Thermal Desorption Unit

Thermal Desorption Unit Banner

Coking issues? Low thermal efficiency in oil sludge pyrolysis? Beston Group Thermal Desorption Unit is designed to overcome these challenges. Utilizing advanced decanter centrifuge +thermal washing + pyrolysis technology, it effectively converts oil-contaminated sludge with complex compositions into usable fuel oil. This process ensures clean, efficient recycling while promoting both profitability and environmental sustainability. Read on to explore TDU – a reliable solution for oil sludge treatment.

4 Main Reasons to Choose BLL-30 Thermal Desorption Unit First

Beston Group’s BLL-30 continuous thermal desorption unit has achieved significant performance enhancements through key technical breakthroughs. These upgrades enable investors to realize higher output, lower operational costs, and enhanced operational stability. Below are the reasons to choose BLL-30 first:

12,000 Tons Oil Sludge/Yr

↓55% Fuel Use & ↓50% Emission

±10°C Precise Temperature Control

Government Policy Driven

12,000 Tons Oil Sludge Processing Capacity

12,000 Tons Oil Sludge/Yr

With an advanced oil-gas condensation system, the plant supports:

  • 30 days non-stop machine operation
  • Handling up to 12,000 tons of oil sludge per year
Reduce 55% Fuel Use and 50% Emission

↓55% Fuel Use & ↓50% Emission

Reuses 80% of high-temperature exhaust and utilizes 20% for preheating the air supply, the plant supports:

  • Fuel consumption is cut by 55%
  • Emissions are reduced by 50%
  • Meets EU environmental compliance
±10°C Precise Temperature Control

±10°C Precise Temperature Control

Adopt automated combustion and heat recirculation system, the machine can achieve:

  • Keep reactor temperatures stable within ±10°C
  • Ensure consistent pyrolysis effects when using different types of fuel
BLL-30 TDU Government Policy Driven

Government Policy Driven

  • Government Bans: Many regions are banning batch systems.
  • Policy Incentives: Low-emission systems qualify for subsidies, tax relief, and green financing.
  • Faster Approval: Continuous systems ease EIA approval.

Decanter Centrifuge + Thermal Washing + Pyrolysis Technology: Production Efficiency Increase 200% ⬆️

Closed Loop TDU Pyrolysis Treatment of Oil Sludge
Closed Loop TDU Pyrolysis Treatment of Oil Sludge
0
Coking Blockage
95%
Thermal Efficiency Improvement
200%
Production Efficiency Increase

Decanter Centrifuge + Thermal Washing

As a critical pre-treatment step, decanter centrifuge + thermal washing can prepare the oil sludge for efficient pyrolysis. This process uses heat, emulsifiers and centrifugal force to separate oil, water, and solid particles. Through heating and stirring, the oil becomes more fluid, while water carries away fine particles and impurities. It effectively removes inorganic matter such as sand, salts, and metal particles, along with excess water. It brings key benefits to the pyrolysis process:

  • Improves the purity of oil sludge;
  • Increases oil yield;
  • Reduces pyrolysis plant wear and extends service life.

Pyrolysis Technology

Pyrolysis (also known as thermal desorption) is a process in which polymerized hydrocarbons in oil sludge are thermally broken down and restructured under oxygen-free conditions. TDU unit typically operates at 300–450 °C and continuously converts waste into valuable fuel oil, gas, and solid residues. Product composition varies depending on temperature and processing method. Key features of the pyrolysis process:

  • Maximizes oil recovery from treated oil sludge;
  • Minimizes secondary pollution with closed, oxygen-free design;
  • Enables continuous and automated operation.

