Pyrolysis Plant
In the field of sustainable waste resource recovery, pyrolysis plants have become the focus of technology today. The machine converts solid waste such as oil sludge, plastics, tires, etc. into valuable pyrolysis oil. In addition, Beston Group’s pyrolysis technology strikes the best balance between sustainability and high efficiency. Eco-friendly concepts and excellent design allow Beston pyrolysis projects to be spread all over the world.
What is Pyrolysis Plant
The basic logic of a pyrolysis plant is the pyrolysis of substances. The pyrolysis reaction utilizes a controlled thermal desorption reaction in the presence of microoxygen. The process converts various materials into valuable end products: pyrolysis oil and syngas. The entire plant has dedicated facilities from feeding to exhaust emissions. Therefore, this truly enables efficient waste management.
What Raw Materials Can Pyrolysis Plant Process?
Unlike charcoal making machine that mainly collects solid charcoal, pyrolysis plants mainly recover liquid pyrolysis oil. Therefore, the machine is mainly suitable for waste containing petroleum-derived compositions or residues. Below are some common waste types.
Oil Sludge
- Source: oil field drilling, crude oil storage, refinery wastewater treatment, etc.;
- Type: oil-based cuttings, tank bottom oil sludge, scum bottom mud, oil-contaminated soil, etc.;
- Pyrolysis products: pyrolysis oil, syngas, solid residue;
Waste Plastic
- Source: plastic product manufacturers, plastic recycling centers, etc.;
- Type: PE, PP, PS, ABS, and other plastic products. Oxygen&chlorine-containing plastics not included (PET, PVC);
- Pyrolysis products: pyrolysis oil, syngas, solid residue;
Waste Tyre
- Source: tyre recycling center, transportation fleet, heavy industry, etc.;
- Type: Passenger tyres, commercial tyres, OTR (off-the-road) tyres;
- Pyrolysis products: pyrolysis oil, syngas, carbon black, steel wire;
Waste Rubber
- Source: scrap recycling bins, landfills, etc.;
- Type: cable sheaths, rubber gloves, and other rubber products;
- Pyrolysis products: pyrolysis oil, syngas, carbon black;
Applications of End Products from Pyrolysis Plant
The end products of pyrolysis machine have a wide range of uses. First, because they originate from waste reuse, these resources are inherently sustainable. In addition, for some energy-consuming industries, the end products of pyrolysis, especially pyrolysis oil, play the role of alternative energy sources.
Pyrolysis Oil
- Provide alternative fuels for large energy consumers such as cement plants, ceramics plants, and steel plants;
- Obtain non-standard diesel with higher economic value through distillation;
- Heavy oil obtained after distillation is distributed to Heavy Fuel Oil Generator.
Solid
- Used in the production of building materials;
- Sand produced by oil sludge pyrolysis can be reused as fill material for oilfield drilling;
- Carbon black produced by tire pyrolysis can be processed into higher quality carbon black.
Steel Wire
- For sale directly;
- Recycled to produce steel products.
Models & Parameter of Beston Pyrolysis Plant
In line with the customer-centered business philosophy, Beston Group provides various types of pyrolysis plant for sale according to customer needs. Divided according to working capacity and operation mode, we provide a total of 6 models of pyrolysis plant for you to choose from. The following are specific parameters for your reference.
Skid-Mounted Type
Skid-mounted design, occupy less space
Convenient for intallation
Easy to operate and maintain
Batch Type
Cost-effective machine price
One furnace a day
mid-scale production, reduce energy consumption
Fully Continuous Type
24 hours working continuously
Large capacity, high-volume production
PLC automated control, reduce labor costs
| Model | BLJ-3 | BLJ-6 | BLJ-10 | BLJ-16 | BLL-16 | BLL-30 | |
| Capacity | 1-3t/d | 4-6t/d | 8-10t/d | 12-16t/d | 8t/d (only for rubber powder) | 30-35t/d | |
| Working Process | Batch | Batch | Batch | Batch | Semi-continuous | Fully continuous | |
| Reactor Size | φ1400*4900mm | φ2200*6000mm | φ2600*6600mm | φ2800*7100mm | φ2800*7100mm | φ1800*18500mm | |
| Reactor Material | Q345R | Q345R | Q345R | Q345R | Q345R | 310S stainless steel | |
| Drive System | 350 reducer+4kw drive motor | 400 reducer+5.5kw drive motor | 400 reducer+5.5kw drive motor | 500 reducer+7.5kw drive motor | 500 reducer+7.5kw drive motor | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 18m*4.2m*6m | 30m*12m*8m | 30m*13m*8m | 33m*13m*8m | 33m*13m*8m | 70m*20m*10m | |
| Power | 16.65kw | 37.85kw | 44.3kw | 55.6kw | 55.6kw | 256kw | |
| Burner | 2*200,000 kcal | 2*300,000 kcal | 2*300,000 kcal | 2*400,000 kcal | 2*400,000 kcal | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 18t | About 24.5t | About 28t | About 34.5t | About 34.5t | About 150t | |
| Number of Containers | 1*40HQ | 1*40FR+1*40HQ+1*20 GP | 1*40FR+2*40HQ | 1*40FR+2*40HQ | 1*40FR+2*40HQ | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | ≤60 | ≤60 | ≤60 | ≤60 | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | ||||||
| Condensing System | Vertical Condenser | φ426*3000 Single piece condensing area 7.58m2 | φ630*3600 Single piece condensing area 17.8m2 | φ630*3600 Single piece condensing area 17.8m2 | φ820*3600 Single piece condensing area 35.6m2 | φ820*3600 Single piece condensing area 35.6m2 | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 3000*2200*2250 Condensing area 17.51m2 | 5800*2260*2500 Condensing area 35.85m2 | 5800*2260*2500 Condensing area 35.85m2 | 8000*2260*2500 Condensing area 49.5m2 | 8000*2260*2500 Condensing area 49.5m2 |
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Things Need to Know about Pyrolysis Equipment Components
As an industrial equipment for integrated waste recycling, the pyrolysis unit has its main components performing their own duties. Each component performs a critical function to ensure efficient conversion from raw materials to products. The functions of the main components of a pyrolysis plant are discussed in detail below.
