About Raw Materials
What raw materials can the pyrolysis plant handle?
Waste tires: Big car tires, truck tires, OTR tires, motorcycle tires, bicycle tires, etc.;
Waste plastics: PP, PE, PS, ABS, etc. (except PET and PVC);
Waste rubber: Rubber cable sheath, rubber soles and all the other kinds of rubber sheets or carpets;
Oil sludge: floor oil sludge, tank bottom oil sludge, refinery oil sludge, crude oil sludge, petroleum sludge, engine oil sludge, drilling cuttings etc.
Are all the tires suitable for your pyrolysis plant?
Yes. The tires with normal diameter of less than 1200mm can directly enter the pyrolysis reactor, while the tires that larger than 1200mm need to be shredded before pyrolysis.
Can waste plastics and tires be pyrolyzed together at the same time?
Better not. It is recommended to handle the plastics and the tires separately. The pyrolysis temperatures of the two materials are different, so it will affect the process. The plastic pyrolysis process is prone to blockage of the system by wax oil, so the catalytic tower system is equipped as needed; while the tire pyrolysis process does not have the above problems. In addition, the carbon black from waste tire pyrolysis can be further processed and utilized, but the plastic residues are general industrial solid wastes. After being mixed with plastic and pyrolyzed, the residue will reduce the utilization value of tire pyrolysis carbon black. So it is recommended to classify separately and treat by quality to improve the added value of products.
Does the types of plastics affect the pyrolysis oil?
Yes, totally. Different types of plastics have different oil yields and quality.
Are there any requirements for the size and moisture of the raw materials?
For manual feeding and hydraulic feeding, tire diameter and plastic bales are required to be smaller than 1.2m and can be fed directly;
For screw feeding, tire ≤5cm, plastic ≤5cm, moisture content below 10%.
What is the processing capacity of various materials in the pyrolysis process?
|Model||Waste Tires||Waste Plastics||Oil Sludge|
|BLJ-3 (skid-mounted, batch)||1-3t/d||0.5-1t/d||3t/d or 3m3/d (subject to whichever comes first)|
|BLJ-6 (batch)||4-6t/d||2-3t/d||6t/d or 6m3/d (subject to whichever comes first)|
|BLJ-10 (batch)||8-10t/d||3-5t/d||10t/d or 10m3/d (subject to whichever comes first)|
|BLJ-16 (batch)||12-14t/d||6-8t/d||16t/d or 12.5m3/d (subject to whichever comes first)|
|BLL-30 (fully continuous)||1.25-1.14t/h||0.83-1.25t/h||1.875-2.08t/h|
About Final Products
What is the final products obtained from the pyrolysis plant?
Note: We will get different finished products from different raw materials. The proportions of the final products also vary according to the raw materials.
|Raw Materials||End Products|
|Waste plastic||Fuel oil, carbon black, combustible gas;|
|Waste tire/rubber||Fuel oil, carbon black, steel wire, combustible gas;|
|Oil sludge||Fuel oil, water, sand.|
What is the applications of the final products?
|Pyrolysis oil||35-45%||1. Further processed into non-standard diesel.
2. Can be used as fuel in heavy industries such as steel, iron and boiler factories, ceramics, power, chemical industries.
|Carbon Black||30-35%||1. Used as construction material or low-grade fuel or as filler in the rubber industry, paints and coatings, ink production and other industrial applications.
2. Making carbon brick by briquetting equipment and sell.
|Steel Wire||8-15%||1. Sell directly.
2. Making steel bloom by hydraulic press-packing.
|Combustible Gas||8-15%||Alternative fuel to heat the reactor. (self-sufficient pyrolysis process)|
How is the oil yield?
The oil yield of different raw materials is very different. You can refer to the picture below for a general understanding. If you want to know the specific oil yield, you can contact us to send samples for testing.
Can pyrolysis oil be used to produce diesel?
Yes. After further distillation, the pyrolysis oil can be mixed with conventional diesel to be used as fuel for low-speed vehicles.
Can pyrolysis oil be used as generator fuel?
Yes, it can be used as special generator fuel.
Will waste water, waste particulate matter, oil residues be produced during the process?
No. The waste water in the water seal and spray tower can be evaporated at high temperature in the discharge chamber and furnace, and the residual oil in the residual oil tank can be directly re-entered into the main reactor for re-pyrolysis or stratified and directly mixed into the pyrolysis oil. The flue gas emission will be discharged up to the standard after exhaust gas treatment, and there will be no waste particulate matter discharged.
Do you have analysis report of the pyrolysis oil generated from Beston pyrolysis machine?
Yes, we have SGS reports for tire and plastic pyrolysis oil. Please contact us if you need more details.
What are the factors that affect tire oil yield?
