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
- 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.
- 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
- Maximizing Resource Recovery: High crude oil recovery rate, turning waste into treasure, directly generating economic benefits.
- Stable and Reliable Treatment Effect: Ensuring that solid residue and effluent quality consistently meet or exceed design standards.
- Mature Process with Controllable Costs: Energy consumption and chemical costs are controllable. The recycling of water significantly reduces water consumption and sewage discharge fees.
- 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.
- 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
- Recovered Oil： If the quality is good, the recovered oil can be sold as raw materials for refineries, realizing resource reuse.
- Purified Water: The purified water is recycled within the system, saving energy and reducing consumption.
- 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.