How Proper Solids Control Equipment Saves Time and Money

In today's competitive environment, operators across industries — from oil and gas to mining, trenchless drilling, and wastewater treatment — are constantly looking for ways to improve operational efficiency and reduce costs. One area that consistently delivers both immediate and long-term ROI is proper solids control.

At KOSUN, we specialize in manufacturing a full range of separation and solids-control equipment designed to maximize your system's performance. In this post, we'll explore how effective solids control not only protects your equipment but also helps you save money, reduce downtime, and operate more sustainably.
 

The Cost of Poor Solids Control

When solids are not effectively removed from fluids, several costly issues can occur:

Accelerated equipment wear: Abrasive solids can damage pumps, piping, and other critical components, leading to unplanned maintenance and costly repairs.
Reduced process efficiency: Excessive solids negatively affect fluid properties and process performance, increasing energy consumption and chemical usage.
Higher disposal costs: Poor separation creates larger waste volumes that require transportation and disposal.
Regulatory risks: Inadequate solids control can lead to noncompliance, fines, or operational disruptions.
 
How Proper Solids Control Equipment Delivers Value

Investing in properly sized and operated equipment provides measurable savings across multiple areas.

1. Primary Separation with Shale Shakers
Shale shakers serve as the first stage of solids control. KOSUN's linear motion shale shakers provide high G-force separation of coarse solids.
Proper shaker selection and screen optimization reduce the load on downstream equipment, lower fluid dilution and chemical costs, and improve fluid recovery.

2. Secondary and Tertiary Treatment with Hydrocyclones and Centrifuges
Desanders and desilters remove medium and fine solids, while KOSUN's modular hydrocyclone systems provide flexibility for changing process requirements.
For fine solids removal, KOSUN decanter centrifuges deliver high-performance separation with G-forces exceeding 3000 G. Continuous operation, optimized bowl design, and durable construction improve throughput, extend equipment life, and increase solids dryness.
A properly specified centrifuge helps reduce waste volume, recover valuable fluids, and minimize wear on downstream equipment.

3. Supporting Systems: Tank Cleaning and Vacuum Pumps

Sediment buildup in tanks and pits can affect fluid quality and system performance. KOSUN Solids America offers automatic tank cleaning systems and industrial vacuum pumps for efficient sludge removal.
Routine tank cleaning reduces manual labor, maintains fluid quality, and helps prevent unplanned shutdowns.

A Real-World Example: ROI from Upgraded Solids Control

A client in the HDD (Horizontal Directional Drilling) industry upgraded its solids control system with shakers, desanders, and a decanter centrifuge. The results included:

25% reduction in fluid-related operating costs
50% decrease in waste disposal volumes
Increased rig uptime due to fewer equipment failures

This outcome demonstrates how effective solids control can generate significant operational savings.
 
Conclusion

Proper solids control is not an expense—it is an investment that delivers measurable returns. Whether optimizing a drilling rig, improving waste management, or upgrading a mining operation, KOSUN provides the expertise and equipment needed to improve performance and reduce costs.