Plastic to fuel machine offers an alternative solution to waste recycling and fossil fuel usage. Through pyrolysis technology, the machine converts waste plastic into pyrolysis oil, a high-quality fuel. Thus, this innovative machine promotes solid waste management by reusing plastic waste. Furthermore, it relieves current pressure on fossil fuel supplies. For recyclers, plastic into fuel machine not only provides a more efficient recycling solution, but plastic pyrolysis oil also creates higher economic value.
Current Dilemma of Waste Plastic Recycling
tons Plastic Production per year
tons Directly into Ocean per year
tons Carbon Emissions from Incineration per year
years Degradation Time
Disposal Method of Waste Plastic
Negative Impacts of Discarded Plastic
Ecological Threats
- Land: Plastic waste accumulated in the soil for a long time will hinder soil fertility, aeration and water penetration. This affects plant growth.
- Atmosphere: During incineration of plastics, harmful substances, especially dioxins and polychlorinated biphenyls, are released. It negatively affecting air quality.
- Ocean: Discharge of plastic into the ocean leads to marine life ingesting the plastic. In addition, harmful substances are passed throughout the food chain.
Resource Consumption
- Social Resource: Disposal of plastic requires a large amount of social resources. Recycling plastic waste requires huge amounts of money to set up and maintain recycling facilities. Meanwhile, plastic recycling projects also involve significant labor, technical and managerial staff.
- Fossil Resource: Lack of effective plastic recycling methods leads to significant waste accumulation. However, plastic production heavily relies on non-renewable fossil fuels such as crude oil and natural gas. Neglect of discarded plastics means the unsustainable consumption of fossil resources.
Energy Transition is Imminent
Traditional Fossil Energy Faces Difficulties
- Fossil Fuel Dominance: The existing energy structure comprises 30% crude oil, 25% coal, 25% natural gas, 15% alternative energy, and 5% nuclear energy. In the global energy structure, fossil fuel (including crude oil, natural gas and coal) still dominates. However, global greenhouse gas emissions continue to rise due to the use of traditional fossil energy.
- Transition in a Dilemma: As non-renewable energy source, the global reserves of fossil energy are gradually decreasing. This poses a severe challenge to energy supply. Paradoxically,, the mining, processing and transportation of fossil energy have established a huge infrastructure system. Transition of these systems requires a lot of time and capital investment.
Chance and Challenge Coexist in Alternative Fuels
- Clean Fuels from Waste: Alternative fuel production takes the form of waste-to-wealth. This valuable fuel is from various wastes such as plastics, tyres, biomass, etc. In addition, the combustion of alternative fuels such as pyrolysis oil, biogas, and bioethanol has lower emissions. Therefore, the use of alternative fuels can alleviate the emission pollution of fossil resources.
- Technical & Cost Barriers: Technically, some alternative fuels are still in the development stage and face significant technical issues. In addition, the production of alternative fuels may face high initial investment and production costs. To make alternative fuels cost-competitive with fossil fuels, continuous technological progress and stable cost control are required.
Exploration of Converting Waste Plastic into Fuel
In recent years, people have begun to explore the possibility of converting waste plastics into fuel. There are currently two main forms of fuel, direct incineration of plastics and pyrolysis oil from plastic to fuel machine. Below is a comparison of the fuel performance between these two plastic-derived fue:
Direct Plastic Incineration
Some projects try to burn plastics directly in incinerators to obtain energy. Although this method can generate some energy, it also comes with emission issues.
Plastic Pyrolysis Oil
Plastics undergo pyrolysis reactions in high-temperature, oxygen-free environments to form pyrolysis oil. In this process, long-chain polymers in plastics break down into short hydrocarbon chains that are more energy efficient. In addition, gases and volatile substances contained in plastics are released at high temperatures. Pyrolysis oil is therefore a purer fuel.
Below is a comparison of the two fuels:
| Fuel Form | Plastic Incineration | Pyrolysis Oil |
|---|---|---|
| Energy Efficiency | Low (Incomplete Combustion) | High (Stable Energy Supply) |
| Fuel Quality | Contains Impurities & Contaminants | Free of Impurities & Contaminants |
| Emissions | Produce Air Pollutants & Toxic Substances | Less Emissions |
In the growing fields of plastics management and energy production, the superiority of plastic pyrolysis oil as a fuel source is obvious. This shift to more sustainable fuels represents the future of waste utilization. Especially, plastic to fuel machine, also called plastic pyrolysis machine, plays a key role in the efficient production of this revolutionary fuel.
