Advanced Oil Sludge Treatment Solutions by KOSUN: Maximizing Oil Recovery & Minimizing Environmental Impact

In petroleum operations, oil sludge remains one of the most complex waste streams – containing recoverable hydrocarbons (10-50%), contaminated water (20-60%), and hazardous solids (20-50%). KOSUN Solids Control delivers innovative separation technologies that transform this environmental liability into recoverable resources while ensuring regulatory compliance.

KOSUN’s Cutting-Edge Separation Technologies

1. Three-Phase Decanter Centrifuge System

KOSUN’s flagship solution achieves 90-95% oil recovery through:


  • Simultaneous separation of oil/water/solids in continuous operation



  • Adaptive control system that adjusts to varying sludge compositions



  • Low-energy consumption design reducing operational costs by 30% vs conventional systems


Case Example:
A Middle East refinery processed 5,000 tons of tank-bottom sludge with KOSUN equipment:
✔ Recovered 1,450 tons of reusable crude oil
✔ Reduced disposal volume by 88%
✔ Achieved ROI in 14 months

2. Mobile Sludge Treatment Units

For lagoon and pond remediation, KOSUN offers:


  • Pontoon-mounted extraction systems with heating capabilities for viscous sludge



  • Integrated pretreatment with shale shakers removing >75μm particles



  • Closed-loop processing preventing secondary contamination




Key Advantages:


  • 90% oil recovery from legacy sludge ponds



  • 80% reduction in transportation costs



  • Eliminates long-term environmental liabilities




3. Tank Cleaning Residual Processing

KOSUN’s specialized solution for crude storage tank cleaning:


  • Processes up to 50 m³/hour of tank bottoms



  • Recovers 93-97% of residual hydrocarbons



  • Reduces final waste volume to 5-10% of original




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Environmental & Economic Benefits


  • Resource Recovery: Up to 98% hydrocarbon reclamation



  • Cost Savings: 60-80% reduction in disposal expenses



  • Regulatory Compliance: Meets EPA, EU and OSPAR standards



  • Carbon Footprint: 40% lower emissions than thermal alternatives




Why Global Operators Choose KOSUN

✔ Proven Technology: 300+ installations worldwide
✔ Custom Solutions: Engineered for specific sludge characteristics
✔ Lifecycle Support: From feasibility studies to aftermarket services
✔ Sustainable Focus: Circular economy approach to oil waste

Future Innovations in Development


  • AI-Powered Separation: Real-time process optimization



  • Plasma-Assisted Treatment: Zero-residue solutions



  • Modular Micro-Units: For offshore applications


For project consultation or technical specifications:

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