Continuous pyrolysis plant offers large-scale, highly automated solutions for solid waste. At present, the ecological crisis caused by the unsustainable recycling of solid waste has attracted great attention, especially plastic, oil sludge and tyre. They are large in quantity and difficult to decompose harmlessly. The emergence of continuous pyrolysis technology has solved these problems. With automated operation mode and strict emission control, continuous pyrolysis machine has become the first choice for recycling these solid wastes.
Continuous Pyrolysis Plant: Driving Modernization of Recycling
After entering the modern era, recyclers have a growing demand for automation, eco-friendliness, and intelligence in pyrolysis equipment. As a result, continuous pyrolysis plant has gradually entered the public eye. Unlike batch operation, continuous pyrolysis technology enables uninterrupted feeding, oil collection, and solid discharge at the same time. Meanwhile, the introduction of high-end tail gas treatment and the IoT system has made continuous pyrolysis plant an eco-friendly and intelligent recycling option. The following is a component diagram and parameter table of the machine for your reference.
Component Diagram of Continuous Pyrolysis Equipment
Side A
Side B
Parameter Table of Fully Continuous Pyrolysis Plant
| Model | BLL-30 | |
|---|---|---|
| Capacity | 30-35t/d | |
| Working Process | Fully continuous | |
| Reactor Size | φ1800*18500mm | |
| Reactor Material | 310S stainless steel | |
| Drive System | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 70m*20m*10m | |
| Power | 256kw | |
| Burner | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 150t | |
| Number of Containers | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | |
| Condensing System | Vertical Condenser | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 8000*2260*2500 Condensing area 49.5m2 |
|
Raw Materials for Continuous Pyrolysis Plant
Waste Plastic
Oil Sludge
Waste Tyre
Plastic is derived from the polymerization of fossil raw material extracts. It’s corrosion-resistant and easy to process. However, plastic is difficult to degrade in the environment and causes pollution. Continuous plastic pyrolysis plant a great way to recycle waste plastics on a large scale.
- Types: PP, PE, PS, ABS, etc.
- Components for pyrolysis: long-chain polymers.
- End products: pyrolysis oil, industrial residue (containing small amount of carbon black), syngas.
During oil extraction, transportation, processing and refining, oil sludge forms They are usually by-products from equipment wear, improper operation or chemical reactions in the production process.
- Types: tank bottom sludge, oil-based drill cuttings, oil-contaminated soil, etc.
- Components for pyrolysis: petroleum hydrocarbons.
- End products: pyrolysis oil, sand, syngas.
The main components of tyre include artificial rubber, natural rubber, steel wire, synthetic fiber and other materials. The durability of tyre makes it difficult to degrade naturally. Some countries have listed is as hazardous waste.
- Types: passenger tyres, commercial tyres, off-the-road tyres, etc.
- Components for pyrolysis: rubber polymer.
- End products: pyrolysis oil, carbon black, steel wire, syngas.
Step-by-Step Workflow of Fully Continuous Pyrolysis Plant
01Raw Material Pretreatment
Since the machine uses a screw conveyor for feeding, the raw material needs to be shredded to the appropriate size:
- For continuous tyre pyrolysis plant, tyre rubber powder feed size is less than 15mm. Steel wire is obtained after shredding.
- For continuous waste plastic pyrolysis plant, Plastic feed size is less than 20mm.
02Raw Material Feeding
Before the pyrolysis raw material enters the continuous pyrolysis reactor, they need to go through the following stages:
- Raw material is transported to the silo manually or mechanically.
- High-angle belt conveyor transports the raw material to sealed silo with inert gas system.
- After the inert gas system exhausts the excess air, the material enters the weighing tometer through the first screw conveyor.
- After raw material is accurately weighed, the second screw conveyor transports the material to the reactor.
03Pyrolysis
04Pyrolysis Oil & Syngas Formation
The oil gas coming out of the reactor forms pyrolysis oil after going through the following stages:
- Oil gas enters the primary manifold system. This system separates heavy impurities in the oil gas into the residual oil tank.
- The purified oil gas enters the secondary&tertiary tube condensation systems, each forming different fractions of oil products. Due to gravity, the pyrolysis oil falls into the oil storage tank.
- Non-condensable oil gas passes through the vacuum system and water seal to form syngas. It enters the burner through the pipeline as fuel for pyrolysis process.
