1. Challenges Faced
The project is located in Southeast Asia, where the client operates industrial incineration systems that rely heavily on auxiliary fuels. In daily operation when treating plastics and oil sludge, the client has long faced two major challenges:
- High fuel costs: Conventional auxiliary fuels are expensive and subject to price volatility. It significantly increasing the long-term operating costs of the incineration system and compressing the project’s overall economic margins.
- Significant environmental impact: Direct incineration of large volumes of oil sludge and medical plastic waste can result in the emission of harmful exhaust gases. With increasingly stringent local environmental regulations, the client faces a tangible risk of non-compliance penalties.
Driven by both cost pressure and environmental requirements, the client urgently needed an alternative solution capable of balancing economic efficiency with environmental performance.
2. Goals for Change
The client aimed to introduce pyrolysis equipment to establish a “resource recovery first, incineration second” treatment pathway, addressing fuel and environmental challenges while improving overall project economics.
- Reduce fuel costs: Convert plastics and oily sludge into pyrolysis oil for use as an alternative fuel in incineration systems, partially replacing conventional fuels and lowering overall operating expenses.
- Reduce environmental impact: Shift from direct incineration to a combined pyrolysis–incineration process, enabling controlled material conversion and improved emissions performance under strict regulatory requirements.
- Create additional revenue streams: Sell surplus pyrolysis oil to external markets when internal demand is met, generating extra income and further enhancing the project’s economic returns.
3. Action and Solution
After fully understanding the client’s feedstock characteristics, processing capacity requirements, and environmental compliance standards, Beston Group delivered a targeted, integrated solution for this project.
- Equipment configuration: The project adopted 3 sets of BLJ-16 oil sludge & plastic pyrolysis plant. The equipment adopts screw feeding systems, multi-stage water-cooled slag discharge, and 3-in-1 condensation system. This configuration ensures both sufficient processing capacity and long-term operational stability.
- High-standard exhaust gas treatment system: A high-configuration off-gas treatment system was included to ensure that exhaust gases generated during the pyrolysis process fully comply with local environmental regulations.
In addition, Beston Group provided full-lifecycle project support, covering everything from solution planning to final delivery. Through this systematic delivery model, we ensured smooth project implementation and rapid transition into stable commercial operation.
4. Project Outcomes
All three BLJ-16 pyrolysis units were commissioned smoothly and have achieved stable, continuous operation. The project has delivered significant and measurable results:
- Enhanced solid waste treatment capacity: The project now processes more than 10,000 tons of oily sludge and plastic waste annually. It substantially reduces the load on direct incineration.
- Effective operating cost reduction: Pyrolysis-derived fuel is used as an alternative fuel for incineration systems. It significantly lowers the client’s overall fuel cost.
- Improved environmental performance: By combining pyrolysis technology with high-standard exhaust gas control, the project demonstrates a high level of environmental responsibility. Also, full regulatory compliance is maintained throughout operation.