1. The condensation area of the combustible gas condenser;
2. The water volume and water temperature of the circulating water;
3. Heating rate and temperature control.
About Process & Operation
What is the operating temperature for tire and plastic pyrolysis?
The normal operating temperature for plastic and tire pyrolysis is between 280-350 degrees, generally not higher than 400 degrees. Overall, the temperature for plastic pyrolysis is a little higher than tire pyrolysis.
What is the temperature range in tire pyrolysis oil generation process? What is the maximum pressure
The tire pyrolysis oil starts generating at 180℃, and the maximum oil generates at 280-350℃. the working pressure does not exceed 0.02Mpa.
What kind of fuel can be used for pyrolysis? What is the consumption?
Natural gas, diesel, heavy oil are all available. Consumption depends on the specific model.
What should be paid attention to pyrolysis of plastic?
Similar chlorine and oxygen-containing plastics such as PVC and PET are not recommended to be treated; the feeding method is recommended to be packaged; the condenser is recommended to be 3-in-1 box-type condensation, and also equipped with a pyrolysis catalyst tower, special catalyst and catalyst regeneration system.
How often do ceramic rings need to be cleaned in dust removal system?
3-4 months. Or determine the frequency of cleaning based on actual usage.
What are the judging conditions for the basic completion of oil production in batch equipment?
1.The temperature of the main reactor increases and the temperature of the steam drum decreases;
2.The oil output is reduced and the oil is dark brown.
How is the waste water in the water seal treated?
1. Enter the main reactor and then react;
2. Connect the water pipe to the exhaust combustion chamber and add a nozzle to burn.
What is the working pressure and maximum pressure of the batch pyrolysis furnace?
The working pressure of batch pyrolysis reactor is 2-10kPa. The maximum pressure in the reactor is 20kPa.
What about emissions and pollution problems in the pyrolysis process?
The amount of exhaust gas is different according to the selection of model. The exhaust gas is mainly composed of two parts, most of which are produced by fuel combustion and process of heating the reactor, and small part is produced by the direct burning of excess pyrolysis gas. The exhaust gas mainly contains sulfur compounds, nitrogen oxides, dust, carbon monoxide and carbon dioxide, etc.
There are many European customers who are running the plant and the emissions meet the local standards.
Is the exhaust gas emission standard qualified?
Yes, it can reach the emission standard. The high-temperature flue gas is first treated by condensation and cooling in the flue, washed with water to remove oil and dust, and then goes through desulfurization tower, denitrification tower, dust removal, activated carbon adsorption, and finally the flue gas that meets the standard is discharged. We have many European success stories to meet European emission standards.
Is it complicated to operate the pyrolysis plant?
No. Just 100% operate the plant as the operation manual guides (will provide after making the deal) and the engineers of Beston Group will be responsible for training your workers how to operate the plant correctly and how to maintain it. We are here to help at any time.
Will the consumption of heating fuel be a large expense for me?
Generally not. It depends on what kind of fuels you want to choose. Generally, if you’d like to process 1 ton feedstock, the estimated consumption of each kind of fuel is,
Coal: 85-90 KG;
Natural Gas: 70-80 m;
Diesel: 55-65 KG;
LPG: 50-55 KG.
Don’t forget that Beston has combustible gas recycling design for the pyrolysis plant. You can fully take use of the combustible gas generated from the pyrolysis process to heat the reactor.
What catalytic pyrolysis technology is used for waste plastic treatment?
Waste plastic treatment adopts gas-phase catalytic pyrolysis technology. It solves the technical problem of clogging the pipeline with wax oil and ensure the continuous and stable operation of the equipment. At the same time, it is helpful to improve the yield and quality of pyrolysis oil.
How long does the tyre pyrolysis process take?
Batch type: feeding 3h + pyrolysis 11h + cooling down 7h + discharging 3h, about 24 hours per batch;
Semi-continuous: feeding 1.5h + pyrolysis 8h + cooling down 2h + discharging 2h, feeding again 1.5h + pyrolysis 6h + cooling down 2h+ discharging 2h, about 3 days every two batches;
Fully continuous: continuous feeding and discharging + pyrolysis 2h, running 24 days per month.
What are the safety designs of Beston pyrolysis machine?
Keep sufficient safety distance between the reactor and the oil tank;
The pyrolysis syngas is burned as fuel, and a safety hydro-seal system is set up to prevent safety accidents caused by back fire;
The PLC control system is designed with a temperature and pressure safety threshold alarm system;
The feeding system of the fully continuous production line is designed with a nitrogen seal to isolate the air;
There are special pressure relief and cooling devices;
The oil storage tank is designed with a liquid level alarm system.
What are the environmental-friendly advantages of Beston pyrolysis plant?
