the recovered oil can be sold as raw materials for refineries, realizing resource reuse.
  2. Purified Water: The purified water is recycled within the system, saving energy and reducing consumption.
  3. Deoiling Solid Phase: If the oil content is less than 2% , it can be sent to a professional institution for:

Pyrolysis: Further recovery of energy and solid phase resources

Incineration: Complete harmless treatment

Biodegradation: Ecological restoration

This ensures compliance with local environmental protection policies, ultimately achieving harmless disposal.

Conclusion

The 1m³/h Oily Sludge Treatment System from KOSUN Machinery offers a cost-effective, efficient, and environmentally responsible sludge treatment solution. By recovering valuable crude oil, recycling water, and producing solid residue with oil content below 2% , the system delivers significant economic and environmental benefits. Whether for oilfield operations, storage tank cleaning, or refinery waste, KOSUN provides the expertise and technology to turn waste into value.

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KOSUN SP Series Mixing Pump: Advanced Mixing Technology for Drilling Projects

The KOSUN SP Series stainless steel mixing pump provides instant hydration of polymers and bentonite. Discover how its axial turbine and pressure chamber eliminate “fish eyes” and reduce drilling fluid costs.

In modern drilling, whether onshore or offshore, drilling fluid quality determines everything. Its stability directly affects penetration rate, wellbore integrity, and overall project safety. However, preparing ideal fluid is not simply mixing powders with water. It is a complex process requiring powerful mechanical energy. This is where the KOSUN SP Series mixing pump excels.

Shear Pump

Why a Conventional Pump Is Not Enough

Standard centrifugal pumps are designed for transfer, not mixing. When powdered polymers or bentonite are added to conventional flow, they form dense gel lumps,”fish eyes.” These lumps clog shakers, settle in tanks, and increase additive consumption. Solving this requires a fundamentally different approach.

Innovative Hydrodynamics: Turbine and Pressure Chamber

KOSUN engineers developed a design combining an axial-flow turbine pump with a horn-shaped pressure chamber.

How does it work? Fluid is accelerated by the turbine impeller to high velocity, then directed through nozzles toward an impact plate. At impact, intense mixing forces break molecular bonds, allowing polymers to fully hydrate. The result: complete elimination of “fish eyes” and perfect homogenization.

Materials That Ensure Long Service Life

Drilling fluid is aggressive, abrasive particles and chemicals quickly damage cast iron. For this reason, KOSUN uses precision-cast stainless steel for all wetted parts. Stainless steel provides corrosion resistance and strength to withstand continuous wear. The benefits: extended service intervals and reduced downtime.

Reliable Operation Under Any Conditions: Low NPSH

One main threat is cavitation, caused by insufficient suction pressure. Cavitation damages impellers and seals, leading to premature failure. The SP Series is optimized for low NPSH , maintaining stable operation even where conventional pumps fail.

Global Field Experience and Fast ROI

The KOSUN SP Series has proven itself worldwide, from Middle Eastern deserts to Russian winters and Southeast Asian humidity. A 75 kW configuration delivers 120–150 m³/h , ideal for large-scale systems. Improved chemical utilization and faster hydration reduce cost per cubic meter. Investment typically pays back within months through reduced material consumption and shorter mixing times. API compliance and a compact design simplify maintenance, even in remote locations.

Conclusion

The KOSUN SP Series mixing pump is a critical tool for maximizing drilling efficiency and minimizing non-productive time. With innovative hydrodynamics, durable stainless steel construction, and proven global performance, it delivers reliable, cost-effective mixing for the most demanding operations.

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How Does KOSUN Drilling Fluid Jet Mixer Improve Drilling Mud Efficiency?

Drilling fluid plays a vital role in oil and gas drilling because it helps cool and lubricate the drill bit, as well as remove cuttings from the wellbore. Ensuring the proper density and viscosity of drilling fluids is critical to successful drilling operations. This is where KOSUN’s DJM series fluid jet mixer comes in handy.

The KOSUN DJM series fluid jet mixer is specifically designed to prepare drilling fluid and adjust its density and viscosity. With its advanced features and functionality, this fluid jet mixer is a game-changer for the industry.

Versatility of the Fluid Jet Mixer

One outstanding feature of the KOSUN fluid jet mixer is its versatility. It is available in two variants: a single jet mixer combined with a sand pump and jet slurry hopper, or a double jet mixer consisting of two pumps and two hoppers. This flexibility allows drillers to choose the configuration that best suits their specific drilling needs.

Weighing hoppers play a vital role in the mixing process. They can be used in combination with the pump, or they can be used alone with the pump connected through the manifold valve. This seamless integration ensures efficient transfer of materials and additives into the drilling fluid, optimizing its performance.

Simplified Additive Integration

The KOSUN fluid jet mixer simplifies the addition of drilling fluid materials and chemical additives. Bentonite and barite powders, as well as polymer additives, can be easily introduced into the circulation tank. By increasing the overall volume of material, the fluid jet mixer ensures consistency and balance of the drilling fluid.

