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.
A Microscopic Perspective on Plastic Pyrolysis
Plastics are derived from hydrocarbons extracted from fossil fuels, such as ethylene, propylene, benzene, etc. These chemical base monomers are formed into long-chain polymers, plastics, through polymerization reactions. In essence, pyrolysis process is to break the chemical bonds of plastic polymer chains in a micro-oxygen high-temperature environment. As a result, short-chain hydrocarbon molecules escape from the original plastic matrix. In short, plastic pyrolysis forms the following products:
- Pyrolysis Oil: a condensable liquid mixture of short-chain hydrocarbons;
- Syngas: non-condensable hydrocarbon molecules;
- Solid Residue: carbon black and incompletely decomposed industrial solid residues.
Plastic Pyrolysis Plant: Multi-system Integrated Recycling Facility
The plastic pyrolysis plant realizes the multi-phase resource collection of waste plastics, including liquid (plastic pyrolysis oil), gas (syngas), and solid (industrial residue containing carbon black). It is an integrated equipment including multiple systems such as feeding, reactor, condensation, discharge, and gas treatment. From the perspective of composition structure, the plastic pyrolysis 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.
Batch Model: BLJ-16
- Suitable for medium-scale plastic recycling;
- Flexible feeding, condensation, and discharge configuration options are available;
- Intermittent production mode with one furnace per day.
Continuous Model: BLL-30
- Suitable for large-scale plastic recycling;
- Automatic feeding and three water-cooled slag discharges enable 24-hour continuous production;
- A high-end exhaust gas treatment system is standard.
Parameter Table of Plastic Pyrolysis Plant for Sale
| Model | BLJ-16 | BLL-30 | |
| Capacity | 12-16t/d | 30-35t/d | |
| Working Process | Batch | Fully continuous | |
| Reactor Size | φ2800*7100mm | φ1800*18500mm | |
| Reactor Material | Q345R | 310S stainless steel | |
| Drive System | 500 reducer+7.5kw drive motor | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 33m*13m*8m | 70m*20m*10m | |
| Power | 55.6kw | 256kw | |
| Burner | 2*400,000 kcal | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 34.5t | About 150t | |
| Number of Containers | 1*40FR+2*40HQ | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | ||
| Condensing System | Vertical Condenser | φ820*3600 Single piece condensing area 35.6m2 | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 8000*2260*2500 Condensing area 49.5m2 |
||
Main Component Diagram of Waste Plastic Pyrolysis Plant
Side A
Side B
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 pyrolysis. 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:
Wax Oil Nemesis: Catalytic Pyrolysis Technology
What is Wax Oil?
Due to the type of plastic and reaction conditions, the plastic pyrolysis process is prone to produce wax oil. Wax oil is a viscous, high-condensation-point substance composed of long-chain hydrocarbon compounds. These wax products gather or deposit in the plastic pyrolysis plant, resulting in pipeline blockage. Not only that, the long-chain & side-chain hydrocarbon components in wax oil will also have a negative impact on the quality of the final finished plastic pyrolysis oil, forming a viscous oil product.
Plastic Catalytic Pyrolysis Technology
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. It is worth mentioning that you can also reactivate the catalyst for reuse.
Engineering Perspective of Plastic Pyrolysis Equipment Operation
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.
01
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 oil and gas enter the shell and tube condenser. Finally, it condenses into liquid oil and enters the oil storage tank.
02
Syngas Recovery
- The uncondensed cracking gas is recovered through the liquid seal device for combustion in the main furnace to save fuel consumption.
- The excess syngas enters the exhaust chamber for combustion emission treatment.
03
Waste Gas Treatment:
- The high-temperature 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. The flue gas treated by this system can meet EU emission standards.
04
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 three-way screw conveyor solution
05
Application Solutions of Plastic Pyrolysis Oil for Making Benefits
Industrial Energy Supply
Plastic pyrolysis oil can be used for combustion energy supply in boilers and industrial kilns. Through direct combustion, it can produce efficient and clean heat energy. Thus, it provides the high-temperature heat source required for industrial production processes.
Sustainable Plastic Production
Plastic pyrolysis oil can be used as a raw material to replace traditional petrochemical products for the production of new plastics. Through further processing, the chemical components in pyrolysis oil can be used to manufacture a variety of plastic products.
Engine Fuel Substitution
After distillation, plastic pyrolysis oil can produce non-standard diesel. This fuel can be used as an alternative fuel for heavy machinery and large vehicle engines. Therefore, it provides a cost-effective energy solution for the transportation and industrial sectors.
Investment Opportunities in Plastic Pyrolysis Equipment 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 machine 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 to fuel machine 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.
Reasons for Choosing Beston Plastic Pyrolysis Machine
Plastic Pyrolysis Technology
Beston waste plastic treatment adopts gas-phase catalytic pyrolysis technology. This technology effectively solves the problem of clogging pipelines with wax oil. It ensures that the equipment can run continuously and stably. At the same time, it can also help to improve the oil yield of plastic cracking oil.
IOT Monitoring Technology
Beston plastic pyrolysis equipment can be equipped with IOT technology. It can realize intelligent data remote transmission and control. At the same time, the mobile terminal of the device realizes timely online monitoring of the Internet of Things. This system is convenient for customers to control the overall operation.
Integrated Control System
Beston plastic pyrolysis equipment has a high degree of automation control. The whole set of equipment can adopt PLC (standard BLL-30) and DCS remote control systems. They have data storage and download capabilities. High control efficiency will save manpower and improve the working environment.
Full-life Project Cycle Design
Beston provides supporting solutions for the entire project life cycle. Beston provides customers with tire oil distillation, purification technology, decolorization & deodorization technology and other pyrolysis technologies. In this way, Beston helps customers increase the value of end products. It also improves overall profitability by extending the industrial chain.
Eco-friendly Design
This equipment is environmentally friendly and discharges up to standard. The combustion exhaust gas is treated by environmental protection facilities to meet the emission standards. The carbon black is discharged by the water-cooling system to reduce dust pollution. This meets the customers’ local environmental policy requirements.
Product Value-added Services
Layout drawing design, installation drawing design and other drawing files are provided free of charge for customers according to customers’ site layout. At the same time, Beston provides system software upgrade services free of charge. This service could help customers save additional investment, including time cost, management cost, and technical cost.
See some pyrolysis FAQs here.
Beston Plastic Pyrolysis Machines to 80+ Countries
Beston pyrolysis equipment has been shipped to more than 80 countries. These countries include Argentina, Cyprus, Croatia, Italy, Morocco, South Africa, South Korea, Bangladesh, Netherlands, Botswana, Argentina, and so on. Beston not only provides mobile pyrolysis equipment and other types to customers in these countries, but also provides project plans and various documentation support. Please see the details of the case below.
Delivery of BLJ-16 Beston Plastic Pyrolysis Equipment to the Netherlands
Four sets of semi-continuous plastic pyrolysis equipment were sent to the Netherlands. Beston provided this customer with customized system (dust removal system) and document technical support services. As a result, this customer placed great trust in Beston.
Installation of BLJ-16 Beston Waste Plastic Pyrolysis Machine in Morocco
In Morocco, a customer installed Beston semi-continuous plastic pyrolysis plant this year. The customer was very concerned about the quality of the plastic pyrolysis oil. When you use Beston equipment, you don’t have to worry. Beston has the patented technology of plastic cracking, which can well solve the problem of wax oil and plastic oil quality. But after this customer understood this, he chose to cooperate with Beston. Under the online installation guidance of Beston engineers, the project was successfully installed. And, it’s working fine now.
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.
