Faced with the increasingly severe solid waste management crisis, the emergence of pyrolysis plant resolves this challenge. This equipment realizes the reduction, resource utilization and harmless treatment of waste. The machine adopts cutting-edge pyrolysis technology, which transforms waste into pyrolysis oil. This method of turning waste into treasure has gradually become the focus of the solid waste recycling industry. Therefore, investors regard pyrolysis machine as a promising investment option. Want to learn about the recycling potential of pyrolysis? Please read on.
Pyrolysis Technology: Giving Waste a Second Life
The term “pyrolysis” stems from the Greek words “pyro”(heat) and “lysis”(splitting). Therefore, “pyrolysis” can be explained as the thermal decomposition process that occurs under high-temperature conditions. For some wastes that seem to have lost their use value, such as oil sludge, waste plastic, and waste tyre, pyrolysis technology gives them a second life. Through pyrolysis plant, the structure of the hydrocarbon compounds in these waste transforms high molecules into low molecules. As a result, low-molecular hydrocarbons form liquid products (pyrolysis oil) and gaseous products (syngas), which are precious clean energy.
Why Oil Sludge/Plastic/Tyre are Suitable for Pyrolysis Treatment?
When selecting a raw material suitable for pyrolysis treatment, its hydrocarbon content is often considered. Raw materials rich in hydrocarbon compounds are more likely to produce large amounts of pyrolysis oil, syngas, and other end products. These end products have economic value. Especially, oil sludge, plastic, and tyre completely fit this need.
Oil Sludge
The oil sludge mainly comes from crude oil mining, gathering, transportation, and refining. It is mainly composed of unused petroleum components and various impurities. The petroleum component forms heavy hydrocarbon compounds. These compounds are easy to decompose during pyrolysis.
Plastic
Plastic manufacturing often derives hydrocarbon compounds from fossil fuels. These compounds form polymer chains through polymerization reactions to form plastics. Through plastic pyrolysis process, these hydrocarbon polymers can be efficiently broken down.
Tyre
Natural rubber and synthetic rubber are the main components of tyre. Natural rubber is an organic hydrocarbon compound. Meanwhile, synthetic rubbe, is made from the polymerization of hydrocarbon compounds found in fossil fuels. Therefore, tyre also decomposes efficiently during the pyrolysis process.
It is not difficult to see that the formation or manufacture of three types of waste all involve the consumption of fossil energy. However, pyrolysis technology has rediscovered the energy potential in these wastes. Therefore, oil sludge, plastic, and tyre are also the best options for pyrolysis treatment in terms of sustainability.
What is Pyrolysis Plant?
Pyrolysis machine is an efficient carrier of pyrolysis technology. It integrates a variety of facilities and can realize a series of functions such as raw material processing, pyrolysis reaction, product collection, and emission treatment. This integrated machine ensures both efficient recycling and eco-friendly production. In addition, to adapt to different production scales, the machine has multiple designs, including batch and continuous pyrolysis machine. The following are specific parameter information for your reference.
| Model | BLJ-16 Standard | BLJ-16 TDU | BLJ-16 WAX | BLJ-16 CAT | BLJ-16 ULTRA | BLL-30 |
| Manufacturer | BESTON | BESTON | BESTON | BESTON | BESTON | BESTON |
| Time to Market | 2013 | 2013 | 2022 | 2022 | 2022 | 2024 |
| Motor Brand | Chinese brand | Chinese brand | Chinese brand | Chinese brand | ABB Explosion-proof | Chinese brand |
| Suitable Raw Materials | Whole tire<120cm; Tire blocks<15cm; Oil soil with liquid content<30% | Oil sludge; Landing oil sludge; Drilling waste; Tank bottom oil sludge | 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.) | Whole tire <120cm or Tire blocks<15cm: 10-12t/batch Sidewall removed tire: 15-16t/batch Oil soil: 16-18t/batch | 16-18t/batch | 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 | Batch | Batch | Fully Continuous |
| Final Oil Quality | Pyrolysis oil | Pyrolysis oil | 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 | Q345R Boiler steel | 304 Stainless steel | 304 Stainless steel | 304 Stainless steel | 304 Stainless steel | 304/310S Stainless steel |
| Reactor Life Span (Years) | 2-3 | 5-8 | 5-8 | 5-8 | 5-8 | 5-8 |
| Guarantee (Months) | 12 | 12 | 12 | 12 | 12 | 12 |
| Delivery Time (Calendar Days) | 45 | 60 | 60 | 60 | 90 | 150 |
| Land Space Required (L*W*H*m) | 33*13*8 | 33*13*8 | 33*13*8 | 33*13*8 | 33*26*8 | 70*20*10 |
| Packing | 1*40FR+3*40HQ | 1*40FR+3*40HQ | 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 | 45 | 45 | 60 | 90 |
Multi-stage Working Process of Pyrolysis Machinery
Preheating & Feeding
Pyrolysis Oil & Syngas Formation
Exhaust Gas Disposal
Solid Residue Discharging
How to Expand Production Line of Pyrolysis Equipment?
