Harnessing Centrifugal Power: An In-Depth Look at KOSUN Decanter Centrifuges

In the world of modern industry, where efficiency and environmental safety have become critical parameters, separation technologies hold a special place. Among them, horizontal decanter centrifuges stand out as versatile and highly efficient solutions. KOSUN’s equipment in this category serves as a prime example of engineering ingenuity, transforming complex technological challenges into manageable and economically advantageous processes.

The Principle of Forced Sedimentation: Physics in Action

At the core of a horizontal decanter centrifuge lies the principle of forced sedimentation. While natural gravity causes solid particles to settle slowly and inefficiently, the centrifugal force generated by a high-speed rotating rotor amplifies this process by thousands of times. This allows separation of particles as small as 3–5 microns—practically invisible to the naked eye, yet significantly affecting the properties of drilling fluids and other industrial media.

The Heart of the System: Structural Features

The KOSUN decanter centrifuge is a sophisticated mechanism, where every component serves a precise function:

Rotor (Drum): Comprising cylindrical and conical sections, it creates the optimal space for phase separation.

Screw Conveyor: Rotates slightly slower than the rotor, ensuring continuous removal of settled solids.

Differential Mechanism: A key unit that creates a controlled speed difference between the rotor and screw (typically 20–70 RPM). KOSUN uses highly reliable planetary and cycloidal gearboxes with ratios of 35:1 and 71:1.

Hydraulic Coupling: Protects the main motor from overloads, transmitting torque smoothly while damping vibrations.

From Theory to Practice: How Separation Works

The separation process works as follows:

1. The feed slurry enters the hollow shaft of the screw through the inlet pipe.

2. Centrifugal force distributes the mixture along the inner wall of the rotor.

3. Solid particles settle on the wall and are conveyed by the screw to the discharge ports at the conical end.

4. Clarified liquid moves in the opposite direction and exits through adjustable overflow ports.

5. A key feature is the “drying zone,” where the solid phase is further dewatered before discharge.

Applications in Oil & Gas: Cost Savings and Environmental Benefits

In drilling operations, KOSUN centrifuges address two critical tasks:

1. In weighted drilling fluids: They efficiently separate valuable weighting agents (barite) from fine drilled solids. This allows up to 95% of barite to be reused, significantly reducing material costs while maintaining optimal fluid rheology.

2. In conventional drilling fluids: They “polish” the fluid by removing ultra-fine particles, enhancing system stability and reducing wear on drilling equipment.

​Reliability and Safety: KOSUN’s Engineering Approach

As high-speed equipment, centrifuges require strict adherence to operational guidelines. KOSUN places special emphasis on:

• Simplicity and reliability of design using explosion-proof components.

• Clear maintenance protocols, including regular inspection of bearings, gearboxes, and lubrication systems.

• Modular construction, facilitating transportation, installation, and servicing in field conditions.

KOSUN horizontal decanter centrifuges are more than just equipment—they are strategically important components of modern industrial processes. They embody a deep understanding of physics, engineering precision, and a results-oriented approach. From oil rigs to environmental remediation tasks, this equipment demonstrates that even issues invisible to the naked eye can be effectively addressed through the power of centrifugal technology.