A comprehensive analysis of the piling mud recovery system, from its composition, principles to cases

In construction projects such as building pile foundations and bridge foundations, piling operations generate large amounts of waste mud containing impurities such as sand and stone. Direct discharge not only pollutes the environment but also wastes high-quality mud materials and increases construction costs. Piling mud recovery systems utilize physical separation and purification technologies to achieve mud recycling, achieving both environmental and economic benefits. They have become an indispensable component of modern pile foundation construction.

TR Solids Control's piling mud recovery system uses physical separation technology to achieve solid-liquid separation and recycling of mud, mainly through processes such as mud collection and transportation, solid phase particle separation and purification, and mud storage and reuse.

I.Core components: modular design and clear division of labor

1. Shale Shaker:

   Equipped with a coarse screen (e.g., 60 mesh) and a fine screen (e.g., 200 mesh), it filters particles from the slurry in layers. The coarse screen removes large particles (such as rocks and clods), while the fine screen further intercepts fine sand and slurry impurities.

   For example, TR's solids control equipment uses a double-layer screen design, which increases screening efficiency by 30% and reduces the moisture content of the slag to below 25%.

2. Desanding and Desilting Cyclones:

   These include desanding cyclones (separating particles ≥ 0.045mm) and desilting cyclones (separating particles ≥ 0.007mm). They accelerate the sedimentation of sand particles in mud using centrifugal force.

   For example, the Tianrui solids control system utilizes two cyclones in series, achieving a sand removal rate of 95% and significantly improving mud purity.

3. Sand Pumps and Mud Tanks:

   Sand pumps (such as centrifugal sand pumps) provide the power for mud circulation. Mud tanks (capacity 8m³-360m³) store treated mud, supporting a closed-loop circulation system.

   For example, Tianrui Solids Control used a 150m³/h mud tank for a project in India, achieving a daily processing capacity of 360m³, meeting the needs of large-scale construction.

4. Filter Press:

   Using high-pressure membrane filter press technology, the slurry is compressed into a cake with a moisture content of ≤30%, enabling dry-stack solid waste treatment.

5. Additive System:

   Adding flocculants (such as polyacrylamide) or quicklime accelerates the coagulation of slurry particles and improves separation efficiency.

II.Core advantages: environmental protection, economy and high efficiency

TR Solids Control's "waste mud + circulating mud" model and piling mud recovery system have significant environmental, economic and efficiency advantages.

1. Environmental Advantages: Reduced Pollution, Compliant with Policy Requirements

   Reduced Waste Mud Discharge: The system's mud recovery rate can reach 85%-95%, significantly reducing waste mud discharge and preventing mud leakage from contaminating soil, groundwater, and surface water.

   Reduced Solid Waste Disposal: Separated drill cuttings and sand and gravel have low moisture content and can be used as construction backfill or disposed of by compliant entities, reducing the amount of solid waste transported and the cost of disposal.

2. Economic Advantages: Reduced Costs, Improved Efficiency

   Saving Mud Material Costs: Purified mud can be recycled, reducing the purchase of new materials like bentonite and admixtures, and reducing material costs by 30%-50%.

   Reduced Transportation and Disposal Costs: Reduced waste mud discharge eliminates the need for frequent transportation and avoids high hazardous waste disposal costs.

   Reduced Equipment Wear: Purified mud has a low sand content, reducing wear on drilling rigs, mud pumps, and other equipment, extending equipment life and reducing maintenance costs.

3. Efficiency Advantages: Ensure Construction and Improve Progress

   Stable Mud Performance: The system adjusts mud density and viscosity in real time to ensure effective pile hole wall protection, reduce construction accidents such as hole collapse and diameter shrinkage, and minimize rework.

   Reduced Waiting Time for Mud Supply: Recycled mud can be reused at any time, eliminating the need to wait for new mud to be delivered to the site, and avoiding construction interruptions caused by untimely mud supply.

III.Applicable scenarios: covering various types of pile foundation construction conditions

1. Mainstream Pile Foundation Construction Techniques

   Rotary Drilling: Rotary drilling produces slurry with a high sand content. The system efficiently separates drill cuttings and ensures slurry circulation.

   Percussion Drilling: Percussion drilling produces slurry with high viscosity. The system uses a slurry adjustment module to adjust the viscosity to prevent excessive slurry from affecting drilling progress.

   Direct and Reverse Circulation Drilling: Direct and reverse circulation drilling requires a continuous slurry supply. The system provides a stable supply of high-quality slurry to meet continuous construction requirements.

2. Typical Geological Conditions

   Sand and gravel layers: The slurry in these types of geological conditions contains a very high sand content. The system quickly separates the sand and gravel to prevent slurry failure.

   Clay layers: Mud in clay layers is prone to containing clay particles. The system uses a cyclone to separate the fine particles and adjust the slurry density.

3. Project Types

   Construction Engineering: Pile foundation construction for residential communities, commercial complexes, and other buildings, particularly suitable for projects within cities with high environmental protection requirements.

   Bridge Engineering: Pile foundation construction for highway and railway bridges often requires work near rivers and farmland, and the system can reduce environmental pollution.

   Municipal Engineering: Pile foundation construction for subways and utility corridors, often located in urban areas, requires the system's low noise and low pollution characteristics to meet site requirements.

   Water Conservancy Engineering: Pile foundation construction for dams and docks, adaptable to aquatic and humid environments, ensuring mud recycling.

TR Solids Control's piling mud recovery system has strong adaptability and can be flexibly adjusted according to construction technology, geological conditions, and mud type.

The piling mud recovery system utilizes physical separation and recycling technologies to recycle construction waste, providing key support for green construction. Tianrui Solids Control designs specialized systems tailored to specific working conditions, enhancing adaptability. It also provides integrated services encompassing "equipment + maintenance + slag disposal" to reduce customer management costs.