Beston pyrolysis reactor for sale has adopted the latest design and technology, to achieve the fully recycling of waste. As the core component of the entire pyrolysis plant setup, the reactor directly affects pyrolysis efficiency and stability of the entire system. Therefore, choosing the most suitable reactor is critical for waste recycling project. Beston Group provides a comprehensive product line and flexible configuration solutions. We are an excellent choice for pyrolysis reactor manufacturers.
Core Function of Pyrolysis Reactor
Pyrolysis reactor is the core of pyrolysis machine. The reaction is carried out in a high-temperature micro-oxygen environment. Plastic, oil sludge, and tyre undergo thermal decomposition to form high-temperature oil gas and solid residues. The reactor is a link for the conversion of waste materials into pyrolysis oil. The front of the reactor is connected to the feed system, and the rear is the oil gas condensation system. Substances formed in pyrolysis reactor for sale become pyrolysis oil, syngas, carbon black and other valuable resources after undergoing subsequent processes.
Conversion Mechanisms of Waste Inside Pyrolysis Reactor
Waste Plastic
Oil Sludge
Waste Tyre
Plastic is mainly composed of polymers. These polymers are long-chain hydrocarbons such as polyethylene (PE), polypropylene (PP), polystyrene (PS), etc.
Components Involved in Pyrolysis:
- Polyolefin Chains: These chains are mainly composed of ethylene (PE) or propylene (PP) units, which break down into smaller alkanes and alkenes (e.g. ethane, propane, ethylene, propylene).
- Aromatic Rings: These rings present in polystyrene (PS) break down into smaller aromatic compounds such as benzene, toluene and styrene.
Decomposition Products:
- Hydrocarbons: A gaseous mixture of alkanes, olefins and aromatic compounds..
- Syngas: Mainly hydrogen, methane and other light hydrocarbons.
- Inorganic Residues: Industrial solid residues containing residual carbon black and inorganic substances.
Oil sludge is a semi-solid waste generated during the oil extraction or refining process. It is a mixture containing hydrocarbons, water, inorganic materials and trace amounts of heavy metals.
Components Involved in Pyrolysis:
- Heavy Hydrocarbons: These large hydrocarbon molecules, such as asphaltenes and resins, break down into smaller alkanes, olefins and aromatic compounds.
- Organic Compounds: Other organic compounds, including alcohols, ketones, and esters, also undergo thermal desorption process to form various hydrocarbons.
Decomposition Products:
- Hydrocarbons: A gaseous mixture of alkanes, olefins and aromatic compounds.
- Syngas: Hydrogen, methane and other light hydrocarbons.
- Inorganic Residues: Remaining inorganic materials, mainly in the form of sand or coke.
Tyre is mainly made of synthetic rubber. It contains a complex mixture of organic compounds, including styrene-butadiene rubber (SBR), polyisoprene (IR) and carbon black.
Components Involved in Pyrolysis:
Rubber Molecules: Long chains of rubber molecules, mainly composed of SBR and IR, will break down into smaller hydrocarbons, including isoprene, butadiene, styrene and benzene in tire pyrolysis reactor.
Decomposition Products:
- Hydrocarbons: A gaseous mixture of alkanes, olefins and aromatic compounds.
- Syngas: Hydrogen, methane, carbon monoxide and other light hydrocarbons.
- Carbon Black: As a valuable by-product, it is recovered as fine carbon powder.
- Steel Wire: The steel wire in tyre remains intact as a solid residue.
Main Components of Pyrolysis Reactor for Sale
01Drive System
02Base
03Burner
04Main Furnace
05Casing
Key Factors Influencing Pyrolysis Reactor Cost
1.Processing Capacity
As the processing capacity increases, the size and complexity of the pyrolysis reactor design also increases. This means that more parts and steel raw materials are needed to support the additional size expansion. At the same time, large reactors require more efficient heating and cooling systems to ensure smooth operation. They all increase pyrolysis machine cost of reactor. The following are the specific parameters of reactors with different processing capacities for your reference.
| Model | BLJ-16 | BLL-30 | |
|---|---|---|---|
| Capacity | 12-16t/d | 30-35t/d | |
| Working Process | Batch | Fully continuous | |
| Reactor Size | φ2800*7100mm | φ1800*18500mm | |
| Reactor Material | Q345R | 310S stainless steel | |
| Drive System | 500 reducer+7.5kw drive motor | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 33m*13m*8m | 70m*20m*10m | |
| Power | 55.6kw | 256kw | |
| Burner | 2*400,000 kcal | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 34.5t | About 150t | |
| Number of Containers | 1*40FR+2*40HQ | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | ||
| Condensing System | Vertical Condenser | φ820*3600 Single piece condensing area 35.6m2 | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 8000*2260*2500 Condensing area 49.5m2 |
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2.Main Furnace Material
The main furnace material of the pyrolysis reactor directly affects the durability, life and safety of the equipment. Therefore. It is a key factor affecting the cost. Different pyrolysis materials have different requirements for furnace materials. Choosing the right material not only affects the initial investment of the equipment, but also affects its long-term maintenance and replacement costs.
