Convert Waste Plastic/Tyre/Oil-sludge to Fuel Oil & No-standard Diesel
30 days runs continuously
Annual processing capacity:
6,000tons
waste plastic
10,000tons
waste tires
12,000tons
oil sludge
In 1950, global plastic production was about 2 million tons. It’s now about 400 million tons – an increase of nearly 20,000%.
As a material, it has seemingly limitless potential. Plastic is inexpensive to produce while being lightweight and sturdy. Its applications range from food and beverage packing to clothing and health care.
Because plastic is so commonly used, finding new ways to manage and recycle plastic waste is becoming ever more important. Plastic waste pyrolysis is one technology that could help address this issue.
What is Plastic Pyrolysis?
Plastic pyrolysis is a chemical process that involves chemically breaking down plastics into other molecules by heating the plastics to extremely high temperatures in the absence of oxygen. During pyrolysis, the plastic polymers are broken down into smaller molecules, resulting in the production of liquid oil, fuel source gases such as methane, propane and butane, and char.
BESTON plastic pyrolysis plant converts plastic waste into valuable products like fuel oil, solid residue, and combustible gas. Various types of plastic waste can be processed in a pyrolysis plant, including polyethene (PE), polypropylene (PP), and polystyrene (PS).
Suitable Raw Materials For Pyrolysis
Final Products
Fuel Oil
60-80%
High-calorie fuel;
Directly sold to steel mills, boiler plants, cement plant.
After distillation, it can be used in generators for electricity.
Turned into high-quality fuel oil after purification, mixing with standard diesel for low-speed heavy machinery, construction machinery, large trucks, and ships.
Syn Gas
10-30%
Main furnace heating: Recovered combustible gas can be used as fuel directly in the combustion chamber.
Separate collection: Recovered combustible gas can be separately collected for other purposes.
Naphtha (catalytic pyrolysis integrated with distillation)
Petrochemical Industries: Light fractions serve as cracking feedstocks for ethylene/propylene production, essential for manufacturing plastics, rubbers, resins.
Fuel: Naphtha is sometimes used as fuel for industrial engines and ships.
Solvent: Due to its stable chemical properties, naphtha is employed as a solvent in the paint and resin industries.
Aromatic Derivatives: Aromatic naphtha yields key feedstocks: benzene, toluene, xylene (BTX), it is vital for chemical manufacturing.
Technical Breakthrough Of BLL-30 Continuous Pyrolysis Plant
Oil & gas efficient condensation anti-polymerization technology
Oil & gas efficient condensation: Direct spraying, mixing and condensation, rapid cooling, blocking olefin secondary polymerization, blocking oil and gas pipelines, causing equipment shutdown and maintenance.
Hot smoke recycling and air preheating technology
Thermal cycle: 80% high-temperature exhaust gas is recycled into the combustion chamber, mixed with 1300℃ hot air to heat the reactor.
Waste heat utilization: 20% of the exhaust gas is preheated to the combustion air, double energy saving, reduce exhaust emissions by 50%.
Main furnace multi-media automatic temperature control technology
Intelligent adaptation: automatic adjustment of fuel ratio, adapting to mixed feeding of waste plastics/tire/oil sludge.
Precise temperature control: ±10℃ constant temperature pyrolysis, oil product output rate increased by 15%.
Advantages of Technical Breakthrough
1. 30 days runs continuously without topping
2. The exhaust emissions meet EU standards, energy consumption reduced by 55%, emissions reduced by 50%
3. High automation, only 2-3 operators per shift
If you want to know more abou the technical breakthrough of BLL-30 continuous pyrolysis plant, please check our detailed introduction.
Popular Types of Plastic Pyrolysis Plant
BLL-30 Continuous Pyrolysis Plant
- Capacity: 20-25T/D
- Ultra-large annual capacity: 6,000tons waste plastic
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Fully continuous type: Suitable for large-scale, continuous production, with higher automation, less labour required, and a higher equipment cost.
BLJ-16 Batch Pyrolysis Plant
- Capacity: 8-10T/D
- Working way: batch
- Annual capacity： process 3,000 tons waste plastic
-
Batch type: Ideal for smaller-scale operations, requiring more manual labor and offering a more affordable price.
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Parameters of Plastic Pyrolysis Plant
| Model | BLJ-16 WAX | BLJ-16 CAT | BLJ-16 ULTRA | BLL-30 |
|---|---|---|---|---|
| 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 | 60-90 |
| 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 | 60-90 |
How Pyrolysis Plant works
Our waste plastic pyrolysis plant has an exhaust gas treatment system that meets the European Emission Standard. Don’t worry about polluting your working conditions or environment. Here is a workflow diagram of a plastic pyrolysis plant for your reference.
