Oil sludge pyrolysis plant offers an advanced solution for managing industrial waste effectively. Oil sludge, a hazardous industrial waste, poses risks to soil and water resources if improperly handled. Our machine utilizes high-temperature, oxygen-free technology to convert oil sludge into pyrolysis oil. Compared to other treatment options, this solution ensures a more complete and eco-friendly oil sludge management. This achieves the goals of “reduction, resourcing and harmlessness“. Read more details about Beston Group’s oil sludge pyrolysis recycling solution!
Sources and Hazards of Oil Sludge
In various stages of oil exploration, development, production, storage and transportation, and refining, large quantities of oily sludge are produced each year. The oil sludge contains 5% to 50% petroleum and pollutants such as polycyclic aromatic hydrocarbons and heavy metals. This makes it toxic and flammable. It significantly pollutes the air, soil, and water resources, posing severe threats to the ecological environment and human health. There exist considerable challenges to its disposal.
| Source | Category | Water Content (%) | Oil Content (%) | Solid Content (%) |
|---|---|---|---|---|
| Drilling Operation | Oil-based Cuttings | 8-15 | 15-25 | 60-80 |
| Opeartional Sludge | 40-50 | 10-20 | 30-40 | |
| Landed Sludge | 5-25 | 5-10 | 70-90 | |
| Crude Oil Transportation | Landed Sludge | 5-25 | 5-10 | 70-90 |
| Tankbottom Sludge | 40-70 | 20-40 | 5-40 | |
| Crude Oil Refining | Grease Trap Bottom Mud | 60-70 | 10-15 | 25-35 |
| Floatation Pond Scum | 75-90 | 5-10 | 3-10 | |
| Activated Sludge | 75-85 | <5 | 10-20 |
Market Capacity and Prospect Forecast of Oil Sludge Disposal
There is currently no data on international oil sludge disposal market. However, China, as a major global oil producer, generates a large amount of oil sludge annually. Its market performance can serve as a reference for analysis.
Market Data
China’s oil sludge production increased from 7.349 million tons in 2014 to 7.79 million tons in 2022, with a CAGR of 0.74%. During the same period, the disposal volume of oil sludge rose from 3.076 million tons to 5.883 million tons, with a CAGR of 8.44%. The oil sludge treatment rate has significantly improved.
Market Competition
With policy support, the number of oil sludge treatment enterprises in China continues to grow. However, the market concentration remains low, with most companies being small to medium-sized, resulting in relatively low competition overall. So entering the oil sludge disposal market still holds substantial growth potential.
Prospects Analysis
Oil sludge must be properly disposed of. Now, there are hundreds of millions of tons of sludge left over from history in China. Short-term processing capacity is still insufficient to meet demand. Therefore, the oil sludge recycling/treatment industry has enormous growth potential.
Investment Recommendations
Investors should conduct in-depth market research and focus on technological advancements and market entry conditions. They are advised to consider long-term investments to participate in the development of the oil sludge recycling/treatment industry.
Factors Driving Oil Sludge Disposal Market Growth
Rising Oil Production Activities
The increase in global energy demand has led to a rise in oil processing volumes, which in turn has increased the production of oily sludge. This increases the demand for better disposal methods.
Resource Utilization Consideration
The petroleum components in oily sludge have high value and can be appropriately processed and separated for extraction, achieving resource recycling.
Policies and Regulations
Governments worldwide have strict requirements for oil sludge disposal and have enacted subsidy policies to encourage its disposal. This promotes the research, development, and application of oily sludge recycling/treatment technologies.
Technological Advance
Advancements in oil sludge recycling/treatment technologies (automation and integration, etc) and the development of innovative processing equipment (like thermal desorption unit) have improved efficiency and productivity in the treatment process. This trend is also driving market growth.
What Regions Need Oil Sludge Disposal Solution?
For countries rich in petroleum resources, the petroleum industry typically serves as a cornerstone of domestic economies. However, extensive oil extraction inevitably results in large amounts of oil sludge that require treatment. Therefore, establishing projects for oil sludge management in leading oil-producing nations like the United States, Russia, Saudi Arabia, Canada, and Iraq could be promising investments.