Beston Group provides customers with comprehensive configuration value-added solutions. This means you can expand production line of your pyrolysis plant by adding additional components to the standard configuration. We offer the following options:
Tyre Pretreatment Equipment
For continuous tyre pyrolysis plant using spiral feed, the tyres need to be processed into rubber powder . Therefore, tyre pretreatment equipment is necessary. It can realize tyre disassembly, cutting, crushing and wire removal.
Oil Distillation Equipment
If you want higher quality end oil product, oil distillation equipment is essential. Through a distillation reaction, the equipment converts pyrolysis oil into non-standard diesel fuel. Non-standard diesel has higher usage value and commercial value.
Exhaust Gas Treatment Device
To cope with the high emission standards, we provide high-end exhaust treatment equipment. It consists of an electrostatic precipitator, an activated carbon dust collector, and a desulfurization and denitrification tower. The flue gas treated by this equipment can meet EU standards.
Pyrolysis Oil Production Rate When Using the Following Materials
Note:
- Oil sludge comes from many sources and has complex composition. As a result, its oil yield needs to be determined experimentally.
- If you plan to recycle waste through a pyrolysis plant. We recommend that you send samples for testing. In this way, our technical team can evaluate the feasibility of the project and provide the optimal configuration solution.
What are Usages of End Products Getting from Pyrolysis Unit?
Pyrolysis oil, synthesis gas, and solid residue (carbon black & sand) are the main end products of the pyrolysis reaction. In particular, tire pyrolysis plant also produces steel wire. They have a wide range of uses and also have good economic value.
| End Products | Raw Material | Usages |
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Oil Sludge |
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| Plastic | ||
| Tyre | ||
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Oil Sludge |
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| Plastic | ||
| Tyre | ||
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Plastic |
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| Tyre | ||
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Oil Sludge |
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Tyre |
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Cutting-edge Technology of Beston Pyrolysis Plant for Sale
Anti-Wax Oil Clogging
To address the wax oil clogging problem that may occur in plastic to oil machine, Beston Group has developed two process solutions:
- Gas Phase Catalytic Solution: Introduce a catalytic tower after the reactor. Catalyst solves the problem of wax condensation and liquefaction.
- Vertical Condensation Solution: Introduce an electrode boiler after the condensation system. This process realizes direct collection of wax oil and has a low cost.
Anti-Coking
Coking is also a major negative factor affecting pyrolysis efficiency. Different pyrolysis plants have corresponding anti-coking processes:
- Batch Type: The machine uses friction blocks to rotate with the equipment in the furnace at the same time as the raw This slows down coking while increasing thermal conductivity.
- Continuous Type: A mechanical chain is used inside the main furnace to clear coke. The hot air heating method solves the problem of local overheating. Thus, this prevents the material from coking.
Eco-friendly Emissions
- Waste Water: Water seal and spray tower evaporate the wastewater at high temperature in the exhaust chamber and furnace.
- Waste Gas: The emissions of high-temperature flue gas will meet standards after cooling and dust removal.
- Waste Residue: Water-cooled discharging method reduces dust pollution. In addition, no waste particles are discharged from the reaction.
Reliable Safety Facilities
- The machine is equipped with an emergency drain valve, anti-backfire device, flame arrester, and over-temperature and pressure alarm device. They all ensure safe operation.
- Beston Group has developed high-temperature flexible soft packing sealing technology. It greatly improves the high-temperature sealing performance of the equipment.
Intelligent Control Mode
- The equipment adopts PLC (standard on BLL-30) and DCS remote control system. They achieve highly automated control of equipment. Therefore, this operating mode achieves efficient control while saving labor costs.
- Customers can choose the Internet of Things control system. This technology can realize real-time online monitoring of the operating status of the pyrolysis process. Thus, this makes overall operation and control easier for customers.
Pyrolysis Plant Accelerates Sustainable Development Goals Achievement
SDG 7: Affordable and Clean Energy
SDG 12: Responsible Consumption and Production
SDG 13: Climate Action
SDG 14: Life Below Water
Considerations Before Setting up a Pyrolysis Oil Plant
Local Market Research
When assessing the development potential of a pyrolysis project in the local market, several aspects need to be considered:
- Analyze the stability of raw material supply. This includes assessing the type, quantity and sustainability of locally available waste.
- Investigate sales channels for pyrolysis products. This is to ensure there is sufficient market demand to support production of the project.
- Evaluate the project’s profitability cycle. This is to explore the feasibility of increasing the production scale of the pyrolysis plant in the future.
Safety and Environmental Impact Assessment
- Safety impact assessment involves assessing the impact a project may have on worker and public safety, such as fires, explosions and accidents.
- Environmental impact assessment includes an assessment of the impact a project may have on soil, water resources, air quality and ecosystems.
Beston Group’s equipment can be flexibly configured according to the policy requirements of different regions. This ensures compliance and sustainability of the project. In addition, we provide a variety of documents support to assist customers in completing assessment.
Infrastructure Construction
The establishment of a pyrolysis machine for sale requires full consideration of infrastructure construction, including waterways, circuits, fuel supply, etc. In addition, plant construction and layout planning of pyrolysis equipment are also essential. Beston Group provides relevant drawings and technical support. Therefore, customers can plan and build part of the infrastructure in advance before installation. This ensures a smooth installation of the equipment.
