KOSUN has completed a 1 T/H oily sludge treatment system for an African waste oil recovery company. Designed to process oily sludge collected from onshore and offshore oilfields, the system combines thermal washing and three-phase separation to recover oil, recycle process water, and reduce solid waste.
Project Background
The client specializes in the collection, treatment, and recovery of petroleum sludge from onshore and offshore oilfields. Previously, oily sludge in the region was mainly disposed of through incineration, resulting in high treatment costs and environmental concerns.
To address these challenges, KOSUN provided an integrated solution covering pretreatment, heating, chemical dosing, three-phase separation, oil storage, and automatic control. The system is designed to support oil recovery while reducing waste disposal requirements and freshwater consumption.
Treatment Process: Thermal Washing and Three-Phase Separation
The system adopts a thermal washing and three-phase separation process to separate oil, water, and solids from oily sludge.
1. Pretreatment and Thermal Washing
Oily sludge first enters the conditioning tank, where steam heating, chemical additives, and mechanical mixing work together to loosen the sludge structure and release oil from solid particles.
2. Three-Phase Centrifugal Separation
The conditioned material is then pumped into the KOSUN LWS350 three-phase decanter centrifuge. By utilizing density differences between oil, water, and solids, the centrifuge separates the feed into three phases:
- Oil phase: Recovered oil flows into the oil storage unit.
- Water phase: Process water is treated and recycled for reuse in the thermal washing stage.
- Solid phase: Separated solid residues are discharged for subsequent handling.
Process water is recirculated within the system, helping reduce freshwater demand during operation. This design is particularly relevant to oilfield operations in water-scarce regions.
System Configuration
The integrated system consists of six main units:
- Pretreatment unit
- Separation unit
- Oil storage unit
- Chemical dosing unit
- Heating unit
- Control unit
The skid-mounted design enables factory assembly and commissioning before delivery, helping simplify on-site installation and startup.
Key System Advantages
Oil Recovery and Resource Utilization
The system separates recoverable oil from oily sludge, creating opportunities for oil reuse and improving the overall value of the treatment process.
Reduced Solid Waste Volume
By recovering oil and separating water from solids, the system helps reduce the volume of material requiring further disposal.
Flexible Feed Material Handling
The treatment process can be configured for different oily waste streams, including contaminated soil with oil, tank-bottom sludge, oily drilling sludge, and oil-based drill cuttings, subject to feed characteristics and process requirements.
Automated Operation
PLC-based control supports process monitoring and coordinated equipment operation, with remote monitoring available according to the system configuration.
Design for Field Operations
The system can be configured with explosion-proof electrical components and corrosion-resistant structures to suit demanding oilfield environments, including high temperatures and dusty conditions.
Reliable Solutions for Oily Sludge Treatment
From process design to equipment integration, KOSUN provides oily sludge treatment systems designed to support oil recovery, waste reduction, and more efficient resource utilization.
This 1 T/H project demonstrates KOSUN’s approach to combining thermal treatment, chemical conditioning, and three-phase centrifugal separation in an integrated solution for oilfield waste management.