Pyrolysis Vs. Other Oil Sludge Disposal Methods
Oil sludge disposal is complex due to its diverse components and numerous types, posing technical challenges. Currently, there are various oil sludge recycling techniques, each with advantages and disadvantages. Among these, oil sludge pyrolysis plant is considered a superior method due to its comprehensive benefits.
| Technology/Project | Treatment Technology and Crude Oil Recovery | Secondary Pollutants | Technology Maturity | Facility Investment | Energy Consumption | Synthesis Score |
|---|---|---|---|---|---|---|
| Solvent Extraction | Thorough oil recovery | Solvent wetting | Complex, not mature, high | General | Suitable for deep oil recovery |  |
| Thermal Chemical Washing | Incomplete oil recovery | Residual contaminated oil mud | Simple, mature | Low | General | |
| Biological Method | Long treatment cycle, poor treatment effect for cycloalkanes and aromatics | Secondary pollution risk | Complex, not mature | General | Low |  |
| Incineration | All organic matter is treated, but crude oil cannot be recovered | Small amount of ash, generation of toxic and harmful gases | Complex | High | Unlimited scale |  |
| Pyrolysis Treatment | All opportunities can be treated, and crude oil can be effectively recovered | Small amount of ash | Technically mature | Moderate | Moderate |  |
Oil Sludge Pyrolysis Process – Reduction & Resourcing & Harmless Disposal
01Feeding
Input oil sludge into pyrolysis reactor. Select the appropriate transportation mode according to the liquid content of oil sludge.
- below 40% – belt conveyor
- between 40% – 60% – shaftless screw conveyors
- above 75% – oil sludge pumps.
02Pyrolysis
Pyrolysis reactor always maintains an low-oxygen and sealed environment. With the combustion chamber heating the reactor, the temperature rises. At 200-450℃, oil gas will come out. Due to the absence of air participating in high-temperature decomposition reactions, the process effectively eliminates the generation of dioxins, and NOx, and produces almost no H2S or SO2.
03Oil Gas Condensation
Heavy particles in the oil gas will be liquefied into heavy oil and then dropped into the heavy oil tank. Light particles in the gas will rise up and be liquefied into light oil in the vertical condenser and then also be reserved in the oil tank. The combustible gas will be desulfurated and cleaned in hydra seal and then come into combustor as fuel.
04Slag Collection
In this process, oil sludge pyrolysis plant cool the solid slag produced from pyrolysis through water-cooling heat exchange and then automatically collects it.
05Flue Gas Treatment
Treatment Results Analysis of Oil Sludge Pyrolysis Plant
Test Report of Pyrolized Oil Sludge
Test Process: Heating a 210g oil sludge sample to 242°C.
Test Result: 67.14% of the oil sludge is converted to heavy oil, 25.24% remains as oil sludge, and 7.62% is lost.
Analysis:
- A 67.14% yield of heavy oil is an ideal pyrolysis outcome. The converted heavy oil has broad applications as fuel or raw material for other processes.
- A 25.24% yield of sludge is within a reasonable range. Sludge is a more stable and less hazardous substance compared to oil sludge.
- A 7.62% loss of oil sludge is acceptable. The loss may be due to the formation of volatile gases (e.g., combustible gas) and light hydrocarbons.
- The pH value of the pyrolysis residue is between 8 and 9, slightly alkaline. This is an ideal result, indicating that the residue is not hazardous.
Conclusion: The conditions of the oil sludge pyrolysis plant are favorable for the production of heavy oil and the stabilization of oil sludge.
Test Report of Residues from Oil Sludge Pyrolysis
Different countries have different standards for the disposal of oil sludge pyrolysis residues. Moreover, oil sludge pyrolysis residues used in different industries’ landfill disposal (e.g. agricultural land, building land) can also make standards different. Therefore, this report is for simple reference only.
Test Analysis:
- Residual oil ratio: The petroleum hydrocarbon content in the final residue after oil sludge pyrolysis is 293 mg/kg, which is within the national standard range. For instance, the United States allows petroleum hydrocarbon limits in different scenarios to range from 4,000 to 20,000 mg/kg.
- Heavy Metal Content: The heavy metal content in the final residue after oil sludge pyrolysis is below or near the standard values for the corresponding elements in relevant national standards.
Conclusion: Oil sludge pyrolysis plant can effectively recover oil and reduce heavy metal content in sludge. It is an effective harmless and resource recycling solution.
Profit Source Analysis of Oil Sludge Pyrolysis Plant
Profit from Regenerated Oil
The fuel oil produced from pyrolysis of oil sludge can be sold to fuel sales units or refineries. This can generate significant economic benefits.
Profit from Solid Residue
The residue produced from oil sludge pyrolysis plant can be used in landfills, sold to brick factories for brick production, or sold to oil companies as an anti-collapse agent for oil wells.
Subsidies from Petroleum Departments
Due to the high hazard and severe pollution caused by oil sludge, petroleum departments typically provide economic subsidies for pyrolysis treatment of oil sludge. The amount of subsidy depends on local policies.