01Pretreatment and Feeding
Batch waste plastic pyrolysis machine: Feed size diameter is less than 600mm. Feed plastic by manual labor. Batch pyrolysis plant: Feed size diameter is less than 1200mm. Feed plastic by manual labor.
Continuous pyrolysis plant: Feed size diameter is less than 20mm. Feed plastic by screw feeder.
02Plastic Catalysis Pyrolysis
Heat the main furnace. When the temperature reaches 180 degrees Celsius, gas oil begins to generate. A significant amount of gas oil is produced at temperatures between 280-350 degrees Celsius.
After the oil gas enters the catalytic tower, it undergoes a reaction with the catalyst. This step mitigates issues related to wax deposition and liquefaction. Simultaneously, it contributes to enhancing the quality of the plastic pyrolysis oil
03Plastic Pyrolysis Oil Collection
04Combustible Gas and Solid Residues Recycling
The non-liquefiable oil gas will be desulfurated, cleaned in the hydro seal, and then recycled in the burning room as the heating source.
The solid residues will be discharged by labor (skid-mounted type) or water-cooling discharger.
05Emission Gas Recycling
How Can You Get Profits from Waste Plastic Pyrolysis Plant
| Return on Investment of BLL-30^1 set waste Plastic pyrolysis project in Italy | ||||||||
|---|---|---|---|---|---|---|---|---|
| Project name | BLL-30 waste plastic pyrolysis plant | |||||||
| Introduction | According to the market data of Mongolia, the estimated ROI report, the various expenses are as follows: | |||||||
| Item | Details | Unit | Unit price/USD | Quantity | Amount/USD | Total amount | Remark | |
| Fixed Investment Cost | Equipment | BLL-30 | Set | 1024761.00 | 1.00 | 1024761.00 | ||
| Transportation | From China to destination port | Set | 80000.00 | 1.00 | 80000.00 | |||
| From Port to Site | Set | 5000.00 | 1.00 | 5000.00 | ||||
| Customs tax | 9% | Set | 92228.49 | 1.00 | 92228.49 | |||
| Installation | Beston technician’s salary | Day | 150.00 | 120.00 | 18000.00 | 2 workers; each workers 60days. | ||
| Round -trip airtickets | Ea | 3200.00 | 2.00 | 6400.00 | ||||
| Visa | Ea | 100.00 | 2.00 | 200.00 | ||||
| Local welder | Day | 15.00 | 240.00 | 3600.00 | 4 welders are needed | |||
| Local plumber | Day | 15.00 | 240.00 | 3600.00 | 4 plumbers are needed | |||
| Local electrician | Day | 15.00 | 240.00 | 3600.00 | 4 electricians are needed | |||
| Local labor | Day | 10.00 | 480.00 | 4800.00 | 8 labors are needed | |||
| Crane forklift etc. | Day | 20.00 | 30.00 | 600.00 | ||||
| Materials | Installation materials ready | Set | 5000.00 | 1.00 | 5000.00 | Foundation, pipe, etc. | ||
| License | Ea | 1500.00 | 1.00 | 1500.00 | Environmental, firefighting, etc. | |||
| Workshop | 1500 | ㎡ | 16.00 | 1500.00 | 24000.00 | 8 years | ||
| US$1,273,289.49 | ||||||||
| Operating Cost | Raw materials | Waste plastic granules | Ton | 0.00 | 20.00 | 0.00 | Estimated capacity: 20ton per day. | |
| Water | / | m³ | 2.30 | 5.00 | 11.50 | |||
| Electricity | / | KWH | 0.15 | 4300.80 | 657.59 | 256kw*0.7*24hrs | ||
| Fuel | Pyrolysis oil | L | 0.00 | 160.00 | 0.00 | Pyrolysis oil is from plant for free | ||
| Labor | / | People | 18.00 | 136.00 | 2448.00 | 6 workers per shift , 3 shifts for 2hrs | ||
| Maintenance | / | Day | 20.00 | 1.00 | 20.00 | |||
| Depreciation | 8 years | Day | 426.98 | 1.00 | 426.98 | |||
| US$3,564.08 | ||||||||
| End Products Price | Fuel oil (estimated oil yeild based on test report 2 ) 79.67% | 80% | Ton | 300 | 15.934 | 4780.20 | 79.67% of output | |
| steel | 0% | Ton | 0 | 0 | 0.00 | |||
| US$4,780.20 | ||||||||
| Daily Income | US$1,216.12 | |||||||
| Monthly Income | Working day | Day | 25 | US$30,403.10 | ||||
| Yearly Income | Working day | Day | 300 | US$364,837.18 | ||||
Due to various factors, the cost and oil yield of pyrolysis plants may vary in different markets. If you need a specific profitability analysis, please contact us for a detailed consultation.