3 Types Plastic to Fuel Machine for Sale
Skid-mounted Type
- Model: BLJ-3
- Smaller floor space
- Less transportation costs
- Easy to operate and maintain
Batch Type
- Model: BLJ-6 BLJ-10 and BLJ-16
- One furnace a day
- Multiple capacity options
- No need for plastic pretreatment
Continuous Type
- Model: BLL-30
- Continuous feeding & discharging
- Intelligent control
- High return on investment
| 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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Identifying Plastic for Plastic to Fuel Machine: Classification Guide
Applicability Analysis
| Types of Plastic | Coming from | Applicability | |
|---|---|---|---|
 |
Polyethylene Terephthalate | Transparent bottles & packaging etc. | × |
 |
High-Density Polyethylene | Plastic pallets, trash cans, etc. | √ |
 |
Polyvinyl Chloride | Building materials, cable sheaths, circuit boards | × |
 |
Low-Density Polyethylene | Cling films, freshness protection bags, etc. | √ |
 |
Polypropylene | Microwave lunch box, fresh-keeping box, etc. | √ |
 |
Polystyrene | Fast food box, bowl of instant noodles box, etc. | √ |
 |
Other Plastics without chlorine and oxygen | Various sources | √ |
|
Other plastics with chlorine and oxygen | Various sources | × |
Oil Yield Analysis
Note:
- Plastics containing oxygen(PET) and halogen elements(PVC) are not suitable. Oxygen-containing plastics pose reaction safety hazards. Combustion of fuel oil containing halogen elements may generate dioxins.
- Oil yield is based on laboratory data from a single plastic type. It is for reference only. Oil extraction effect of the material needs to be tested through experiments by pyrolysis equipment.
Plastic to Fuel Conversion: Sustainable Power of Catalytic Pyrolysis
01Plastic Feeding
Through the feeding system, the plastic enters the waste plastic to fuel conversion plant. You have a variety of feeding methods to choose from, including manual feeding, hydraulic feeding, and screw feeding. Specific feed size requirements are as follows:
| Feeding Method | Model | Size |
|---|---|---|
| Manual/Hydraulic Feeding | BLJ-3 | less than 0.6m |
| BLJ-6/10/16 | less than 1.2m | |
| Screw Feeding | BLJ-3/6/10/16 | less than 5cm |
| BLL-30 | less than 2cm |
02Oil Gas Formation
- After the plastic enters the preheated plastic pyrolysis chamber the pyrolysis reaction begins.
- When the reaction temperature reaches 180℃, oil and gas begin to be generated in the furnace.
- When the reaction temperature reaches 280-350℃, oil and gas are produced on a large scale.
03Oil Gas Condensation
- High-temperature oil and gas enter the catalytic tower and mainfold. Waxy and heavy oils are separated in this process.
- After the condensable oil gas enters the oil channel condenser, the plastic pyrolysis oil formed enters the oil storage tank.
04Solid Residue Discharge
After cooling down at the end of production, the solid residue is discharged through the slag discharging system. You can choose a three-channel water-cooled slag discharge system to achieve high-temperature slag discharge and save cooling time. The final slagging temperature can be reduced to 50-80℃.
05Gas Treatment
- Non-condensable syngas enters the water seal. After purification, the syngas enters the reactor through the pipeline to provide heat energy. Excess syngas is burned in the exhaust chamber or collected separately as fuel.
- The high-temperature exhaust gas first passes through the flue condenser to cool down. Subsequently, it enters the cooling tower and spray tower for dust removal. You can choose a high-end exhaust gas treatment system, and the final emissions can meet EU standards.
Strategies for Producing High-Quality Fuel From Plastic to Fuel Machine
Catalytic Pyrolysis
Unlike recycling oil sludge or tyres, pyrolysis reaction occurs in plastic to fuel machine produces wax oil. It can clog the system. Therefore, a supporting catalytic system is required. These mainly include pyrolysis catalytic towers, catalysts, and catalyst regeneration systems. Catalytic pyrolysis can effectively solve the problem of wax condensation and liquefaction. Reducing the production of wax oil can improve the quality of fuel oil. In particular, the pollution-free catalyst can be regenerated and reused.
Oil Distillation
Distillation is to volatilize pyrolysis oil and separate components with different boiling point ranges. This process helps to further separate higher purity and more stable fuel oil. By controlling the reaction conditions, different components can be separated to obtain non-standard gasoline, non-standard diesel, etc. The products after distillation are closer to the market demand for fuel and chemical raw materials. This means the distilled oil has a higher commercial value.
Application Scenarios of Plastic Pyrolysis Oil
Industrial Fuel
Some factories with large heat energy needs, such as glass factory, steel factory, ceramics factory, cement factory, etc. can use oil from plastic to oil machine as industrial fuel for energy supply. It can replace traditional fuel oil or natural gas and be used in heating furnaces, boilers and other equipment.
