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Home > KOSUN News >
How does the oily sludge treatment equipment achieve efficient separation of oil, sludge and sand in three phases?
Jul 30, 2025
Oil sludge is also known as oily sludge, oil mud sand, fallen oil sludge, etc. During the drilling process, when the drilling rig is replaced and casing is extracted, oily sludge is carried out and left around the well site. This oily sludge is wrapped with various mud, sand and other impurities. It cannot be dealt with on site in time and is temporarily piled up at the well site. As it accumulates more and more, it is produced. The oily sludge comes from deep within the drilling formation and contains a large amount of toxic substances with a foul smell such as benzene series, phenols, anthracene and pyrene. If oily sludge is not treated, it will not only damage the soil and pollute the environment, but also cause a waste of resources.
1- The generation and hazards of oily sludge (oil mud sand)
The generation of oily sludge (oil mud sand) :
Oily sludge is an oily solid waste produced in the processes of oil extraction, transportation, refining and oily wastewater treatment. It is one of the main pollution sources in the production process of oilfield enterprises. There are many types and complex properties of oily sludge. The sludge produced during crude oil extraction mainly comes from the surface treatment system. The oily sludge generated during the oil production wastewater treatment process, along with the flocs formed by the water purifying agents added in the wastewater purification treatment, corrosion products and scale of equipment and pipelines, bacteria (corpses), etc., constitute the sludge. When oil storage tanks in petrochemical enterprises store oil products, a small amount of mechanical impurities, sand particles, soil, heavy metal salts, as well as heavy oil components such as paraffin and asphaltene in the oil products deposit at the bottom of the tanks, forming tank bottom sludge.
The hazards of oily sludge (oil mud sand) :
Oily sludge contains a large amount of toxic substances with a foul smell such as benzene series, phenols, anthracene and pyrene. If oily sludge is not treated, it will seriously pollute the soil and the environment. On the other hand, if oily sludge is not collected in time, it will cause a waste of resources. The oil content in sludge is generally between 10% and 50%, and the water content is between 10% and 60%. Oily sludge is rich in crude oil. If crude oil is separated and extracted from it, the water content of the crude oil is below 4%, which meets the crude oil recovery standards and can be recycled and utilized by crude oil recovery plants and refineries to achieve economic value.
Current situation of oily sludge (oil mud sand) treatment:
Oily sludge is generally a stable suspended emulsion system composed of oil-in-water (o/w), water-in-oil (w/o), and suspended solids. It has poor dewatering effect, and the composition and physical properties of the sludge are affected by factors such as the quality of the wastewater, treatment process, and chemicals added. Due to the significant differences in oil sludge and oil content, as well as the inconsistent conditions of each unit, it is difficult to formulate standardized equipment, making the treatment highly challenging.
2- The treatment process of oily sludge by Xi 'an Kosun
Xi 'an Kosun Manufacturing, based on the characteristics of oily sludge, relying on the technical advantages of the integrated solid-liquid separation solution and combining years of research and application experience in oilfield solid-liquid separation equipment systems, has launched this economical and efficient "oily sludge treatment solution".
Flowchart of the treatment process for oily sludge
The first step: Through the sorting equipment, the stones, weeds, tree roots and other impurities in the oily sludge are sorted out.
Step 2: Through heating tank equipment, stirring equipment, and dosing equipment, by taking advantage of the physical property of different specific graviums between oil and water, water, oil, silt, etc. are fully stratified through water temperature, chemicals, and stirring. Oil, with a lower specific gravity, adheres to the top layer; water, with a lower specific gravity, follows in the middle layer; and silt, with a higher specific gravity, settles at the bottom layer.
Step 3: Utilize three-phase separation equipment. This step can also be achieved through oil-water separation equipment and sludge-water separation equipment, etc. The aim is to achieve the three-phase separation of water, oil and sludge, as well as the reuse of crude oil and water. The slurry water enters the slurry water treatment equipment. The water can be reused in the heating tank or further processed through the water treatment equipment.
3- Composition of Xi 'an Kosun Oily Sludge Treatment System
Xi 'an Kosun has designed and configured a complete set of integrated oily sludge treatment systems based on the "Oily Sludge Treatment Plan". It features flexible equipment selection, flexible configuration, low investment and high output. The Xi 'an Kosun oily sludge treatment system consists of: oil sludge pretreatment equipment, oil sludge sand screening equipment, dosing system, oil-water separation equipment, sludge-water separation equipment and other types of equipment.
Oily sludge treatment system
4- Xi 'an Kosun Oily Sludge Treatment System Case
In terms of the treatment of oil mud and oil-based mud in oil fields, Xi 'an Kosun has designed and produced a number of integrated solutions for oil field projects in domestic regions such as Gansu, Inner Mongolia, Xinjiang, and Sichuan, as well as in international countries like Kuwait, Russia, and Uzbekistan. As a professional equipment manufacturer specializing in the treatment of oilfield oil mud and sand, oily sludge, oil sludge and oil mud, we can design integrated solutions for our customers based on the specific conditions of each oilfield, and provide dedicated oily sludge treatment equipment and systems, truly achieving low-cost, large-scale and resourceful treatment of oilfield oil mud and sand, oil sludge and other pollution sources. Welcome to consult. We will serve you wholeheartedly!