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Why to Choose Pyrolysis Plant to Recycle Plastics
The United States, the European Union, Australia, China, Thailand, Malaysia, etc. have all enacted laws and regulations requiring the recycling of plastic waste. For example, the EU’s PPWR proposal requires that by 2030, all plastic packaging on the EU market must contain at least 30% recyclable components.
Global production of plastic products is expected to reach 76.5 million tons in 2024, and it is growing rapidly at a rate of 2% per year currently, only about 9% of plastic waste is recycled, 10%-20% is incinerated, 30% is improperly disposed of, and nearly 50% is landfilled. Choosing a pyrolysis plant to recycle plastics is becoming an increasingly viable option for managing plastic waste:
| Technology | Oil recovery | Secondary pollutants | Process maturity | Facility Investment | Energy consumption | Scope of use and characteristics |
|---|---|---|---|---|---|---|
| Landfill | Incomplete recycling | Very likely to cause secondary soil, water and air pollution | Simple, mature | Lower | Lower | No limit, has been gradually eliminated by the market |
| Incineration | Recycling is thorough | Prone to causing secondary air pollution | More complex | Higher | Higher | Any size |
| Granulation | Incomplete recycling | May cause secondary water pollution | Mature technology | Higher | Higher | Suitable for recycling bottles and engineering plastics |
| Pyrolysis | Incomplete recycling | May cause secondary water pollution | Mature technology | Moderate | Lower | Any size |
Waste Plastic Pyrolysis Projects
As a company specializing in the design and manufacture of waste plastic pyrolysis plants, Beston has successfully cooperated with customers from more than 100 countries, including Italy, the United Kingdom, the Netherlands, Belgium, France, Germany, Poland, Romania, Czech Republic, Greece, Finland, Portugal, Ireland, Croatia, Indonesia, Kazakhstan, Russia, Turkey, Turkmenistan, Armenia, Uzbekistan, etc. Beston is committed to helping our customers solve waste recycling problems, choose feasible and optimal solutions, and make good profits while carrying out environmentally friendly and sustainable projects.
4 Sets Plastic Pyrolysis Plant & 1 Set Distillation Plant in Netherland
- Client Background
A European startup plans to build a plastic-to-fuel chemical recycling plant to support the EU’s circular economy goals. Their mission: to produce new plastics without using virgin resources and reduce industrial CO2 emissions. - Problems Faced
1. Excessive plastic waste, fossil fuel dependency, and harmful incineration practices
2. Plant must comply with NOx emission standards
3. Wax oil buildup in plastic pyrolysis - Solutions
1. Scalable capacity: Parallel pyrolysis units enable 30TPD processing & get enough fuel oil
2. Emission control: Upgraded combustion + advanced exhaust treatment for NOx compliance
3. Wax oil solution: Dual-catalytic system prevents pipeline clogging - Results
1. Sustainable waste solution: Meets rising demand for plastic recycling while cutting CO2
2. Circular economy: Pyrolysis oil for new plastic production, creating closed-loop recycling
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BLJ-16 Plastic Pyrolysis Plant in UK
Operation time: 2021.06
Location: British
Raw material: plastic waste
Type: Bath
Capacity: 6-8T/D
Installation method: on-site installation
End product: fuel oil
BLJ-16 Plastic Pyrolysis Plant Delivery to Spanish
Delivery time: 2024.10
Location: Spanish
Raw material: plastic waste
Type: Bath
Capacity: 6-8T/D
Installation method: on-site installation
End product: fuel oil
BLJ-16 Plastic Pyrolysis Plant in Cyprus
Operation time: 2023.10
Location: Cyprus
Raw material: plastic waste
Type: Bath
Capacity: 6-8T/D
Installation method: on-site installation
End product: fuel oil
3 Sets BLJ-16 Plastic Pyrolysis in Malaysia
Operation time: 2024.3
Location: Malaysia
Raw material: medical waste plastic
Type: Bath
Capacity: 6-8T/D
Installation method: on-site installation
End product: fuel oil
Beston Service
24-hour consultation service
Free 24/7 consultation is provided through various channels such as email, phone, website message, WhatsApp, WeChat, etc.
Customized Design
Self-designed and manufactured machines to meet customer’s different demands, such as color, size or capacity.
Technical support
Free technical consultation and design drawings providing, such as layout plan, foundation plan, circuit diagram, installation drawing for customers.
After-sales warranty
On-site/online installation assistance, regular equipment examination feedback, spare parts replacement and free control system software upgrading service.