High-end Exhaust Gas Treatment Equipment
The crusher is used to break down larger pieces of biomass feedstock into smaller particles before entering the reaction furnace. This helps improve the efficiency of the charcoal making process.
Distillation Equipment
A dryer is used to reduce the moisture content in the biomass feedstock before the reaction begins. Lower moisture levels enhance the efficiency of the carbonization process and reduce energy consumption.
Tyre Pretreatment Equipment
The charcoal briquette machine is responsible for shaping the charcoal into specific forms, such as briquettes, depending on the intended use. This step is essential for producing uniform and market-ready products.
How to Get Pyrolysis Oil: Working Process of Pyrolysis Plant
Raw Material Feeding
You can choose a manual or automatic feeding system to put the raw material into the reactor. To some extent, the former one can save your initial investment cost, while the latter one is much more effective and it will save your time and labor cost. In general, it is better to preheat the reactor for 30 minutes before feeding to push the air out of the reactor to improve the safety and working efficiency.
Oil&Gas Formation
Beston pyrolysis plant adopts an indirect heating system to prolong the service life of the reactor. The pyrolysis process starts and oil gas generates when the temperature reaches up to 200 ℃. The oil gas first enter the drum to separate impurities such as heavy oil. While the light oil gas will go through the condenser system and be collected as liquid oil. Meanwhile, syngas after purification will be transferred to heat the reactor.
Solid Residue Discharge
Beston discharging system is fully-sealed to protect workers from fly ash. Besides, we also employ water cooling system to cool down the carbon black to 30 degrees soon. (use wastewater from the pyrolysis process). This design makes the discharging system safe and energy-saving. The whole pyrolysis process is pollution-free.
Emission Treatment
There will be exhaust gas produced with oil. That’s why we have designed a dedusting system to purify the exhaust gas. Generally, it includes water washing, water spray, ceramic ring adsorption, and activated carbon adsorption, etc.
Superiority of Beston Pyrolysis Plant
Safe Design
- The design of both mechanical mechanism and process ensures the safe operation of the device.
- The main furnace reducer is equipped with a protective cover to ensure stable operation of the equipment.
- Control system design supporting security alarm system.
Cutting-edge Technology
- For oil sludge, BLL-30 continuous equipment is a technical solution for coking during the reaction process.
- For plastic, gas-phase catalytic pyrolysis technology is used to improve reaction efficiency.
- Pyrolysis process of waste tyres is mature and stable, and there are various supporting solutions.
Smart Control Mode
- The entire pyrolysis system can be equipped with PLC and DCS remote control systems. This greatly improves control efficiency.
- The machine can realize timely online monitoring of the Internet of Things on the mobile terminal. This facilitates customers’ overall operation control.
Certification&Qualification of Beston Group
Why Choose Beston Group as Pyrolysis Plant Manufacturer?
Rich Export Experience
Founded in 2013, Beston Group is a leader in waste recycling in China. Our manufacturing plant covers an area of approximately 200,000 square meters. Not only that, Beston Group carries out recycling projects in 100+ countries. In addition, we have 20+ senior engineers with 10+ years of experience.
Strict Production Supervision
From raw material storage to factory installation, the entire process has standardized quality control procedures. In addition, pyrolysis plants must pass inspections by various departments before leaving the factory. In addition, the production process of material cutting, welding, equipment assembly, grinding, and painting is carefully controlled.
Comprehensive Technical Support
In the early stage of the project, the technical team can provide customers with material testing services. Combining testing data and customer needs, we provide customized process solutions. After the project is approved, we also provide support such as layout diagram design, basic diagram design, PID diagram design, and 3D simulation diagram.
One-Stop After-Sales Service
The equipment is installed and put into production after on-site debugging by engineers. In addition, the technical team will help customers train professional operation teams. During the project, our account management team provides 24/7 online service. Engineers can go directly to the site to troubleshoot. Not only that, Beston Group provides free software upgrade services to customers.
