Components of a Solids Control System: Selection, Sizing, and System Integration

A Solids Control System is not simply a list of machines. It is an engineered process where each component must be correctly selected, properly sized, and carefully integrated with the others. Installing a high‑performance shale shaker with an undersized centrifuge, or placing a degasser after a desander, will cripple the entire system. This article explains the components of a solids control system from a system‑engineering perspective: how to choose each piece, how to match capacities, and how to avoid common mistakes. AIPU Solid Control provides all the components needed for a fully balanced system.

1. The System Engineering View

A drilling solids control system is designed to remove drilled solids progressively, from large cuttings down to ultrafine particles. Each component has a specific cut point (the particle size it removes most effectively). The components must be arranged in descending cut‑point order, and their processing capacities must be balanced so that no single component becomes a bottleneck.

The main components, in correct sequence, are:

1. Shale shaker – cut point ≈75 µm and larger

2. Vacuum degasser – removes gas, not solids (but essential for density)

3. Desander – cut point ≈44–74 µm

4. Desilter – cut point ≈15–44 µm

5. Decanter centrifuge – cut point ≈2–7 µm
   Supporting components: Mud agitators, shearing pumps, jet mixers, centrifugal pumps, and mud tanks.

2. Component #1: Shale Shaker – Sizing and Selection

The shale shaker is the first line of defense. If it is undersized, mud will overflow the screen, and large cuttings will break down into finer particles that overload downstream equipment.

Selection criteria:

• Flow rate capacity – Must be at least 1.2× the maximum mud pump output. For a pump circulating 200 m³/h, select a shaker rated for ≥240 m³/h.

• Number of screens – Single deck is common, but dual‑deck or triple‑deck (AIPU Hunter‑MG4D) allows finer first‑screen mesh while maintaining capacity.

• Motion type – Linear motion for high flow, balanced elliptical for finer screening, dual‑motion for flexibility (AIPU Hunter‑MGD).

AIPU recommendation: Hunter‑MG3 (120 m³/h) for small rigs; Hunter‑MG4 (140 m³/h) or Hunter‑MG5 (180 m³/h) for standard land rigs; Hunter‑MG4D (280 m³/h) for high‑flow or offshore.

3. Component #2: Vacuum Degasser – When and Why

Not every well needs a degasser, but when drilling through gas‑bearing formations, it is mandatory. The degasser removes entrained gas bubbles that reduce mud density and cause pump cavitation. It must be placed before the desander, because gas interferes with hydrocyclone separation.

Selection criteria:

• Mud flow rate – Degasser capacity should equal or exceed the pump rate. AIPU offers 240–360 m³/h models.

• Gas content – For high gas, choose a centrifugal type (AIPU APLCQ300) for maximum efficiency (≥95%).

• H₂S risk – Specify H₂S‑resistant steel (316L/2205).

AIPU recommendation: APZCQ300 for tank mounting, APLCQ300 for limited space.

4. Component #3: Desander – Hydrocyclone Sizing

Desanders remove sand‑sized particles (44–74 µm). They use large‑diameter cyclones (10″ or 12″). The number of cones determines capacity.

Sizing rule: A single 10″ cone handles approximately 90–120 m³/h. For 240 m³/h, you need two cones; for 360 m³/h, three cones.

Selection criteria:

• Flow rate – Match cone quantity to pump output.

• Bottom shaker – Adding a small shaker (mud cleaner) dries the solids and reduces mud loss.

• Material – Polyurethane cones last longer than ceramic or cast iron.

AIPU solutions: Hunter S120 (single cone), Hunter S240 (two cones), Hunter S360 (three cones); also APCS series with bottom shaker options.

5. Component #4: Desilter – Fine Solids Removal

Desilters use smaller cones (4″ or 5″) to remove particles down to 15 µm. Each 4″ cone treats about 12–15 m³/h. For a 240 m³/h system, you need 12–16 cones.

Selection criteria:

• Desired cut point – 4″ cones remove down to 15 µm; 5″ cones down to ~20 µm.

• Bottom shaker – Strongly recommended to dewater the fine solids; otherwise, the underflow is a wet slurry.

• Pressure requirement – Hydrocyclones need 0.25–0.45 MPa feed pressure.

AIPU solutions: Hunter N120 (8 cones), Hunter N240 (12 cones), Hunter N360 (16 cones); APCN series with 100% polyurethane cones.

