Plastic pyrolysis plant is emerging as a transformative solution in addressing the global plastic waste crisis. This advanced technology enables the conversion of waste plastics into valuable fuel oil through advanced catalytic pyrolysis process. As the world seeks sustainable methods to combat plastic pollution, plastic pyrolysis machine stands out as a promising solution. It creates alternative energy options and mitigates environmental impact. Read on, you will learn the technological advancements of this modern equipment in plastic recycling field.
Plastic Pyrolysis Plant: Multi-system Integrated Recycling Facility
The plastic pyrolysis machine realizes the multi-phase resource collection of waste plastics, including plastic pyrolysis oil, syngas, and industrial residue. It is an integrated equipment including multiple systems such as feeding, reaction, condensation, discharge, and gas treatment. From the perspective of composition structure, the machine can be divided into 2 categories: continuous type and batch type. They correspond to different processing capacities and operating modes. The following is parameter table and main component diagram for your reference.
Continuous Type: BLL-30
- Large-scale choice: process 6,000 tons annually
- 30 day continuous operation
- High automation: two operators required
- Policy support and incentives
- Easy to get environmental compliance and project approval
Batch Type: BLJ-16
- Small-scale choice: process 3,000 tons annually
- 1 furnace/day
- 3 Configuration options
| Model | BLJ-16 WAX | BLJ-16 CAT | BLJ-16 ULTRA | BLL-30 |
| Manufacturer | BESTON | BESTON | BESTON | BESTON |
| Time to Market | 2022 | 2022 | 2022 | 2024 |
| Motor Brand | Chinese brand | Chinese brand | ABB Explosion-proof | Chinese brand |
| Suitable Raw Materials | Waste plastic bales (Max.0.9*0.9*1.6m) | Waste plastic bales (Max.0.9*0.9*1.6m) | Waste plastics; Tires; Oil sludge | Waste plastics; Tires; Oil sludge |
| Input Capacity (Max.) | 8-10t/batch | 8-10t/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 with wax | Pyrolysis oil with naphtha | Pyrolysis oil Pyrolysis oil with wax or naphtha | Pyrolysis oil Pyrolysis oil with wax or naphtha |
| Reactor Materil | 304 Stainless steel | 304 Stainless steel | 304 Stainless steel | 304/310S Stainless steel |
| Reactor Life Span (Years) | 5-8 | 5-8 | 5-8 | 5-8 |
| Guarantee (Months) | 12 | 12 | 12 | 12 |
| Delivery Time (Calendar Days) | 60 | 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*20GP | 1*40FR+8*40HQ | 20*6*3m in bulk+13*40HQ |
| Installation Period (Calendar Days) | 45 | 45 | 60 | 90 |
Plastic Catalytic Pyrolysis Technology – 200% Efficiency Boost
Plastic catalytic pyrolysis is a technology that solves the wax oil blockage problem through the action of a catalyst. This technology introduces a catalytic tower at the manifold. Molecular sieve catalysts and Bauer ceramic rings are placed in the catalytic tower. Oil gas from the pyrolysis reactor contacts it. The catalytic action not only solves the wax decondensation and liquefaction problem, but also increases the reaction efficiency 200%. This technology creates the following core values:
Optimize Project ROI
- Increase Oil Value: Wax oil is a long-chain hydrocarbon, which is easy to solidify and clog in pipeline. After catalytic liquefaction, it forms a low-freezing point light oil product. It has higher calorific value, better clarity, and higher market value.
- Low Maintenance Cost: Removing wax oil avoids maintenance and shutdown of plastic pyrolysis plant. This significantly reduces maintenance frequency and labor costs. Meanwhile, it reduces production capacity losses caused by downtime.
Improve Safety Performance
- Prevent Overpressure Risk: There is no wax or oil solid deposition in the pipeline. Therefore, the system pressure is stable and controllable. This avoids the risk of sudden pressure increase, pipeline rupture or leakage caused by blockage.