Designed for Efficiency

In addition to superior functionality, the KOSUN DJM Series fluid jet mixer is designed with efficiency in mind. A powerful 45 kW (or 55 kW) sand pump ensures reliable flow for fast and efficient mixing of drilling fluids. This saves valuable time during drilling operations and increases overall efficiency.

Conclusion

The KOSUN DJM series fluid jet mixer is a reliable and efficient tool for the oil and gas drilling industry. With its versatile configuration, seamless integration, and powerful pump, it enhances the efficiency and performance of drilling fluids. Whether adjusting density, viscosity, or adding drilling material, this fluid jet mixer is an invaluable asset to any drilling operation. It is believed that KOSUN Machinery can provide excellent solutions, optimize the drilling process, and promote success.

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Centrifuge in Slurry Separation: Core Power for Efficient Processing

In slurry separation systems, the centrifuge is the core power unit, essential for efficiently separating solids and liquids. From construction mud treatment to mining tailings recovery and chemical slurry purification, centrifuges are the key equipment for tackling complex separation challenges. For KOSUN Industrial, mastering high-performance centrifuge technology is central to its competitive edge, delivering reliable support for efficient separation across multiple industries.

How Centrifuges Work

Centrifuges work by using centrifugal force to rapidly separate dense solids from liquids. Slurry enters the rotating drum, solids are pushed outward forming a cake, and the clarified liquid discharges through dedicated outlets. This method is 5–10 times faster than gravity-based separation and excels with fine particles below 20 μm.

Applications in Construction

In construction, centrifuges handle slurry with fine sand and clay, precisely controlling solid content to stabilize boreholes. KOSUN’s construction centrifuges use variable-frequency speed control, reducing sand content to under 1% for high-quality operations.

Applications in Mining

In mining, centrifuges treat tailings slurry with high viscosity, producing dry tailings (<40% moisture ) and clear water for recycling. KOSUN’s mining centrifuges feature wear-resistant drums and corrosion-proof components, doubling service life under harsh, continuous operation.

Applications in Chemical and Environmental Sectors

Centrifuges are also vital in chemical and environmental sectors. They enhance product purity in chemical processing and accelerate solid-liquid separation in wastewater treatment, reducing costs and complexity.

Performance Factors

Performance depends on drum material, speed range, and automation. KOSUN Industrial offers a full spectrum of high-performance centrifuges , from lab to large-scale systems, with intelligent controls for real-time monitoring and parameter adjustment.

Future Trends

As industries demand higher efficiency and stricter environmental compliance, centrifuges are evolving toward smarter, faster, and more durable designs. With innovation at its core, KOSUN continues to optimize centrifuge performance , making it the preferred choice for slurry separation projects across sectors.

Conclusion

Whether for efficient separation, resource recovery, or environmental goals, KOSUN centrifuge provides the reliable, high-performance foundation that modern slurry operations require.

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Functions of Solid Control Equipment – Balanced Elliptical Motion Shaker

Balanced Elliptical Motion Shaker

Balanced Elliptical Motion Shaker is a key component of the solid  control equipment for the drilling industry. Drilling operations use drilling techniques to penetrate deep into the surface to achieve fossil fuels, and in this quest, the mudstone machine first needs to be sampled to determine the depth and quality of the rock it penetrates. In the oil field excavation, assuming that the offshore site, the drilling will be completed with the help of the rig.

 

Balanced Elliptical Motion Shaker
Balanced Elliptical Motion Shaker

The drill bit itself will carry cuttings, which are basically shredded with drilling mud. The mud collector will extract these shavings from the drill for further analysis. As mentioned earlier in the article, the drilling fluid is very expensive, so the operator must recover the drilling fluid from the drilling waste . To this end, the use of various solid control devices, where the shale oscillator is the most important.

The vibrating screen with a vibrating   screen helps to separate the cuttings from the drilling fluid and direct the separated drilling fluid to a separate container for further processing and handling. The dried solids, i.e., the drilling chips, are transported to a separate container for further processing and disposal.

A very important factor in solid control systems is its contribution to environmental balance. If the efficiency of the solid control system is not high enough, the cuttings are likely to carry some drilling fluids containing chemical substances that may be harmful to the environment and cause contamination of the soil or groundwater. For environmental reasons, the drilling industry follows the strict rules for drilling waste treatment .

All in all, the main function of the shale shaker is to filter the drilling waste through an effective shaker screen shield, thus contributing to the overall drilling operations and the economy of environmental precautions.

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Shale Shaker Screen Good Cleaning System from Kosun Manufacturer

Shale Shaker Screen

Shale shaker screen mainly classified into soft sieve screen, sieve plate type screen,and  frame plate type screen .

Any machinery will give its best performance if maintained properly, so a preventive measure is a prerequisite if an operator wants to ensure the long life of the machinery.