05Solid Residue Discharge
The discharge and collection of solid residue includes the following processes:
- Check whether the solid residue meets the discharge standard through the sampler .
- High-temperature solid residue enters the water-cooled storage tank through the screw conveyor.
- Three water-cooled screw conveyors discharge the solid residue.
06Exhaust Gas Treatment
The continuous pyrolysis plant uses a high-end waste gas treatment system. The exhaust gas treated by this system can meet the EU emission standards. The specific treatment process is as follows:
- Chemical tower desulfurizes and denitrates the exhaust gas.
- Electrostatic precipitator removes dust particles in the exhaust gas.
- Activated carbon dust collector removes odors in the exhaust gas.
- Chimney discharges exhaust gas that meets the emission standards.
Application Cenarios of Continuous Pyrolysis End Products
Alternative Energy Supply
- Industrial factories can use pyrolysis oil as fuel for kilns, furnaces, and boilers.
- Pyrolysis oil and syngas can be reused as fuel for the continuous pyrolysis machine.
Further Processing
- Distilling pyrolysis oil can obtain non-standard diesel, which provides energy for heavy oil generator.
- Pyrolysis oil can be refined at refineries to produce commercial gasoline and diesel.
- Reprocessing carbon black yields rCB (recovered carbon black), which is raw material for eco-friendly tyre production.
Industrial Production Materials
- Cement and asphalt manufacturers can incorporate carbon black as an ingredient.
- Ink and coating industries use carbon black as a filler.
- Steel products can use steel wire from tyre pyrolysis as a raw processing material.
- Brickyards can use sand to produce permeable bricks.
Cutting-edge Innovation in Beston Continuous Pyrolysis Plant
“Gram” Level Weighing Tometer
95% Pure Nitrogen System
Hot Air&Flue Gas Mixed Heating
Triple Anti-coking Technologies
3-Stage Condenser Self-Cleaning
Oil Gas Leakage-free Discharge
Intelligent Control & Monitoring
Coking seriously affects the efficiency of pyrolysis, especially oil sludge pyrolysis. Continuous pyrolysis equipment adopts the following anti-coking technologies:
- High-temperature flue gas reuse reduces the temperature difference of the reactor, thereby preventing coking;
- High-temperature catalyst prevents the material from coking during the rapid reaction time;
- Use the contact and friction between the furnace mesh chain and the inner wall of the reactor to physically remove coking.
Market Potential of Continuous Pyrolysis Machine
Overcome Ecological Challenge
With the rapid development of modern productivity, the amount of waste continues to rise. Taking plastics as an example, the current waste plastics have reached 7 billion tons, but the global production of plastic products is still growing rapidly at a rate of 2% per year. This trend has put forward higher requirements on the existing recycling system. Continuous pyrolysis plant has a large recycling scale and a high degree of automation. This waste treatment method has great potential in meeting the challenge of recycling this huge amount of waste.
Cater to Sustainable Policies
In order to achieve sustainable development goals, various regions have enacted regulations requiring clean recycling. In addition, with the continuous upgrading of environmental protection policies, the emission standards of pyrolysis projects are becoming increasingly stringent. Compared with landfill and incineration, continuous pyrolysis equipment structurally decomposes waste thoroughly to obtain valuable fuel oil. Meanwhile, wastewater recycling, waste gas emission treatment and resource utilization of solid residues avoid secondary pollution of waste.
Beston Group Provides Pyrolysis Solutions for Global Customers
If you have plans to invest in a continuous pyrolysis plant, Beston Group is your reliable choice. We integrate equipment manufacturing and solution provision. Our professional project consultants provide you with the most suitable solutions. In addition, our own manufacturing factory and experienced technical team ensure the long-term success of your project. Therefore, Beston Group has reached cooperation with many customers around the world. The following are some successful cases of pyrolysis projects:
Launch Continuous Pyrolysis Business with Beston Group
Beston Group’s state-of-the-art continuous pyrolysis plant is the future benchmark for the recycling industry. The machine is profitable and sustainable, making it the best investment for recyclers. If you are interested in launching a continuous pyrolysis project, please share your project requirements with us. We will provide you with tailor-made solutions and detailed information. Follow us on LinkedIn for the latest updates.