- Eliminate Local Overheating: There is no wax attached to the pipeline wall. Therefore, the system temperature is evenly distributed. This reduces the thermal stress and fatigue damage of components caused by local high temperature.
Continuous Plastic Pyrolysis Machine – 6,000 Tons/Year Processing Capacity
Continuous plastic pyrolysis plant offers an efficient and sustainable solution for plastic waste management. It ensures continuous operation, maximizing output and minimizing downtime. With features like automated control and energy recovery, it reduces environmental impact and enhances efficiency. Below are the technical advantages of the Beston BLL-30 continuous plastic to fuel machine:
Anti-polymerization Condensation
Spray condensation technology can quickly reduce the oil and gas temperature. This effectively inhibits the secondary polymerization of olefins from clogging the pipeline, ensuring continuous operation for 30 days without stopping.
Hot Flue Gas Reuse
The high-temperature resistant induced draft fan draws 80% of the high-temperature flue gas from the furnace. It is evenly mixed with 1000-1300 °C hot air and used to heat the reactor, saving 55% of energy consumption.
Air Preheating
20% of the high-temperature flue gas enters the combustion chamber after heating the combustion air through the waste heat recovery device. This reduces the fresh air heating load and reduces exhaust emissions by 50%.
Automatic Temperature Control
The multi-media automatic combustion valve group operates in conjunction with the hot air system. Accurate temperature control of ±10 °C is achieved by adjusting the fuel-air ratio, thereby greatly reducing manual intervention.
Plastic Pyrolysis Plant Creates Multiple Value: 3 Types Oil Collection
Pyrolysis Oil
Pyrolysis oil has a high calorific value and low viscosity. Therefore, it can be used directly as fuel oil. This oil is widely used in places with high energy demand such as boilers and industrial heating equipment.
Naphtha
Naphtha is a light hydrocarbon liquid obtained by distillation of pyrolysis oil. This oil has a high olefin content. It is mainly used in petrochemical industry, especially in production of polymers, synthetic rubber, etc.
Non-standard Diesel
Non-standard diesel is a fuel oil obtained by distillation of pyrolysis oil. This oil has high-density and good combustion performance. It is suitable for non-road machinery, generator sets and other equipment.
Acceptable Range of Waste Plastics for Plastic Pyrolysis Machine
As a high molecular polymer, plastics come in many different types. Therefore, waste plastics are generated in various industries. However, not all plastics are suitable for waste plastic pyrolysis plant. The following is an analysis of common plastic types and their suitability for plastic to oil plant:
PET
- Oil Yield: 0%;
- Sources: transparent bottles, mechanical parts, fiber products, etc.
- Feature: No oil is produced during the plastic-to-oil process. Additionally, the oxygen produced by the reaction poses a safety hazard.
HDPE
- Oil Yield: 85%~95%;
- Sources:daily necessities containers, pipe fittings, household items,etc.
- Feature: high tensile strength, corrosion resistance.
PVC
- Oil Yield: unstable;
- Sources: wire insulation, municipal pipes, outdoor building materials, etc.
- Feature: oil obtained from PVC contains chlorine. Burning oil produces dioxins.
LDPE
- Oil Yield: 85%~95%;
- Sources:packaging films, bags, disposable tableware, etc.
- Feature: low strength, good flexibility.
PP
- Oil Yield: 80%~90%;
- Sources:food packaging, medical supplies, household products, etc.
- Features: good heat resistance, chemical corrosion resistance.
PS
- Oil Yield: 80%~90%;
- Sources: disposable tableware, lightweight casings, crafts, etc.
- Features: Good formability, meets food grade certification standards.
ABS
- Oil Yield: 40%;
- Sources: Electrical appliance shell, daily necessities, advanced toys, etc.
- Features: good mechanical properties, easy to paint and print.