6. Component #5: Decanter Centrifuge – The Final Polisher

The centrifuge removes the smallest particles (2–7 µm). In unweighted mud, it discards ultrafine solids that cause high viscosity. In weighted mud (barite), it separates barite (SG≈4.2) from low‑gravity drilled solids (SG≈2.6) and returns the barite to the system.

Selection criteria:

• Unweighted mud – Choose a high‑speed centrifuge (3200 rpm) with fine separation point (2–5 µm). AIPU APLW355X1257‑N or APLW355X1460‑N.

• Weighted mud (barite recovery) – Choose a lower‑speed centrifuge (1500–2200 rpm) with coarser separation point (5–7 µm). AIPU APLW600X1019‑N or APLW530X1540‑N.

• Capacity – Must match the overflow from the desilter; typically 35–65 m³/h is sufficient for most rigs.

AIPU recommendation: For combined duties, the APLW450X1350‑N (60 m³/h, variable speed) offers flexibility.

7. Supporting Component #1: Mud Agitator – Preventing Settling

Agitators are often overlooked, but without them, solids settle into a hard cake, reducing tank capacity and causing inconsistent mud properties.

Sizing rule: One agitator per 3 m of tank length, or one per compartment. For deep tanks (>2 m), use dual impellers. Shaft length must place the impeller ~1.5× impeller diameter from the bottom.

AIPU APMA series: 5.5 kW to 15 kW, single or dual impeller, with optional shaft stabilizer.

8. Supporting Component #2: Shearing Pump – Polymer Hydration

Shearing pumps are not always included, but for wells that use high‑molecular‑weight polymers, they are essential. They reduce polymer hydration time from 4 hours to 15 minutes, save 15–30% on chemicals, and eliminate fish eyes.

Selection criteria: Flow rate should match the mixing pit circulation (typically 100–150 m³/h). AIPU APJQB6535 (100 m³/h) or APJQB6545 (155 m³/h).

9. Supporting Component #3: Jet Mud Mixer – Powder Addition

Jet mixers (jet hoppers) are used to add barite, bentonite, and dry chemicals. They work with a centrifugal pump.

Sizing rule: The centrifugal pump must supply 0.22–0.4 MPa at the nozzle. AIPU provides matched pump‑mixer pairs.

AIPU APSLH series: Fixed or portable, mixing rates up to 315 kg/min barite, 180 kg/min clay.

10. Supporting Component #4: Centrifugal Pump – The Workhorse

Centrifugal pumps are used for:

• Feeding desanders and desilters

• Supplying jet mixers

• Transferring mud between tanks

• Feeding centrifuges (some models need a separate feed pump)

Selection criteria: Head (20–35 m) and flow rate must match the downstream equipment. Oversizing wastes power; undersizing causes poor performance.

AIPU APSB series: Vertical or horizontal, 7.5–75 kW, 40–255 m³/h, API 7th edition design.

11. Component #11: Mud Tanks – The Foundation

Mud tanks are not passive containers. They must be divided into compartments with weir plates to force mud through each stage. Sloped or V‑shaped bottoms prevent dead zones. AIPU custom‑designs tanks with integrated walkways, piping, and equipment mounts.

12. Common Component Sizing Mistakes

13. How AIPU Solves Component Integration

AIPU Solid Control offers full system engineering. Instead of buying components from different vendors and hoping they match, AIPU provides:

• Balanced capacities – Shakers, desanders, desilters, and centrifuges sized to work together.

• Matched pumps – Centrifugal pumps selected to provide correct head and flow for jet mixers and hydrocyclones.

• Tank layout design – Compartment sizes calculated for retention time.

• Unified materials – Same H₂S‑resistant steel and coating throughout.

• Single‑source responsibility – One warranty, one support team.

14. Conclusion

The components of a solids control system are much more than a shopping list. Each component – shaker, degasser, desander, desilter, centrifuge, agitator, shearing pump, jet mixer, centrifugal pump, and mud tank – must be correctly selected, properly sized, and seamlessly integrated. Mistakes in any component will reduce efficiency, increase costs, and create operational risks.

AIPU Solid Control supplies all the components you need, backed by over 20 years of engineering experience and deliveries to more than 30 countries. Whether you are building a new system from scratch or upgrading an existing one, AIPU ensures that every component works in harmony.

Choose AIPU for a perfectly balanced solids control system.