Oil sludge pyrolysis plant is rapidly becoming the preferred solution for treating oily waste. In the global petroleum industry, oil sludge is ecologically harmful and expensive to treat. Pyrolysis technology decomposes oil sludge through high temperatures. This method not only effectively reduces the volume of waste, but also obtains valuable pyrolysis oil. More importantly, oil sludge, a hazardous waste, can be treated harmlessly. Therefore, the machine’s unique environmental and economic benefits make it popular among investors.
Oily Waste Treated by Oil Sludge Pyrolysis Plant
Oil Extraction
- Oil-based Drilling Cuttings: generated during oil drilling, containing oil-based drilling fluid, rock cuttings and silt, with complex composition and high oil content.
- Operational Sludge: generated during oilfield maintenance operations. Contains oil, water, silt and chemical additives, etc.
Oil Storage & Transportation
- Tank Bottom Sludge: from the bottom sediment of crude oil storage tanks. Contains heavy oil, water, silt and metal impurities.
- Oil-contaminated Soil: formed by the mixture of crude oil leakage and soil, silt, etc. Contains high concentration of oil and environmental impurities.
Oil Refining
- Oil-water Separation Sludge: from the oil-water separator of the refinery. Contains oil, water and suspended solids, as well as some heavy metals.
- Floating Sludge: formed when flotation is used to treat refinery wastewater. Contains floating oil and fine suspended matter.
Pyrolysis of Oil Sludge Analysis: Material Composition Perspective
Main Components of Oil Sludge
To understand the reaction mechanism of oil sludge treatment plant, we must first understand its material composition. As hazardous waste originating from oil extraction, storage and refining, its composition is quite complex. The main components of oil sludge include:
- Moisture: Unlike the pyrolyzed raw materials for plastics and tyres, oil sludge has a higher moisture content. Usually the proportion ranges from 10% to 70%.
- Oil Residue: Oil sludge contains petroleum hydrocarbons like alkanes, olefins, and PAHs. It also includes long-chain organic compounds, such as paraffin and asphaltenes. Usually the proportion ranges from 5% to 40%.
- Solid: Minerals, metal oxides and other inorganic substances are residual components in oil sludge. They do not undergo significant chemical changes during pyrolysis.
Material Changes in Oil Sludge Pyrolysis Process
Oil sludge pyrolysis occurs in a high-temperature, oxygen-free environmen. Then, the complex organic matter in the sludge undergoes thermal decomposition under closed conditions. This process breaks the molecular bonds of long-chain compounds, forming simpler hydrocarbons. Such a thermal desorption process generates three main products:
Pyrolysis Oil
This clean fuel is derived from the pyrolysis of light and heavy hydrocarbons. It mainly contains some short-chain alkanes, alkenes, and aromatic hydrocarbons. It has the following main uses:
- Used as fuel for industrial boilers, kilns, etc.
- Further distillation into non-standard diesel.
Syngas
Syngas comes from the non-condensable components of small molecular hydrocarbons formed by pyrolysis It includes methane, ethylene, hydrogen, etc. It has the following main uses:
- Used as an alternative fuel to power the burners of pyrolysis plant.
Solid Residue
After oil and gas are formed and released from oil sludge pyrolysis plant, the remaining inorganic minerals constitute solid residue. Solid residue is often used to add to building materials:
- Used in the production of permeable bricks
- Used as oil well anti-collapse agent
2 Types of Oil Sludge Pyrolysis Plant for Sale
There are 2 main types of oil sludge pyrolysis plants, namely batch and continuous pyrolysis equipment. These 2 types of equipment have their own characteristics in terms of treatment methods, production capacity and operational complexity.
- Batch Type: It has many production line configuration options and flexible capacity. It is suitable for medium-scale production;
- Continuous Type: It has greater processing capacity and automation. It is suitable for large-scale industrial production.