Note:
- Plastics containing halogen elements and oxygen elements are not recommended for pyrolysis treatment;
- We can assist in testing the plastics you have and determine the feasibility of the project;
- The simpler the type of plastic, the purer the plastic, the higher the pyrolysis oil yield.
Here are some common plastic oil yields for your reference:
Engineering Perspective of Plastic Pyrolysis Equipment Operation
01 Plastic Material Feeding
- Use a hydraulic feeder or a screw feeder (for plastic pellets after granulation) to feed the plastic raw materials into the equipment. Subsequently, remove the feeder and close the locked furnace door.
02 Plastic Pyrolysis Oil Collection
- Start the main furnace and preheat it. Fuel options include diesel, natural gas, heavy oil or pyrolysis oil.
- After preheating, feed the material. Then, when the temperature of the plastic pyrolysis reactor rises to about 100°C, the plastic is thermally decomposed to produce oil gas.
- Next, the high-temperature oil and gas enter the catalytic tower. Then, it contacts the catalyst and bauer porcelain rings.
- After passing through the catalytic tower, the high-temperature oil gas enters the condenser. Finally, it condenses into liquid oil and enters the oil storage tank.
03 Gas Recovery
- Uncondensed pyrolysis gas re-enters into the burner as heating fuel for the plastic pyrolysis plant, saving fuel consumption.
- For hot air heating system, high temperature flue gas re-enters the combustion chamber for waste heat utilization.
04 Waste Gas Treatment
- The exhaust flue gas generated by the catalytic tower and the main furnace merges and enters the flue condenser for cooling.
- The cooled flue gas enters the spray tower for dust removal and then is discharged into the atmosphere through the chimney.
- We provide high-end exhaust gas treatment system(BLL-30 is standard). The flue gas treated by this system can meet EU emission standards.
05 Solid Residue Discharge
- After the pyrolysis process is completed, the burner is turned off, the main furnace and the fan continue to operate, and the temperature is naturally reduced for 7-8 hours.
- Discharge the solid residue using water-cooled screw conveyor. If you want to achieve rapid cooling, we provide a multiple screw conveyor solution.
Application Solutions of Plastic Pyrolysis Oil for Making Benefits
Industrial Energy Supply
- Pyrolysis oil can be used for combustion energy supply in boilers and industrial kilns. Thus, it can produce efficient and clean heat energy.
- Also, pyrolysis oil can directly used in the burner of the plastic pyrolysis machine to provide energy for the system.
Sustainable Chemical Materials
- Naphtha can serve as production of basic chemicals like ethylene, propylene etc., which can further processed into plastics, synthetic fibers etc.
- Due to its good dissolving power, naphtha can serve as paints, coatings, cleaning agents and industrial solvents.
Higher Standard Fuel Substitution
- Non-standard diesel can serve as fuel for heavy machinery engines and heavy oil generator set.
- Naphtha can serve as a blending component of gasoline to improve performance indicators.
- Some types naphtha can serve as raw material to produce kerosene and jet fuel.
Investment Opportunities in Plastic Pyrolysis Plant Across Industries
Plastic Products Processing
- Promote Circular Economy: Pyrolysis oil, as a clean energy, can be directly used as fuel in the processing of plastic products, replacing traditional energy sources. Thus, this reduces the energy cost and carbon footprint of enterprises. Waste plastics re-enter the production cycle through pyrolysis, promoting the circular economy of the plastic industry.
- Promote Industrial Linkage:Plastic pyrolysis plant can provide alternative raw materials for polymer production and re-enter the resource cycle. This “product” to “raw material” model promotes resource sharing in the upstream and downstream industries of plastics. Such a two-way cooperation helps promote the green transformation of the entire plastic industry chain.
Domestic Waste Disposal
- Reduce Land Occupation: The domestic waste treatment industry has traditionally relied on landfilling for the treatment of plastics. This method requires a lot of land resources. In contrast, plastic pyrolysis equipment can effectively convert waste plastics into smaller energy or chemicals. Therefore, this avoids occupying a large amount of land for stacking or disposal.