Beston Oil Sludge Pyrolysis Plant for Sale
Skid-mounted Type
- Model: BLJ-3
- Easy to transport, install, and operate
Batch Type
- Model: BLJ-6. BLJ-10 and BLJ-16
- One furnace per day
Semi-continuous Type
- Model: BLL-16
- Automatic feeding and three water-cooled slagging
| Model | BLJ-3 | BLJ-6 | BLJ-10 | BLJ-16 | BLL-16 | BLL-30 | |
|---|---|---|---|---|---|---|---|
| Capacity | 1-3t/d | 4-6t/d | 8-10t/d | 12-16t/d | 8t/d (only for rubber powder) | 30-35t/d | |
| Working Process | Batch | Batch | Batch | Batch | Semi-continuous | Fully continuous | |
| Reactor Size | φ1400*4900mm | φ2200*6000mm | φ2600*6600mm | φ2800*7100mm | φ2800*7100mm | φ1800*18500mm | |
| Reactor Material | Q345R | Q345R | Q345R | Q345R | Q345R | 310S stainless steel | |
| Drive System | 350 reducer+4kw drive motor | 400 reducer+5.5kw drive motor | 400 reducer+5.5kw drive motor | 500 reducer+7.5kw drive motor | 500 reducer+7.5kw drive motor | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 18m*4.2m*6m | 30m*12m*8m | 30m*13m*8m | 33m*13m*8m | 33m*13m*8m | 70m*20m*10m | |
| Power | 16.65kw | 37.85kw | 44.3kw | 55.6kw | 55.6kw | 256kw | |
| Burner | 2*200,000 kcal | 2*300,000 kcal | 2*300,000 kcal | 2*400,000 kcal | 2*400,000 kcal | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 18t | About 24.5t | About 28t | About 34.5t | About 34.5t | About 150t | |
| Number of Containers | 1*40HQ | 1*40FR+1*40HQ+1*20 GP | 1*40FR+2*40HQ | 1*40FR+2*40HQ | 1*40FR+2*40HQ | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | ≤60 | ≤60 | ≤60 | ≤60 | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | ||||||
| Condensing System | Vertical Condenser | φ426*3000 Single piece condensing area 7.58m2 | φ630*3600 Single piece condensing area 17.8m2 | φ630*3600 Single piece condensing area 17.8m2 | φ820*3600 Single piece condensing area 35.6m2 | φ820*3600 Single piece condensing area 35.6m2 | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 3000*2200*2250 Condensing area 17.51m2 | 5800*2260*2500 Condensing area 35.85m2 | 5800*2260*2500 Condensing area 35.85m2 | 8000*2260*2500 Condensing area 49.5m2 | 8000*2260*2500 Condensing area 49.5m2 |
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Technical Breakthrough of Beston Oil Sludge Pyrolysis Plant
Triple Anti-coking Technology
- Utilize hot flue gas reuse technology to reduce the temperature difference inside and outside the reactor to prevent coking.
- Adopt high-temperature catalysts to prevent materials from coking during rapid reactions.
- Use physical de-coking through friction between the internal mesh belt and the reactor’s inner wall.
Nitrogen Replacement Technology
- Introduce nitrogen with a purity of over 95% to displace the air before ignition and slag discharge.
- Maintain a low-oxygen environment in the reactor to prevent flash explosions.
- Ensure safe and stable operation of the oil sludge pyrolysis plant.
Continuous Operation Technology
- Design with continuous feeding and discharging system to ensure uninterrupted operation of the oil sludge pyrolysis plant.
- Integrate real-time monitoring and feedback systems to detect and respond to any operational deviations promptly.
- Utilize automated controls and sensors to maintain optimal operating parameters such as temperature, pressure, and feed rate.
Precise Temperature Control Technology
- Utilize a high-temperature induced draft fan to channel 400-450°C waste gases from the reactor into burner, where they are mixed uniformly with 1000-1300°C hot air provided by burner.
- Achieve precise temperature control in the reactor by employing precise airflow ratios.
- Achieve residual heat recycling, saving 20-30% of energy consumption.
Oil Sludge Pyrolysis Project – Customer Practices
Beston Group: Your Premier Partner for Oil Sludge Pyrolysis Treatment
Beston Group stands out as the top choice for companies seeking oil sludge recycling/treatment solutions. Our oil sludge pyrolysis plant for sale effectively reduces pollution from oil sludge, achieving the goals of “reduction, resource recovery, and harmless treatment”. Given the environmental and market value, this holds a promising future. So far, Beston Group is one of the minorities that uses pyrolysis technology maturely and safely in the waste recycling industry. If this has aroused your interest, please leave messages on our website or social media (Facebook/LinkedIn/YouTube/Pinterest) now.