Power Generation
Plastic pyrolysis oil can undergo further distillation processing. After removing the gasoline components, customers can use the obtained non-standard diesel components in heavy oil generator sets to generate electricity. This helps reduce the negative environmental impact of fossil fuel demand.
Plastic Production
The core step in the production of plastics is the polymerization of fossil raw material extracts. In some cases, plastic manufacturer can use plastic pyrolysis oil as a partial substitute for raw materials in plastic production. This helps recycle discarded plastics and promote the development of a circular economy.
Current Opportunities for Plastic to Fuel Business Plan
Currently, plastic bans are prevalent around the world. Even if some areas do not implement this policy, plastic recycling remains an important part of environmental protection policies. Therefore, the plastic to fuel machine has good prospects for development.
Huge Recycling Demand
With plastic bans in place, demand for alternative ways to deal with plastic waste is likely to surge. Additionally, increased awareness of environmental issues and demand for sustainable practices may prompt consumers and industry to support recycling initiatives. This is undoubtedly a boost to the plastics to fuel business plan.
Government Policy Incentives
Governments often create policies and incentives to promote eco-friendly technologies. In response to a plastic ban, governments may offer incentives, subsidies or tax breaks to companies working on innovative recycling methods, such as plastic fuel technology. Recyclers can take advantage of government support to reap financial benefits and grow their businesses.
Plastic Industry Transformation
Plastic bans require the plastics industry to shift in a more sustainable direction. This transformation is in line with the overall trend of circular economy and sustainable resource management. Plastic to fuel technology can position itself as key players in this evolving landscape. This thus contributes to the sustainable development of the plastics industry.
Profitability Analysis of Plastic to Fuel Machine
| BLJ-16 Plastic Pyrolysis Project in South America | ||||||||
|---|---|---|---|---|---|---|---|---|
| Introduction | According to the market data of South America, 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 | BLJ-16 | Set | 169650.00 | 1.00 | 169650.00 | Supporting high-end exhaust dust removal and 304 stainless steel main furnace material | |
| Transportation | From China to Santa Marta port | Set | 23362.00 | 1.00 | 23362.00 | Frame Delivery should through Hamburg, then deliver to Czech. |
||
| Customs tax | 16% | Set | 27144.00 | 1.00 | 27144.00 | |||
| Installation | Beston technician's salary | Day | 150.00 | 50.00 | 7500.00 | |||
| Round -trip airtickets | Ea | 5200.00 | 2.00 | 10400.00 | ||||
| Visa | Ea | 3000.00 | 1.00 | 3000.00 | ||||
| Local labor | Day | 20.00 | 6.00 | 120.00 | 4 labors are needed | |||
| Materials | Installation materials ready | Set | 5200.00 | 1.00 | 5200.00 | Foundation, pipe, etc. | ||
| License | Environmental, firefighting, etc. | Set | 2000.00 | 1.00 | 2000.00 | |||
| Workshop | 1000 | ㎡ | 1000.00 | 0.00 | 8 years | |||
| US$248,376.00 | ||||||||
| Operating Cost | Raw materials | plastic | Ton | 20.00 | 8.00 | 160.00 | ||
| Water | / | m³ | 0.013 | 2.00 | 0.026 | |||
| Electricity | / | KWH | 0.22 | 562.00 | 123.64 | 18 hours per day | ||
| Fuel | Pyrolysis oil | kg | 150.00 | 0.00 | ||||
| Labor | / | People | 6.00 | 20.00 | 120.00 | |||
| Maintenance | / | Day | 20.00 | 1.00 | 20.00 | |||
| Depreciation | 8 years | Day | 80.00 | 1.00 | 80.00 | |||
| Tax | 19% | Day | 497.04 | 1.00 | 497.04 | |||
| US$1,000.71 | ||||||||
| End Products Price | Pyrolysis oil | 70% | Ton | 480 | 5.45 | 2616.00 | ||
| Subsity | / | Ton | / | / | / | |||
| US$2,616.00 | ||||||||
| Daily Income | US$1,615.29 | |||||||
| Monthly Income | Working day | Day | 25 | US$40,382.35 | ||||
Beston Group Bring Innovations to Plastic Recycling Worldwide
As an experienced manufacturer and solution provider, Beston Group meets various plastic recycling challenges with high manufacturing standards and strong R&D capabilities. We can provide you with excellent quality equipment at reasonable plastic to fuel machine price. In addition, Beston Group is consistently enhancing R&D efforts in converting plastic into high-quality fuel. We hava established long-term and stable cooperative relationships with many customers. Here are some successful cases for your reference.
Partner with Beston
Plastic to fuel machine contributes to sustainable waste management. If you would like to get involved in a plastic recycling project, contact us! Just tell us your needs and Beston Group will customize a professional plastic recycling solution for you. In particular, if you want to know more information related to solid waste recycling, you can follow us on Facebook.