The following are the detailed parameters of each type of equipment:
| Model | BLJ-16 Standard | BLJ-16 TDU | BLJ-16 ULTRA | BLL-30 |
| Manufacturer | BESTON | BESTON | BESTON | BESTON |
| Time to Market | 2013 | 2013 | 2022 | 2024 |
| Motor Brand | Chinese brand | Chinese brand | ABB Explosion-proof | Chinese brand |
| Suitable Raw Materials | Oil soil with liquid content<30% | Oil sludge; Landing oil sludge; Drilling waste; Tank bottom oil sludge | Waste plastics; Tires; Oil sludge | Waste plastics; Tires; Oil sludge |
| Input Capacity (Max.) | 16-18t/batch | 16-18t/batch | Waste plastic bales: 8-10t/batch Whole tire <120cm or Tire blocks<15cm: 10-12t/batch Sidewall removed tire: 15-16t/batch Oil sludge: 16-18t/batch | Waste plastic pellets: 0.8-1.05t/h Rubber powder: 1.25-1.5t/h Oil sludge:1.8-2.3t/h |
| Working Method | Batch | Batch | Batch | Fully Continuous |
| Final Oil Quality | Pyrolysis oil | Pyrolysis oil | Pyrolysis oil Pyrolysis oil with wax or naphtha | Pyrolysis oil Pyrolysis oil with wax or naphtha |
| Reactor Materil | Q345R Boiler steel | 304 Stainless steel | 304 Stainless steel | 304/310S Stainless steel |
| Reactor Life Span (Years) | 2-3 | 5-8 | 5-8 | 5-8 |
| Guarantee (Months) | 12 | 12 | 12 | 12 |
| Delivery Time (Calendar Days) | 45 | 60 | 90 | 150 |
| Land Space Required (L*W*H*m) | 33*13*8 | 33*13*8 | 33*26*8 | 70*20*10 |
| Packing | 1*40FR+3*40HQ | 1*40FR+3*40HQ | 1*40FR+8*40HQ | 20*6*3m in bulk+13*40HQ |
| Installation Period (Calendar Days) | 45 | 45 | 60 | 90 |
System Components and Functions of Oil Sludge Treatment System
Pyrolysis Reaction System:
- Components: drive system, burner, main furnace, casing
- Function: The burner provides the necessary heat for the main furnace to maintain the reaction temperature. Under high temperature, the oil sludge decomposes into oil gas. The drive unit rotates the pyrolysis reactor to ensure uniform heating. The insulation filler in the casing reduces heat loss of the oil sludge pyrolysis plant .
Oil Gas Condensation System:
- Components: manifold, residual oil tank, condenser, oil storage tank, water seal
- Function: Oil gas enters the manifold where impurities are separated. The remaining oil gas flows into the condenser, where cooling water converts the condensable components into pyrolysis oil. It then falls into the oil storage tank. Non-condensable components purified by the water seal form syngas. It re-enters the reactor to provide heat source.
Solid Discharge System:
- Components: screw conveyor, water-cooled screw extractor
- Function: After the pyrolysis reaction, high-temperature solid residue remains in the main furnace. The screw conveyor transports this residue to the water-cooled screw extractor, where it cools in three stages to a temperature of 50℃-80℃.
Tail Gas Treatment System:
- Components: flue condenser, spray tower, chimney
- Function: After the reaction, high-temperature exhaust gas first cools in the flue condenser. The cooled gas then passes through the spray tower for dust removal. Finally, the clean exhaust is discharged through the chimney. We provide high-end exhaust gas treatment facilities to ensure compliance with EU emission standards.
Structure of Oil Sludge Treatment Plant
Structure of Oil Sludge Treatment Machine
Oil Sludge Treatment Process: 3D Video Demonstration
To give you a better understanding of the detailed process of oil sludge pyrolysis plant, a comprehensive 3D video demonstration is provided below. Thus, you can understand each step from feed to final product in a process-oriented way. For more information on pyrolysis, please visit our YouTube channel!
Advantages of Beston Oil Sludge Pyrolysis Plant
Safety Protection System:
Before and after the reaction, the nitrogen system introduces inert nitrogen into the main furnace to remove excess oxygen and pyrolysis oil gas, preventing flash explosions. Additionally, when overpressure occurs, the main furnace automatically opens the safety valve to release pressure, avoiding equipment failure due to overpressure.
Unique Sealing Design:
Oil sludge pyrolysis reactor adopts a combined floating seal made of carbon fiber and high-temperature soft filler. Compared to traditional graphene filler seals, it is more resistant to high temperature, corrosion, and wear, ensuring the system’s sealing performance and long-term stable operation.
Advanced Heating Method:
The hot air heating method ensures more uniform heating and precise temperature control. Compared to traditional direct heating, it is more energy-saving and environmentally friendly. It also reduces energy consumption by 20%-30% while enhancing the safety and efficiency of the oil sludge treatment plant.
Anti-coking Design:
In the batch system, the material rotates synchronously with the friction block, improving thermal conductivity and slowing down coking. The continuous equipment uses hot air heating combined with high-temperature catalysts to prevent coking from overheating. Additionally, a mesh chain friction structure is included to efficiently remove coke.
Projects of Beston Oil Sludge Pyrolysis Machine All Over the World
Beston Group‘s waste oily sludge treatment system has been installed in 10+ countries, including China, Nigeria, Oman, Libya, South Sudan, Uganda, etc. Customers use these equipment to harmlessly treat oily sludge and obtain pyrolysis oil resources. Beston engineers have assisted some customers with installation. The installation process, commissioning and post-operation were smooth.See some projects here.
After-sales Service is to Serve Customers in an All-round Way
To help customers install and operate equipment smoothly, Beston Group provides a range of after-sales services.
- Beston Group provides customers with various design drawings, including PID drawings, site layout drawings, etc.
- The professional installation team guides customers in installation and debugging online or on-site.
- The after-sales management team provides customers with after-sales operation technical answers online.
- Beston Group will provide customers with free lifetime product software upgrades.
Oil sludge pyrolysis plant for sale is able to process non-degradable oil sludge in an eco-friendly way. Beston Group offers customized service in terms of parts and layout design. The final dedusting effectiveness also can be strengthened as your requirement. Just tell us your demand.