Technological Process Workflow of Thermal Desorption Unit

01Raw Material Feeding

Three feeding methods for different oil sludge liquid contents:

  • Below liquid content 40%: belt conveyor
  • 40%-60% liquid content: shaftless spiral
  • More than 75% liquid content: sludge pump

02Oil Sludge Thermal Desorption

Thermal desorption reaction occurs in a high-temperature microaerobic reaction environment. During the reaction, oil sludge undergoes the following changes in thermal desorption system:

  • Under high temperature conditions, long-chain hydrocarbons in oil sludge are broken into small molecular hydrocarbons.
  • Condensable components in the oil gas can be cooled through the condenser to form fuel oil.
  • Non-condensable oil gas are purified by water sealing to form syngas, which provides energy for reactor.

03Oil Distillation(Optional)

Fuel oil is converted into higher-quality non-standard diesel through the oil distillation equipment. In this equipment, fuel oil goes through the following stages:

  • Distillation: heating the fuel oil and separating components with different boiling points.
  • Condensation: cooling and liquefying the evaporated components.

04Exhaust Gas Treatment

The high-temperature exhaust gas passes through the flue condenser and spray tower for cooling and dust removal. In addition, our thermal desorption equipment provides high-end exhaust gas treatment systems, including electrostatic dust removal, activated carbon dust removal, and desulfurization & denitrification treatment. The flue gas emitted by high-end exhaust gas treatment can meet EU standards.

05Solid Residue Discharge

Some solid substances in oil sludge cannot participate in the thermal desorption process and eventually form solid residues. The solid residue is discharged through the water-cooled screw conveyor.

Thermal Desorption Technology Meet Three Principles of Oil Sludge Treatment

Thermal Desorption Unit Technology

Reduction

Significantly reduces the volume of oil sludge as well as the oil and water content in the residue.

Resource Utilization

Thermal desorption unit can recover high-quality fuel oil and syngas and improve energy efficiency through heat recovery.

Harmless Treatment

Ensures safe discharge and reuse of residue, wastewater, and gas with no secondary pollution.

Models of Thermal Desorption Unit for Sale

Beston Group’s comprehensive product system provides customers with 2 types to choose from. They can meet the different production needs of customers. In addition, the diverse pyrolysis equipment options ensure that customers get the most suitable solution at a reasonable thermal desorption unit price.

Continuous Type of Thermal Desorption Unit

Continuous Type: BLL-30

  • Large-scale choice: process 12,000 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 of Thermal Desorption Unit

Batch Type: BLJ-16

  • Small-scale choice: process 6,000 tons annually
  • 1 furnace/day
  • 3 Configuration options
ModelBLL-30BLJ-16 StandardBLJ-16 TDUBLJ-16 ULTRA
ManufacturerBESTONBESTONBESTONBESTON
Time to Market2025201320132022
Motor BrandChinese brandChinese brandChinese brandABB Explosion-proof
Suitable Raw MaterialsWaste plastics; Tires; Oil sludgeOil soil with liquid content<30%Oil sludge; Landing oil sludge; Drilling waste; Tank bottom oil sludgeWaste plastics; Tires; Oil sludge
Input Capacity (Max.)Waste plastic pellets: 0.8-1.05t/h
Rubber powder: 1.25-1.5t/h
Oil sludge:1.8-2.3t/h
Whole tire <120cm or Tire blocks<15cm: 10-12t/batch
Sidewall removed tire: 15-16t/batch
Oil soil: 16-18t/batch
16-18t/batchWaste 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
Working MethodFully ContinuousBatchBatchBatch
Final Oil QualityPyrolysis oil
Pyrolysis oil with wax or naphtha
Pyrolysis oilPyrolysis oilPyrolysis oil
Pyrolysis oil with wax or naphtha
Reactor Materil304/310S Stainless steelQ345R Boiler steel304 Stainless steel304 Stainless steel
Reactor Life Span (Years)5-82-35-85-8
Guarantee (Months)12121212
Delivery Time (Calendar Days)60-90456090
Land Space Required (L*W*H*m)70*20*1033*13*833*13*833*26*8
Packing20*6*3m in bulk+13*40HQ1*40FR+3*40HQ1*40FR+3*40HQ1*40FR+8*40HQ
Installation Period (Calendar Days)60-90454560

4 Technical Highlights of TDU

High Combustion Efficiency

Full use of syngas: The entire system makes full use of the syngas generated in the reactor for secondary combustion. This reduces energy consumption. Combustible gas is purified by water seal to ensure clean combustion.

Anti-coking Design

  • Friction-Assisted Self-Cleaning: Internal movement creates continuous friction between materials and components, helping to dislodge coke buildup during processing.
  • Uniform and Controlled Heating: The system maintains a stable temperature distribution to avoid localized overheating – one of the primary causes of coking.

Efficient Emission Control

  • Waste gas emission: The waste gas generated by Beston equipment is processed by a high-end exhaust gas treatment system to meet EU emission standards. Moreover, if the emission standards in your area are higher, it is a good option for your project.
  • Solid discharge: The discharging system is designed with water-cooled discharging method to reduce dust pollution. The discharging system is designed with water-cooled discharging method to reduce dust pollution. In addition, TDU unit can achieve continuous discharging without leaking oil gas.

Intelligent Control Mode

  • PLC control: PLC and DCS(Distributed Control System) guarantee intelligent operation. They have high control efficiency. Therefore, this saves manpower and improves the working environment.
  • IoT control: In addition, you can also choose an IoT real-time monitoring system. This system provides instant data insights, allowing for quick adjustments and improved efficiency. This facilitates customers’ overall operational control.

Model Project: Thermal Desorption Unit in Africa

As a provider of waste recycling solutions, Beston Group’s oil sludge pyrolysis equipment has been exported to more than 100 countries around the world. Rich export experience enables us to fully understand the needs of customers worldwide. Therefore, it enables Beston Group to customize oil sludge recovery solutions to meet the specific needs of customers from different regions. Below is a successful case of a thermal desorption plant in Africa refinery for your reference.

View 1
View 2
View 3
TDU in Africa
Thermal Desorption Unit in Africa
TDU Unit in Africa

01 Problems & Challenges

  • High oil sludge volume: Oil extraction produces massive oil sludge, which is difficult to discharge in compliance with standards.
  • Cost constraints: Local waste recycling companies have high processing costs and limited processing scale.

02 Change in Goals

  • Regulatory compliance: Achieve compliance with local emission and discharge standards.
  • Operational Efficiency: Expand treatment capacity while lowering operating costs.
  • Residual Utilization: Reuse treated residue to produce construction bricks and generate additional revenue.

03 Action Solution

  • Capacity-Fit Equipment: Provide a semi-continuous TDU thermal desorption unit with a 20-ton/day capacity, optimized for local operating conditions.
  • EIA Support: Customize a specialized discharge system to help obtain Environmental Impact Assessment (EIA) certification.
  • Project Integration: Supported the establishment of a dedicated oil sludge recycling center.

04 Results Achieved

  • Cost Reduction: Significantly reduced long-term sludge processing costs through through your own oil sludge recycling center.
  • Revenue Generation: Enabled revenue generation through brick production from solid residue.
  • Improved Safety: Centralized treatment improved site safety and reduced security-related investments.

Numbers Revealing Global Oil Sludge Treatment Crisis

With the rapid development of the petroleum industry, the accumulation of oil sludge has sharply increased per year. However, due to the lack of recycling solutions, oil sludge treatment still faces a big crisis. Here are data for your reference:

4.5 Billion

tons Oil Production per year

60 Million

tons Oil Sludge Production per year

5 Million

hectares of Oil-contaminated Soil

1 Billion

tons Oil Sludge Accumulation Existing

70%

Oil Sludge Can’t be Treated Properly

Classification and Components of Processable Oil Sludge

Oil sludge is generated during the extraction, gathering, transportation and refining process of oil. It is a mixture of mud, sand and water contaminated by organic matter such as crude oil. Unlike scrap tyre or waste plastic, this waste has a complex composition. It can be divided into various types based on its origin and composition. Each type has a different water, oil and solids content. According to the size of sludge particles, it can be divided into:

  • Oil Sludge: Particle diameter <74 μm
  • Oil-contaminated Sand: Particle diameter ≥74 μm
Source Type Water Content % Oil Content % Solid Content %
Drilling and Oil Extraction
(Global share: 40%)
Oil-based Cuttings 8~15 15~25 60~80
Waste Oil-based Mud 40~50 10~20 30~40
Oil-contaminated Soil 5~25 5~10 70~90
Oil Gathering&Transportation
(Global share: 15%)
Tank Bottom Oil Sludge 40-70 20-40 5-40
Oil-contaminated Soil 5~25 5~10 70~90
Oil Refining
(Global share: 30%)
Oil-water Separator Sludge 60~70 10~15 25~35
Air Flotation Tank Sludge 75~90 5~10 3~10
Activated Oil Sludge 75~85 <5 10~20

Profit Analysis of Oil Sludge Thermal Desorption Unit Project

Profit from Recycled Fuel Oil

Profit from Solid Residue

Profits from Environmental Protection Disposal

Subsidy from the Government

Profits from Fuel Oil

Profit from Recycled Fuel Oil

The fuel oil recycled from TDU has diversified applications that make recycled fuel oil popular in the market. This gives it a wide range of sales channels. See the following uses:

  • Directly used as an alternative energy source for factories/mechanical facilities with large energy consumption;
  • Obtain higher value non-standard diesel oil by distillation treatment;
  • After distillation, the heavy oil components are obtained to generate electricity for heavy oil generators;
  • Further processing in the refinery to produce naphtha and diesel.
Profits from Solid Residue

Profit from Solid Residue

The solid residues produced by TDU unit also generate incomes as long as placement properly:

  • Sell to brick factory to make bricks;
  • Sold to oil field companies for use as oil well anti-collapse agents.
Environmental Protection Disposal

Profits from Environmental Protection Disposal

Many companies need to handle waste sludge in compliance with regulations, but lack relevant equipment, so they will seek third-party services. Investors can provide oil sludge treatment services to this industries, charge environmental protection disposal fees, and form a long-term and stable profit model. The relevant industries are as follows:

  • Oil extraction industry;
  • Oil refining industry;
  • Shipbuilding industry.
Subsidy from Government

Subsidy from Government

Due to the significant hazards and serious pollution caused by oil sludge, government departments in various regions provide substantial financial support for oil sludge recycling projects. These subsidies include:

  • Production subsidies: Governments may provide financial subsidies to enterprises that invest in pyrolysis oil production;
  • Tax Benefits: Some governments encourage the production and use of pyrolysis oil through tax reduction policies;
  • Green energy procurement policy: Governments or public institutions give priority to purchasing products and services using renewable fuels, which indirectly drives the thermal desorption system market.

Thermal Desorption Unit Drives Petroleum Industry Transition

Closed-Loop Waste Utilization

TDU enables a closed-loop system where hazardous oil sludge is thermally treated and transformed into valuable byproducts such as fuel oil and non-toxic solids. This reduces landfill reliance and maximizes resource utilization, aligning with circular economy principles. By turning waste into revenue-generating outputs, petroleum operators improve both environmental and financial performance.

Process Optimization Across the Value Chain

From upstream drilling sites to downstream refineries, the equipment integrates seamlessly into multiple stages of the petroleum value chain. Its energy-efficient operation supports integration into existing facilities, helping reduce overall transportation demands and streamline oil sludge management processes across various stages of production.

Proactive Environmental Risk Control

Oil sludge contains hazardous hydrocarbons and heavy metals that pose serious compliance risks. TDU unit minimizes environmental liability by reducing the toxicity and volume of waste. This proactive risk control supports ESG commitments, helps meet regulatory requirements, and enhances long-term operational resilience.

