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/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
↓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
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
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% ⬆️
Coking Blockage
Thermal Efficiency Improvement
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
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: 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: BLJ-16
- Small-scale choice: process 6,000 tons annually
- 1 furnace/day
- 3 Configuration options
| Model | BLL-30 | BLJ-16 Standard | BLJ-16 TDU | BLJ-16 ULTRA |
|---|---|---|---|---|
| Manufacturer | BESTON | BESTON | BESTON | BESTON |
| Time to Market | 2025 | 2013 | 2013 | 2022 |
| Motor Brand | Chinese brand | Chinese brand | Chinese brand | ABB Explosion-proof |
| Suitable Raw Materials | Waste plastics; Tires; Oil sludge | Oil soil with liquid content<30% | Oil sludge; Landing oil sludge; Drilling waste; Tank bottom oil sludge | Waste 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/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 |
| Working Method | Fully Continuous | Batch | Batch | Batch |
| Final Oil Quality | Pyrolysis oil Pyrolysis oil with wax or naphtha | Pyrolysis oil | Pyrolysis oil | Pyrolysis oil Pyrolysis oil with wax or naphtha |
| Reactor Materil | 304/310S Stainless steel | Q345R Boiler steel | 304 Stainless steel | 304 Stainless steel |
| Reactor Life Span (Years) | 5-8 | 2-3 | 5-8 | 5-8 |
| Guarantee (Months) | 12 | 12 | 12 | 12 |
| Delivery Time (Calendar Days) | 60-90 | 45 | 60 | 90 |
| Land Space Required (L*W*H*m) | 70*20*10 | 33*13*8 | 33*13*8 | 33*26*8 |
| Packing | 20*6*3m in bulk+13*40HQ | 1*40FR+3*40HQ | 1*40FR+3*40HQ | 1*40FR+8*40HQ |
| Installation Period (Calendar Days) | 60-90 | 45 | 45 | 60 |
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.
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
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.
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.
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
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
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
Thermal desorption recovery prevents harmful substances from entering water resources. This optimizes water quality and the growth environment of aquatic organisms.
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
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:
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.