No sewage discharge; the heat exchange water source of the condenser is separated from the oil and gas. And water source does not directly contact with the oil and gas; The water inside the water seal can also be discharged into the combustion chamber when the fuel is burned to provide heat for the reactor;
The excess non-condensable combustible gas has a special exhaust combustion chamber, which will not be directly discharged into the air;
The exhaust gas reaches the EU emission standard after being treated by the de-dusting system.
Is it possible to use an electric heating system?
Firstly, we do not provide electric heating system. Secondly, as far as we know, the cost of electric heating systems is very high. Thirdly, the power consumption per hour is huge. Taking BLJ-16 equipment as an example, it needs to consume about 1000kw per hour. Fourthly, the heat loss of electric heating is relatively large.
How many workers are required to operate the equipment?
A normal class of 3-5 staff.
What are the features of the smallest model - BLJ-3 skid-mounted pyrolysis plant?
1.The structure of BLJ-3 model is compact and space-saving, which is convenient for transportation. As the skid-mounted type adopts intensive layout and compact layout, the land occupation can be greatly reduced, which is of great significance to the oil and gas industry that occupies a large amount of land;
2.It is convenient for demolition and movement. The skid-mounted device has the characteristics of demolition and relocation, and is especially suitable for installations in the oil and gas industry, which can avoid blind construction of factories and installations;
3.Indoor work. Most of the work is done in the manufacturing factory, and the on-site installation only requires the installation of the skid to the foundation, the connection of the inlet and outlet pipelines, and the wiring of some electrical instruments, which greatly reduces the on-site workload and installation time.
Do you support custom colors or logos?
What is the comparison of semi-continuous type and batch type?
Semi-continuous pyrolysis equipment is actually batch equipment plus automatic feeding (spiral) and three water-cooled slag dischargers. The tire needs to be pre-treated to the state of rubber powder in advance. Be careful not to have steel wire in it, otherwise the slag outlet will be blocked. Secondly, the three water-cooled slag production can basically achieve carbon black production in two hours. The normal cooling situation takes seven hours, saving five hours.
How long is the warranty?
One year, but we provide lifetime technical service.
How long is the service life of Beston pyrolysis plant?
5-8 years. After 5-8 years, it only needs to replace reactor.
How long is the production cycle of Beston pyrolysis plant?
The normal production cycle of batch and semi-continuous pyrolysis equipment is 40 working days; the fully continuous pyrolysis plant is 60 working days; the production cycle of BLJ-3 skid-mounted type is 30 working days.
How long is the installation cycle of Beston pyrolysis plant?
The normal installation period of batch and semi-continuous pyrolysis plant is 45 working days; the installation period of fully continuous pyrolysis equipment is 45 working days; the installation period of BLJ-3 mobile type is 15 working days.
How to install the pyrolysis equipment?
At present, Beston Group provides customers with two installation methods: online installation and offline installation.
Our after-sales team can provide 24-hour online installation service, and we can also arrange engineers to the customer site for installation guidance if the customer requires it.
What should I do if there is a problem after the plant was installed?
Don’t worry, friend. We have a professional after-sales team to connect with you throughout the process, and will help you to solve problems from beginning to the end.
About Starting Project
What do I need to prepare before starting a pyrolysis project?
1. Confirm the source and cost of local raw materials (tyre/plastic/oil sludge);
2. Confirm the oil prices, sales channels or applications;
3. Prepare an industrial land and project fund;
4. Consulting local EPA (environmental protection agency) or PCB (pollution control board) to get license. After they tell you what things are needed, we will send you relevant documents to assist you in getting the license;
5. Consulting whether there is any governmental subsidy/support for this environmental project in your city.
Is pyrolysis plant profitable? Can I make money by investing in a pyrolysis plant?
Yes. Taking BLJ-16 waste tyre pyrolysis plant in Europe as an example, the ROI is here. You can see that the project can make you return your cost back and start making money quickly.
|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|
|From Port to Site||Set||5,800||1||5,800|
|Installation||Beston technician's salary||Day||350||50||17,500|
|Local welder||Day||120||100||12,000||2 welders are needed|
|Materials||Installation materials ready||Set||5,200||1||5,200||Foundation, pipe, etc.|
|Licenses||/||Ea||2,000||1||2,000||Environmental, firefighting, etc.|
|Operating Cost||Raw Materials||Waste tyre||Ton||0||12||0|
|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|
|Monthly Income||Working day||Day||25||$90,081.17|
|Yearly Income||Working day||Day||300||$1,080,974.00|
What's the price of Beston pyrolysis plant?
Beston pyrolysis plant price starts from $38,000. If you want the detailed quotation, please contact us by leaving your message.
What are the application scenarios of pyrolysis plant?
Alternative fuel for cement plants, boiler plants, brick plants, ceramic plants, power plants, ships and other industrial plant;
Large scrap tires/plastic recycling;
Oil sludge /oil soil remediation…