Innovative Oil Sludge Separation Solutions by KOSUN: Maximizing Recovery & Minimizing Waste

Jun 03, 2025

Oil sludge is a major environmental and economic challenge in the petroleum industry. Generated during drilling, refining, and storage operations, it contains valuable hydrocarbons mixed with water, solids, and contaminants. KOSUN Solids Control, a leader in oilfield waste management, provides cutting-edge oil sludge separation technologies that maximize oil recovery while ensuring eco-friendly disposal.

This article explores KOSUN’s advanced methods for oil sludge separation, their benefits, and how they outperform conventional treatment systems.

1. The Challenge of Oil Sludge

Oil sludge composition varies, but typically includes:

• Recoverable oil (10-50%) – Lost profit if not extracted

• Water (20-60%) – Often contaminated with chemicals

• Solids (20-50%) – Sand, clay, and heavy metals

Without proper treatment, sludge can:
❌ Contaminate soil & water sources
❌ Waste valuable hydrocarbons
❌ Increase disposal costs due to hazardous waste regulations

KOSUN’s solution: A multi-stage separation process that recovers up to 98% of oil while reducing solid waste volume by 90%.
 

2. KOSUN’s Oil Sludge Separation Technologies

A. Primary Separation: Shale Shakers

• Function: Removes large solids (>74 microns) through vibrating screens.

• KOSUN Advantage:

  • High-G force shakers for better solids removal

  • Anti-clogging screens for continuous operation

B. Secondary Separation: Decanter Centrifuges

KOSUN offers two types for different needs:

1. 2-Phase Decanter Centrifuge

   • Separates liquids (oil + water) from solids

   • Best for: Sludge with low oil-water emulsion

   • Recovery rate: 90-95% free oil

2. 3-Phase Decanter Centrifuge

   • Splits oil, water, and solids simultaneously

   • Best for: Complex sludge with emulsified oil

   • Recovery rate: 85-90% oil

C. Advanced Purification: Disc Stack Centrifuges

• Function: Ultra-fine separation for high-purity oil & water
   

• KOSUN Advantage:

  • Self-cleaning design reduces clogging risk

  • Recovers 95-98% of oil from difficult sludge

D. Optional Thermal Treatment

For heavy sludge with high hydrocarbon content, KOSUN integrates:

• Thermal desorption units (250-600°C)

• Vapor recovery systems to capture 99% of oil
   

3. KOSUN’s Customized Treatment Solutions

4. Why Choose KOSUN for Oil Sludge Separation?

✔ Higher Oil Recovery – Advanced centrifuges extract more sellable oil
✔ Lower Disposal Costs – Reduces solid waste volume by 90%+
✔ Fully Automated Systems – Minimizes labor and operational errors
✔ Compliance with EPA/OSHA – Meets global environmental standards
✔ 24/7 Technical Support – On-site or remote troubleshooting

5. Case Study: KOSUN in Action

Client: A major oil refinery in Texas
Challenge: 10,000 tons of tank-bottom sludge with 30% oil content
KOSUN Solution:

1. Shale shaker removed large solids

2. 3-phase decanter recovered 88% of oil

3. Disc stack centrifuge purified oil to 96% purity
   Result:

• Recovered 2,800 tons of reusable oil

• Reduced hazardous waste disposal by 85%
   

6. Future Trends in Sludge Treatment

KOSUN is pioneering: