Plastic Pyrolysis Plant

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Worried about excessive wax oil during plastic pyrolysis? Concerned about the final oil quality? Facing safety risks from wax blockage during machine operation? Let Beston plastic pyrolysis plant boost your production efficiency by 200% with catalytic dewaxing technology! It’s not just about plastic recycling; it’s about maximizing investment returns by yielding high-quality, valuable oil products. Trusted by global customers, Beston Group expects to offer you plastic pyrolysis solution and machine support.

Catalytic Dewaxing Technology: Improve Production Efficiency by 200%

BLJ-16 Plastic Pyrolysis Machine with Catalytic System

Function Mechanism of Catalytic System

Catalytic dewaxing targets the “undesirable” molecules in pyrolysis oil distillates, that is, those with poor cold flow properties (the wax oil).

Under the action of a specialized catalyst, the long-chain wax molecules are cracked into shorter-chain hydrocarbons, such as alkanes and alkenes.

This modifies the molecular structure and properties of the wax. This helps to get the best pyrolysis oil performance.

Benefits of Catalytic System

  • 200% higher production efficiency: BLJ-16 model machine reaches a 3,000 tons capacity per year when integrated with this system.
  • Better oil quality and higher yield: Able to produce plastic pyrolysis oil meeting ISCC certification
  • Safer pyrolysis reaction: Minimize pressure risk with reduced wax oil blocking
  • Less downtime, fewer losses: Keeps your machine running smoothly, with improved equipment lifespan and maintenance intervals.

Get 3 Distinct Oil Products from Plastic Pyrolysis to Apply

Plastic pyrolysis is the mechanism of thermally degrading long-chain plastic molecules into smaller molecules (oil, gas and char) using heat in an oxygen-free environment. Its process conditions and additional refining techniques determine the type of oil product obtained. Here’s how three distinct oil products can be derived:

Wax Oil
Catalytic Pyrolysis Oil
Naphtha
Wax Oil from Plastic Pyrolysis without Catalysis

Wax Oil

It is produced from standard pyrolysis under moderate temperatures without catalysts. The oil has high viscosity and remains solid at room temperature. Common Applications:

  • sent to petrochemical factories for further refining into gasoline and diesel.
  • refined into high-purity chemicals for reprocessing into plastic products—this process aligns with ISCC sustainability standards and is widely used.
  • used as general fuel oil in steel plants.
  • used as marine fuel.
Catalyzed Plastic Pyrolysis Oil

Catalytic Pyrolysis Oil

It is obtained from catalytic pyrolysis. This oil is a lighter, more refined oil with reduced impurities. Common Applications:

  • serve as fuel for boiler plants, cement factories, and brick-making plants.
  • used in the production of new plastic products, facilitating closed-loop plastic recycling.
Naphtha from Catalytic Plastic Pyrolysis and Distillation

Naphtha

It is achieved through catalytic pyrolysis integrated with distillation. It is a low-boiling-point fraction, a light hydrocarbon product separated from pyrolysis oil through distillation. Common Applications:

  • used to produce basic chemicals like ethylene and propylene, which are further used to make plastics and synthetic fibers.
  • used in paints, coatings, cleaners, and industrial solvents.
  • used to blend gasoline to improve its performance.
  • certain types of naphtha are used to produce kerosene, jet fuel, and other fuels.
  • serves as an extraction solvent and cleaning agent in the laboratory.

Are All Plastic Suitable for Plastic Pyrolysis Plant?

Acceptable Plastic Types

Types of Plastic Coming from
Low-Density Polyethylene Cling films, freshness protection bags, etc.
High-Density Polyethylene Plastic pallets, trash cans, 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

Note: Polyolefin waste plastics PP, PE, and PS accounted for 92% of the total plastic products (28% PP, 46% LDPE and HDPE, and 18% PS).

Unacceptable Plastic Types

Types of Plastic Coming from
Polyethylene Terephthalate Mineral water bottles, carbonated beverage bottles, etc.
Polyvinyl Chloride Raincoat, building materials, etc.
Other plastics with chlorine and oxygen Various sources

Note: Plastics containing high amounts of oxygen(O) and chlorine(Cl) are not suitable for pyrolysis. These two substances pose risks to machines, air quality, and safety.

Polyvinyl Chloride (PVC)

  • Contains chlorine, which releases harmful HCl gas during pyrolysis. HCl gas corrodes equipment, harms the environment, and poses health risks to workers.
  • Even if PVC pyrolysis yields oil, the oil still contains chlorine (Cl). When burned, it can release dioxins—highly toxic and carcinogenic compounds.

Polyethylene Terephthalate (PET)

  • PET yields little to no oil through pyrolysis. The resulting products are mostly low-quality, powdery residues with little economic value.
  • PET(chemical formula (C₁₀H₈O₄)ₙ) releases oxygen in pyrolysis. The oxygen reacts with combustible pyrolysis gas, leading to explosive risks.

Plastic Pyrolysis Oil Yield

Oil Yield from Plastic Pyrolysis Plant

Benchmark Case: Plastic Pyrolysis Project in the Netherlands

Plastic Pyrolysis Machine Installed in Netherlands

Client background

In the context of the EU’s aggressive strategy to transition to a circular economy for plastics, a European-based startup hopes to build a plastic chemical recycling plant. The core objective is to produce new plastics without using new natural resources, thereby eliminating additional CO2 emissions from the plastics industry.

Problems faced

  • There is a lot of plastic waste to dispose of. Production relies on fossil fuels. And most waste is simply incinerated, causing environmental pollution and high CO2 emissions.
  • The plant must meet nitrogen oxide emission standards.
  • The problem of wax oil in plastic pyrolysis needs to be solved.

Solution

  • Design multiple plastic pyrolysis equipment operating side by side, achieving 30TPD daily processing capacity.
  • According to local emission reports, upgrade combustion system and configure a high-end exhaust gas treatment system.
  • Develop a double catalytic system to solve the problem of wax oil clogging pipelines.

Value added

  • Through the customer’s plastic waste processing center, it effectively meets the growing demand for plastic waste recycling and reduces CO2 emissions.
  • Sell pyrolysis oil to partners to produce new plastics, thereby perfectly realizing a closed loop.

More Global Cases

Specifications of Plastic Pyrolysis Machine

Here, we list the detailed specifications for your reference. The capacity is different. You can choose one based on your capacity. Contact us to get the plastic pyrolysis machine price.

Plastic Pyrolysis Plant Batch Type

Batch Type

  • 1 furnace/day
  • Several model options to suit your needs
  • Hot-selling series
Plastic Pyrolysis Plant Continuous Type

Continuous Type

  • 24-hour operation/day
  • Less environmental impact than batch operation
  • Will gradually become mainstream
ModelBLJ-16 WAXBLJ-16 CATBLJ-16 ULTRABLL-30
ManufacturerBESTONBESTONBESTONBESTON
Time to Market2022202220222024
Motor BrandChinese brandChinese brandABB Explosion-proofChinese brand
Suitable Raw MaterialsWaste plastic bales
(Max.0.9*0.9*1.6m)
Waste plastic bales
(Max.0.9*0.9*1.6m)
Waste plastics; Tires; Oil sludgeWaste plastics; Tires; Oil sludge
Input Capacity (Max.)8-10t/batch8-10t/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
Waste plastic pellets: 0.8-1.05t/h
Rubber powder: 1.25-1.5t/h
Oil sludge:1.8-2.3t/h
Working MethodBatchBatchBatchFully Continuous
Final Oil QualityPyrolysis oil with waxPyrolysis oil with naphthaPyrolysis oil
Pyrolysis oil with wax or naphtha
Pyrolysis oil
Pyrolysis oil with wax or naphtha
Reactor Materil304 Stainless steel304 Stainless steel304 Stainless steel304/310S Stainless steel
Reactor Life Span (Years)5-85-85-85-8
Guarantee (Months)12121212
Delivery Time (Calendar Days)606090150
Land Space Required (L*W*H*m)33*13*833*13*833*26*870*20*10
Packing1*40FR+3*40HQ1*40FR+3*40HQ+1*20GP1*40FR+8*40HQ20*6*3m in bulk+13*40HQ
Installation Period (Calendar Days)45456090

What is the Plastic Pyrolysis Process?

01 Pretreatment and Feeding

Raw materials need to be processed into different sizes for feeding. Different feeding sizes for your reference:

  • BLJ-16: Work in batch mode. Feed size diameter is less than 1200mm. Feed plastic by manual labor.
  • BLL-30: Work in continuous pyrolysis mode. Feed size diameter is less than 20mm. Feed plastic by screw feeder.

02 Plastic Catalysis Pyrolysis

Heat the main furnace. When the temperature reaches 180 degrees Celsius, gas oil begins to generate. A significant amount of gas oil appears at temperatures between 280-350 degrees Celsius.

After the oil gas enter the catalytic tower, it reacts 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.

03 Plastic Pyrolysis Oil Collection

The oil gas enters the manifold, and heavy particles of the oil gas will be liquefied and dropped into the heavy oil tank. The light oil gas will be liquefied into fuel oil by the condenser and reserved in the fuel oil tank.

04 Combustible Gas and Solid Residues Recycling

The non-liquefiable oil gas will be desulfurated and 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.

05 Emission Gas Recycling

Cool down the emission gas in the flue condenser first. After that, it goes to high-end emission gas treatment system (water washing, water spray, ceramic ring adsorption, and activated carbon adsorption). Finally, the discharged emission gas meets the European emission standards.

Advanced Designs of Beston Plastic Pyrolysis Plant

Dual System Technology

Manifold + catalytic tower dual systems support flexible operation modes. It enables the catalytic pyrolysis of waxy plastics or waxy oil sludge. IT also allows common pyrolysis for common tires or oil sludge.

  • Save customers from redundant investments.
  • Improve pyrolysis unit utilization efficiency and enhance economic returns.

Continuous Pyrolysis Technology

BLL-30 model integrates many advanced technologies to enable continuous pyrolysis, unique compared to peer machines. Advanced designs include:

  • Sealed feeding system with continuous quantitative control, Real-time monitoring and stage statistics;
  • Inert gas (nitrogen) protection system;
  • Accurate temperature control for high-temperature flue gas reuse;
  • Others.

Safety

  • Installation safety: The plastic pyrolysis reactor uses high-temperature ceramic wool of the British Morgan brand. This ensures no carcinogens or risk of lung infection for workers. It complies with EU standards.
  • Operation safety: It has explosion-proof motor, torch system, electric control cabinet, automatic alarm, etc.
  • Environment safety: Water-cooling discharging scheme reduces dust pollution. Dedusting system prevents air pollution.

Intelligentization

  • PLC and DCS remote control system: It features a high level of automation. This enhances production efficiency and reduces the needs and risks of manual operation.
  • IoT technology: It enables real-time online monitoring and feedback. This not only makes the production process more intelligent and automated.

Plastic Pollution Is Everywhere

Plastic Pollution in Human Body

Plastic Pollution in Ocean

Plastic Pollution in Atmosphere

Plastic Pollution in Soil

Plastic Pollution in Human Body

One study shows that a person eats 5g of microplastics per week on average (about the same as eating a credit card’s worth of plastic). The sources include bottled water, food, air, and so on.

  • enter the human bloodstream through inhalation or ingestion and have an impact on human cells.
  • affect certain bodily functions because of the harmful chemical additives present in plastics.
Plastic Pollution in the Ocean

Plastic Pollution in Ocean

Nowadays, more than 10 million tons of plastic waste end up in the ocean each year. And the rate of ocean plastic pollution is rapidly increasing. Common sources of plastic pollution include fishing gear, urban garbage, etc.

  • pose severe impacts on the predation and survival of marine wildlife, leading to some species being on the brink of extinction.
  • pose risks to the water and animals in the marine ecosystem due to the additives and harmful chemicals in plastic.
Plastic Pollution in the Atmosphere

Plastic Pollution in Atmosphere

The main sources of plastic pollution in the atmosphere are plastic production, plastic burning, and microplastics. Plastic production, use, and management all contribute to atmospheric pollution.

  • cause climate change (Producing 1 ton of plastic generates about 20% of CO2 and other greenhouse gases.).
  • affect the health of animals, plants, and humans when burning plastic releases toxins (HCl and CO) into the air.

Plastic Pollution in Soil

A study shows that contaminated soils accumulate substantial amounts of plastics worldwide. It is with a mean of 6153 particles per kilogram of soil. This pollution in the soil is commonly caused by mulch film, agricultural packaging, polymer-containing fertilizers, and so on.

  • limit the soil’s capacity to hold water, discourage plants’ root growth and nutrient uptake, and decrease agricultural yields.
  • take hundreds or even thousands of years to decompose completely, causing long-term effects on soil ecological functions.

Feasibility Analysis of Plastic Recycling

Market capacity and trend

Global plastic production is projected to reach 76.5 million tons by 2024. According to the United Nations Environment Programme, the annual loss of value from discarded plastic packaging waste ranges from $80 billion to $120 billion. Plastic recycling has a broad market prospect.
Plastic Recycling Market

Current recycling situation

Statistics from the Organisation for Economic Co-operation and Development show only about 9% of plastic waste is currently recycled, 10%-20% is incinerated, 30% is improperly disposed of, and nearly 50% is landfilled. So effective waste plastic recycling is needed.

Current Plastic Recycling Situation

Environment challenge

Plastic waste poses significant environmental hazards, polluting various ecosystems. Additionally, the production and degradation of plastics release greenhouse gases, exacerbating climate change. So, plastic recycling is extremely urgent. Waste plastic pyrolysis plant is a good solution.

Policy promoting

The USA, EU, Australia, China, Thailand, Malaysia, etc., have enacted laws and regulations requiring plastic waste recycling. For example, the EU’s PPWR proposal mandates that by 2030, at least 30% of recyclable content must be included in all plastic packaging in the EU market.

Plastic Pyrolysis – True Plastic Recycling Solution

Plastic catalysis of plastic pyrolysis equipment is a process that breaks down long-chain polymers into smaller molecules at high temperatures in a low-oxygen and catalytic environment. This technology allows polymeric compounds (plastics) to be decomposed into oil, combustible gas, etc. Moreover, after catalysis, the solidification point of the waxy oil changes. This significantly reduces the issue of wax oil clogging pipelines in common pyrolysis. This plastic pyrolysis solution also offers the following benefits:

Plastic Reduction

Plastic pyrolysis can effectively reduce the quantities and existence time of plastic waste in the environment. Thus, it can lower the risk of environmental pollution from plastic accumulation or landfills.

Plastic Resource Sustainability

Through plastic to oil machine, waste plastics are transformed into pyrolysis oil that can be used as an alternative energy. This avoids the non-treatment or improper disposal of waste plastics and realizes the sustainable use of plastic resources.

Towards to Circle Economy

Globally, approximately 10% of petroleum is used for plastic production. Plastic pyrolysis oil can be recycled into new plastic products. This recycling reduces the need for virgin fossil oil. It supports the development of a circular economy where resources are continually reused and conserved.

Technical Documents Of Plastic Pyrolysis Plant – Beston Group Offers

Technical Documents Offered by Beston Group

Let Plastic Pyrolysis Contribute to 2030 Plastic Goal

In recent years, the global community has rallied around an ambitious yet essential mission — to reduce plastic pollution and promote sustainable materials management.The 2030 plastic goals represent a series of international commitments aiming to:

  • Eliminate unnecessary plastic packaging
  • Ensure all plastic packaging is reusable, recyclable, or compostable
  • Increase the rate of plastic waste recycling
  • Drastically reduce plastic leakage into the environment

These goals are being promoted through global frameworks such as The UN Global Plastic Treaty and the European Plastics Strategy. Some industry leaders (e.g., Shell, TotalEnergies, and Nestlé) are investing in advanced plastic recycling facilities (including pyrolysis) to promote.

The path to meeting the 2030 plastic goal is challenging—but not impossible. By embracing plastic pyrolysis, we can reduce plastic pollution, preserve natural ecosystems, and build a truly circular plastic economy. Let’s empower pyrolysis to drive sustainability and take a big step closer to a cleaner, greener 2030.

2030 Plastic Goal

Global Cases of Beston Waste Plastic Pyrolysis Plant

As one of the professional plastic pyrolysis plant manufacturers, Beston Group has garnered global acclaim with a myriad of successful cases around the world. The following content showcases the success stories of plastic pyrolysis cases from different regions.

Launch Your Plastic Pyrolysis Project!

Plastic pyrolysis plants play a crucial role in extending the lifespan of plastics and combating plastic pollution. This approach presents new opportunities for the sustainable development of the plastic industry. Let’s join the plastic recycling together and contribute to a more sustainable and environmentally responsible future. Follow our social media channels about plastic pyrolysis machine for sale (YouTube, Facebook, LinkedIn, and Pinterest) for the latest updates!

 

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