While routine services will take place as part of your preventive maintenance, there is something that operators themselves will be able to take care of and be rewarded with even better results. A simple way is to keep the machinery clean.

shale shaker screen
shale shaker screen

In solid control equipment,  shaker screen performs that key job of eliminating the solids through the screen. So it is imperative that they are prone to damage if not kept properly clean and that will naturally increase the overall project cost.
Here are some ways to keep the shaker screen clean and safe:
•    If the shaker has been idle for some time, it is important that the shaker screen be cleaned before the use. To clean the shaker screen , the best way is to use water gun or water hose.
•    Usage of wire brush will actually damage the mesh, so stay clear of brushes in your cleaning process.
•    The shaker screen constantly sieves the waste material and likely to get clogged with waste material and as a result the screen holes will be blinded and hamper the process if filtration. To clean the blinded screen holes, use the water hose from back side. You could consider removing the larger particles manually, but never with a brush or stick, as the mesh of the screen is prone to be torn in the process if you use any of these.
•    Make sure that the screens are not left with the drilling waste i.e. drill cuttings and mud to be dried while in the screen. This will invariably lead to a pre-mature failure of the equipment.
•    Never allow any worn out rubbers to be used in the equipment, this directly lowers the performance of the equipment and damages the  shale shaker screen.
•    Do not allow any other material to be placed over the shaker screens , either in function or in storage.
With these basic cleaning procedures, you could ensure a longer life for the shaker screen.

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Hi-G Dryer Shaker of Solids Control Equipment by Kosun Manufacturer

Hi-G Dryer Shaker

Hi-G dryer shaker  is used to recover mud from cuttings to reduce the liquid / oil content in the cuttings to about 10% (w / w) and to recover part of the drilling mud to reduce drilling costs and reduce drilling waste Volume, reduce environmental pollution.  Drying shaker screen for WBM and OBM.

Hi-G dryer shaker is the key component in solids control equipment used in drilling industry. Drilling operations use a borehole technology to penetrate deep beneath the surface to reach the fossil fuel, in this pursuit the mud-loggers first need to do a sampling to ascertain the depth and quality of rock they are penetrating.

H-I G Dryer Shaker
H-I G Dryer Shaker

The drilling bit will carry with itself drilling cuttings, essentially the rock shavings, mixed with drilling mud. The mud-loggers will extract these shavings from the drilling bit for their further analysis. As explained earlier in the article, the drilling fluid is quite expensive so it is imperative for the operators to restore the drilling fluid from the drilling waste . For this purpose various solid control equipments are used, among them a shale shaker is the foremost.

Hi-G dryer shaker with the help of shaker screens helps in separating the drilling cuttings from drilling fluid, and the separated drilling fluid is channeled to a separate container for further processing and treatment. The dried solid, i.e. drilling cuttings are conveyed to a separate container for further treatment and disposal.

One very important factor in the solid control system is its contribution for environmental balance. If a solid control system is not efficient enough, it is likely that the drill cuttings will still carry some amount of drilling fluid that contains chemicals which could be really harmful for the environment and cause contamination of soil or ground water. The drilling industry follows strict rules on drilling waste management  for the sake of environmental impact.

In conclusion, drying shaker’s main function is to filter the drilling waste with the help of an effective shaker screen and as a result help in economy of overall drilling operations and environmental prevention.

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What Are Functions of The Drilling Fluids Dryer Shaker?

Dryer Shaker

Drilling fluids are used while drilling holes on the surface of the earth for oil, natural gas and even for water wells. The different types of drilling fluids that are used are water, water based muds (mixture of water and clay or other chemicals), oil or synthetic oil.

The advantages of using drilling fluids are;
– Due to the continuous use of machines for long time, the machine get heated. These fluids helps in keeping the drilling machine cool.
– As there is continuous contact between the drill pipes and the walls of the holes, heat may be generated due to friction. Drilling fluids, especially oil based fluids provides lubrication to the drill pipes.
– Keeps the machine clean.
– Maintains pressure on formation fluids (naturally occurring fluids).

Dryer Shaker
Dryer Shaker

This drilling fluids are poured inside the hole with different flow rate and pressure. These fluids then collect the cuttings of rocks from the hole and are then forced out of the hole by a pump. This mixture is then passed through a shale shaker.

A shale shaker is an equipment that removes large solids that are mixed with the drilling fluids, drilling waste , so that the fluids can be reused. These shale shakers not only improve the efficiency but also is very important from the cost cutting point of view. The basic parts of a shale shaker are the base of the shaker called Hopper, a feeder where the mixture of fluid and solid is collected, a screen and a vibrator.

Drilling fluids dryer shaker  is a vibrating equipment that uses a Shaker Screen (a mesh like structure supported on a frame) to separate the mixture. The vibratory motion may either be linear, elliptical or circular. The efficiency of a shale shaker also depends upon the vibration speed and the amplitude and frequency of the shale shakers .

The main functions of  drilling fluids dryer shaker is to make the drilling fluids reusable by separating the solids that are mixed with it.