Relevant Personnel Arrangement
- The installation of equipment requires workers of different types of work to work together. This includes unloading, assembly, welding, etc. Beston Group provides installation manuals and engineer on-site guidance. This allows the installation to proceed smoothly.
- Project operation team is equally crucial. Our installation engineers assist customers in training professional operations teams. We ensure that our customer’s teams have the necessary skills and knowledge to successfully implement and operate the entire project.
Potential of Pyrolysis Plant for Sale in Global Markets
Policy-driven Market
Potential: High
Applicable Regions: Developed countries such as Europe and North America
Features:
- Policy Promotion: Policy-driven markets usually have strong environmental regulations, such as carbon emission restrictions and plastic bans. This promotes the application of green technology.
- Fiscal Incentives: The government provides fiscal incentives to support the promotion of environmental protection technologies. Pyrolysis technology can enjoy these policy supports.
Raw material-rich Market
Potential: High
Applicable Regions: Middle East and African countries
Features:
- Waste Accumulation: The waste management system in these regions is imperfect, and wastes such as plastics, tires, and oil sludge are piled up, and effective treatment solutions are urgently needed.
- Resource Recovery Demand: A large amount of waste is to be recycled, and pyrolysis technology can convert these wastes into valuable by-products.
Energy-short Market
Potential: High
Applicable Regions: Regions far away from the energy supply chain, island countries with energy shortages.
Features:
- High Costs: These regions are seriously short of energy, rely on traditional energy, and have large fluctuations in energy prices. Pyrolysis plants can alleviate this dilemma.
- High Demand: These regions have a strong demand for alternative energy. Pyrolysis technology can produce clean energy from waste and help alleviate energy shortages.
Profitability Analysis of Beston Pyrolysis Plant
| Return on Investment of BLJ-16 Tyre Pyrolysis Project in Europe | |||||||
| 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 | Remark |
| Equipment | BLJ-16 | Set | 89000 | 1 | 89000 | ||
| Transportation | Seafreight | Set | 64600 | 1 | 64600 | ||
| From Port to Site | Set | 5800 | 1 | 5800 | |||
| Customs Tax | 0.15 | Set | 13350 | 1 | 13350 | ||
| Installation | Beston technician's salary | Day | 350 | 50 | 17500 | ||
| Round-trip aritickets | Ea | 3820 | 2 | 1640 | |||
| Visa | Ea | 750 | 1 | 750 | |||
| Local welder | Day | 120 | 100 | 12000 | 2 welders are needed | ||
| Local plumber | Day | 120 | 20 | 2400 | |||
| Local labor | Day | 108 | 50 | 5400 | |||
| Crane forklift | Day | 160 | 30 | 4800 | |||
| Materials | Installation materials ready | Set | 5200 | 1 | 5200 | Foundation, pipe, etc. | |
| Licenses | / | Ea | 2000 | 1 | 2000 | Environmental, firefighting, etc. | |
| Workshop | 500 | ㎡ | 380 | 500 | 190000 | ||
| Total Amount | $452440.00 | ||||||
| Operating Cost | Raw Materials | Waste tyre | Ton | 0 | 12 | 0 | |
| Water | / | m³ | 0.39 | 3 | 1.17 | ||
| Electricity | / | KWH | 0.2 | 864 | 172.8 | ||
| Fuel | Natural gas | Liter | 0.77 | 240 | 184.8 | ||
| Labor | / | People | 72 | 4 | 288 | ||
| Maintenance | / | Day | 85 | 1 | 85 | ||
| Depreciation | 8 years | Day | 175.18 | 1 | 175.18 | ||
| Tax | 5% | 0 | |||||
| Total Amount | $906.95 | ||||||
| End Products Price | Tyre oil | 45% | Ton | 5.4 | 433 | 2338.2 | 45% of input |
| Steel Wire | 15% | Ton | 1.8 | 216 | 388.8 | 15% of input | |
| Carbon black | 3% | Ton | 3.6 | 162 | 583.2 | 30% of input | |
| Subsidy | Ton | 100 | 12 | 1200 | |||
| Total Amount | $4510.2 | ||||||
| Daily Income | $3603.25 | ||||||
| Monthly Income | Working day | Day | 25 | $90081.17 | |||
| Yearly Income | Working day | Day | 300 | $1080974 | |||
Note: the above data is just for reference. Contact Beston Group to get pyrolysis project report.
Successful Beston Pyrolysis Projects All Over the World
See Video of Beston Pyrolysis Plant Delivery and Installment in Middle East
In the End
Beston pyrolysis plant turns waste into energy. At present, the nonrenewable resources have become more and more precious. These end products can yet be regarded as a great alternative to energy. Now, we offer mobile, batch, and continuous models to process 1-24 tons of waste per day. Based on good services, we offer flexible payment methods, turnkey projects, and a period of tracking service. If you want to get more information about Beston Group’s pyrolysis projects, please visit our Facebook.