- Reduce Plastic Pollution: In the traditional landfill or incineration process, waste plastics often fail to be effectively utilized as resources, resulting in the long-term existence of pollution sources. Plastic pyrolysis technology avoids the risk of plastic pollution entering the natural environment. This promotes the waste treatment industry to develop in a greener direction.
Plastic Recycling Center
- Broaden Recycling System: The existing waste plastic recycling system has limited effect on some waste plastics that are difficult to recycle or have low value. After the introduction of plastic pyrolysis equipment, these waste plastics can be converted into valuable pyrolysis products. Thus, this broadens the recycling channels and improves the overall recycling rate.
- Broaden Income Channels: The income of traditional recycling centers mainly depends on the recycled waste plastic raw materials. Under the effect of pyrolysis technology, the recycling center can turn the difficult-to-recycle waste plastics into valuable resources. This not only increases the source of income, but also further improves profitability by selling these by-products.
How Plastic Pyrolysis Machine Meets Policy Challenges
As global environmental policies continue to tighten, plastic pyrolysis process is becoming a key technology to cope with policy challenges and promote green transformation. The following are the specific advantages of plastic pyrolysis plant in the face of environmental regulations and policy challenges:
Accelerate Global Emission Reduction
Plastic pyrolysis meets the needs of more and more environmental regulations through the process of efficiently converting waste plastics into energy.
- The EU’s carbon emission trading system (EU ETS) encourages the use of low-carbon technologies, and pyrolysis technology has become an effective tool for enterprises to reduce emissions by reducing GHG emissions when incinerating plastic waste.
- Plastic pyrolysis equipment meets environmental protection standards by reducing greenhouse gas emissions. This can bring carbon offsets to enterprises. It earns revenue in the carbon trading market and helps enterprises reduce carbon tax costs.
Relieve Corporate Policy Pressure
Enterprises are facing increasingly severe environmental compliance pressure. Fortunately, plastic pyrolysis technology provides solutions that comply with environmental regulations.
- Pyrolysis converts waste plastics into renewable energy. This not only helps companies effectively reduce the impact of plastic waste on the environment. The technology can also reduce corporate processing costs and increase resource utilization efficiency.
- The government is paying more and more attention to plastic processing. If companies fail to handle waste plastics in accordance with regulations, they may face high fines and tax penalties. Pyrolysis technology effectively avoids these potential risks.
Promote Green Transformation
Plastic pyrolysis technology is highly consistent with the strategic direction of promoting green economy and low-carbon technology in countries around the world:
- Plastic pyrolysis technology can promote the use of clean energy, reduce dependence on traditional fossil energy, and provide new impetus for technological innovation in industries such as energy, environmental protection, and circular economy.
- Pyrolysis technology is also continuing to promote the development of a low-carbon economy, helping companies and countries cope with global climate change, and promoting the sustainable development of energy, environmental protection, and circular economy.
Beston Group’s Plastic Pyrolysis Solutions Wordwide
As a leader in the plastic pyrolysis recycling industry, Beston Group‘s solutions and equipment are spread all over the world. With advanced technology and excellent product quality, we assist global customers in successfully implementing plastic recycling projects. These projects help customers achieve efficient recycling and reuse of plastic waste. At the same time, this also accelerates the advancement of global plastic sustainable recycling goals. The following are some of Beston Group’s successful cases around the world:
Contact Beston to Get Plastic Pyrolysis Solution and Machine!
Beston plastic pyrolysis plant environmentally converts these waste plastics into usable pyrolysis oil and other by-products. Beston Group aims to be a provider of plastic recycling solutions. We have established partnerships with multiple companies and are committed to sustainable development and mitigating climate change by implementing a circular economy for plastics. This chemical recycling method allows for the 100% recovery of plastics and provides them with a second life cycle. If you are interested in this solution, please contact us as soon as possible.