TDU Alleviates Ecological Burden

Oil sludge contains 5-50 of petroleum, polycyclic aromatic hydrocarbons (PAHs), dioxins, and radionuclides, heavy metals etc. So, it is toxic and flammable. Oil sludge pollutes the soil, water, and air resources that causing serious harm to the ecological environment and even human health. Currently, oil sludge is classified as hazardous waste. Its disposal is regulated by environmental protection agencies worldwide. Thermal desorption unit can reduce the ecological burden in the following aspects:

Reduce Soil Hazards

Reduce Soil Hazards

Thermal desorption system reduces the amount of harmful components that penetrate into the soil. Thus, problems such as soil degradation and surface vegetation destruction are solved.

Mitigate Water Hazards

Mitigate Water Hazards

Thermal desorption recovery prevents harmful substances from entering water resources. This optimizes water quality and the growth environment of aquatic organisms.

Eliminate Air Hazards

Eliminate Air Hazards

Oil sludge stored in the open air is flammable when exposed to fire. Thermal desorption recovery reduces the risk of release of sulfur-containing gases from burning.

Alleviate Hazards to Human Body

Alleviate Hazards to Human Body

TDU unit decomposes toxic volatile compounds, minimizing inhalation risks of carcinogenic substances and preventing respiratory system damage.

Four Major Forces to Accelerate Transformation of Thermal Desorption

Across oil refining, petrochemical, and oilfield operations, oil sludge has long been a persistent environmental burden. Today, as the world accelerates the shift toward cleaner industrial practices and a circular economy, thermal desorption system is taking center stage in oil sludge treatment. Four major forces are accelerating the transformation of this sector:

Environmental Regulation Accelerates Transformation of Thermal Desorption

Stricter Environmental Regulations

Governments are stepping up enforcement through comprehensive environmental policies to prevent improper handling of petroleum waste. Key policies include:

  • China’s Technical Policy for Hazardous Waste Pollution Prevention and Control
  • The EU’s Waste Framework Directive
  • The U.S. EPA’s Resource Conservation and Recovery Act (RCRA)

Technology Advancement in Resource Recovery

Oil sludge contains recoverable oil, organic matter, and minerals. Thermal desorption unit makes it possible to recover resources at scale. This not only maximizes material reuse but also supports the broader shift toward a circular economy, reducing both waste volumes and treatment costs.

Corporate Commitments to Sustainability

Sustainability is now central to corporate strategy in the oil and gas sector. Oil sludge treatment is no longer just a compliance issue—it’s a reflection of environmental responsibility. Companies are increasingly adopting clean, low-emission technologies to improve ESG performance, strengthen brand value, and meet stakeholder expectations.

Oilfields and Refineries Need

Oil sludge accumulation threatens safe and efficient operations, particularly in aging facilities. Treatment technologies that reduce volume and recover value are becoming essential to maintain productivity and reduce environmental risks. Upgrading sludge treatment capabilities has become a strategic priority for long-term facility sustainability.

Get Customized Oil Sludge Treatment Solution

Beston Group thermal desorption unit has become the optimal choice for oil sludge treatment. Our innovative technology helps customers extract economic value from oil sludge. Furthermore, integrated solutions guide customers from A to Z on their path to sustainable development. Just contact us to get your free customized solution. Also, you can follow us on Linkedin for more oil sludge recycling information.

    Please specify your requirement by referring to the following aspects:

    1-What kind of solution will meet your demand? (Key point)

    2-What kind of material and expected end product are you planning to have? (Right solution begins from material and product)

    3-When is the project supposed to be running? (Key info for A-Z project programming)

    4-Budget for machinery purchasing? (Key info for right model)

    5-Points that you really focus on. (Customized service from our project consultant)

    CONTACT US

    Please Feel Free To Give Your Inquiry In The Form Below.

    Your Message (required):