Return on Investment Analysis of Pyrolysis Project
In the world of sustainable solutions for waste management, return on investment (ROI) analysis is an important compass. It reflects whether the investment in pyrolysis plant can achieve a win-win situation of sustainability and profitability. Not only that, in-depth analysis can allow investors to understand the profit cycle of operating pyrolysis recycling projects. Below is an example of ROI for a pyrolysis project for your reference.
| Project Name | 12-15TPD waste tire pyrolysis project | |||||||
| Introduction | According to the market data of Europe, the estimated ROI report, the various expenses are as follows: | |||||||
| Fixed Investment Cost | Item | Details | Unit | Unit Price/USD | Quantity | Amount/USD | Total Amount | Remark |
| Equipment | BLJ-16 | Set | 89,000 | 1 | 89,000 | |||
| Transportation | Seafreight | Set | 64,600 | 1 | 64,600 | |||
| From Port to Site | Set | 5,800 | 1 | 5,800 | ||||
| Customs Tax | 0.15 | Set | 13,350 | 1 | 13,350 | |||
| Installation | Beston technician's salary | Day | 350 | 50 | 17,500 | |||
| Round-trip aritickets | Ea | 3,820 | 2 | 1,640 | ||||
| Visa | Ea | 750 | 1 | 750 | ||||
| Local welder | Day | 120 | 100 | 12,000 | 2 welders are needed | |||
| Local plumber | Day | 120 | 20 | 2,400 | ||||
| Local labor | Day | 108 | 50 | 5,400 | ||||
| Crane forklift | Day | 160 | 30 | 4,800 | ||||
| Materials | Installation materials ready | Set | 5,200 | 1 | 5,200 | Foundation, pipe, etc. | ||
| Licenses | / | Ea | 2,000 | 1 | 2,000 | Environmental, firefighting, etc. | ||
| Workshop | 500 | ㎡ | 380 | 500 | 190,000 | |||
| $452,440.00 | ||||||||
| Operating Cost | Raw Materials | Waste tyre | Ton | 0 | 12 | 0 | ||
| Water | / | m³ | 0.39 | 3 | 1.17 | |||
| Electricity | / | KWH | 0.2 | 864 | 172.8 | |||
| Fuel | Natural gas | Liter | 0.77 | 240 | 184.8 | |||
| Labor | / | People | 72 | 4 | 288 | |||
| Maintenance | / | Day | 85 | 1 | 85 | |||
| Depreciation | 8 years | Day | 175.18 | 1 | 175.18 | |||
| Tax | 0.05 | 0 | ||||||
| $906.95 | ||||||||
| End Products Price | Tyre oil | 0.45 | Ton | 5.4 | 433 | 2338.2 | 45% of input | |
| Steel Wire | 0.15 | Ton | 1.8 | 216 | 388.8 | 15% of input | ||
| Carbon black | 0.3 | Ton | 3.6 | 162 | 583.2 | 30% of input | ||
| Subsidy | Ton | 100 | 12 | 1200 | ||||
| $4,510.20 | ||||||||
| Daily Income | $3,603.25 | |||||||
| Monthly Income | Working day | Day | 25 | $90,081.17 | ||||
| Yearly Income | Working day | Day | 300 | $1,080,974.00 | ||||
Successful Stories of Beston Pyrolysis Projects
Beston Group has pyrolysis projects all over the world. We have established long-term and stable cooperation with multiple customers. We are not only a manufacturer of equipment, we are also a provider of recycling solutions. Therefore, Beston’s complete solution system is favored by recyclers around the world. Here are some successful cases for your reference. You can view more of the latest news from Beston Group on LinkedIn.
Commissioning of Pyrolysis Plant in Saudi Arabia
- Date: 2024.01
- Country: Saudi Arabia
- Model: BLJ-16
- Raw material: waste tyre
2 Sets of Pyrolysis Plant Installed in South Sudan
- Date: 2024.01
- Country: South Sudan
- Model: BLJ-16
- Raw material: oil sludge
Running of BLJ-3 Skid-Mounted Pyrolysis Plant in Japan
- Date: 2023.12
- Country: Japan
- Model: BLJ-3
- Raw material: waste tyre
Installation of Pyrolysis Plant in Libya
- Date: 2023.10
- Country: Libya
- Model: BLJ-16
- Raw material: oil sludge
Trial Operation of 4 Pyrolysis Plants in Netherlands
- Date: 2023.09
- Country: Netherlands
- Model: BLL-16
- Raw material: waste plastic
FAQ
PVC, PET and other similar chlorine & oxygen-containing plastics are not recommended for disposal.
PVC contains chlorine, which will produce hydrogen chloride that corrodes pipes after pyrolysis. In addition, pyrolysis oil will contain chlorine, and burning will release dioxins.
PET does not produce oil when pyrolyzed and contains oxygen elements. This releases oxygen during the pyrolysis process, which poses a safety hazard.
310s: 8-10 years.