310S Stainless Steel
This material can withstand high temperatures up to 1035℃. Also, it can resistant high-temperature oxidation and acid corrosion. Therefore, 310S stainless steel is the preferred material for processing high-temperature pyrolysis reactions, especially in plastic pyrolysis machine. Its cost is high, but it can ensure safety under extreme conditions.
304 Stainless Steel
This steel is suitable for application scenarios with high temperature resistance of 600-700℃. It is a commonly recommended material for pyrolysis of sludge and tires. It is superior to carbon steel in terms of high temperature resistance and corrosion resistance. The cost is moderate, between 310S stainless steel and Q345R steel.
Q345R Steel
This material is resistant to high temperatures of 450℃ and is suitable for handling reactions with relatively low temperatures. Although this pyrolysis reactor price is low, it is prone to oxidation and corrosion problems under high temperature conditions. Therefore, this material is not recommended for long-term use in high-temperature applications.
3.Pyrolysis Reactor Types
There are two types of operation modes: batch reactor and continuous reactor. Each operation mode has significant differences in performance, efficiency and cost.
Batch reactor
This type of pyrolysis reactor operates in batches. The process begins by loading raw materials into the reactor. Then, pyrolysis reaction proceeds. After reaction, unload the solid products from the furnace and clean it. Finallt, load next batch of raw materials. Due to the simpler design, lower manufacturing requirements and easy installation, the initial investment cost of small pyrolysis reactor is relatively low.
Continuous reactor
This reactor can achieve continuous feeding and discharging. Continuous reactor is suitable for handling large-scale production needs. Due to need for complex pyrolysis chamber design and more supporting systems (such as Independent combustion chamber, gas handling systems), the initial investment of continuous reactors is higher. But in the long run, its economic benefits and operational efficiency are higher.
Unique Technology of Beston Pyrolysis Reactor for Sale
Flash Explosion Prevention
The nitrogen system introduces inert gas, nitrogen, into the main furnace before and after the reaction. This evacuates excess oxygen and pyrolysis oil gas inside the furnace. This prevents flash explosions. In addition, the main furnace automatically opens a safety valve to release pressure when overpressure occurs. This prevents equipment failure or damage due to overpressure.
Floating Seal
The reactor uses a combined floating seal at discharge port (at front&rear of continuous pyrolysis reactor). The seal combines carbon fiber and high-temperature soft filler. Compared with traditional graphene filler sealing, it has better high temperature resistance, corrosion resistance and wear resistance. This ensures the sealing and long-term reliable operation of the reactor.
Hot Air Heating
Hot air heating method(optional) provides a more uniform heating effect and precise temperature control. Compared with direct heating by traditional burners, it is more energy-efficient and has significant energy-saving and emission-reduction effects. This method can save 20% to 30% of energy consumption, while improving the safety and efficiency of the pyrolysis chamber.
Guaranteed Packing Material
Beston pyrolysis reactor can adopt British Morgan high-temperature ceramic cotton as insulation material. This material does not contain carcinogens and meets EU standards. Not only that, the material has excellent high temperature tolerance and environmental protection performance, effectively reducing heat loss and ensuring the safety of the operating environment.
Global Waste Management Solution: Beston Group in Action
As an industry-leading pyrolysis reactor manufacturer, Beston Group continues to contribute to the global waste recycling industry. We are constantly committed to the R&D of cutting-edge pyrolysis technology. In addition, Beston Group holds a customer-centric development philosophy. Everything we do is for the long-term success of our customers’ projects. The following are successful pyrolysis projects of global customers for your reference:
Beston Group: Your Ideal Supplier for Pyrolysis Reactor
Pyrolysis reactor represents a significant advancement in waste management technology. It offers a versatile and efficient solution. As a professional manufacturer, Beston Group continues to push the boundaries of pyrolysis technology with innovative solutions. Our equipment is an excellent investment option for your waste recycling project. We welcome you to become our partner. Visit us on LinkedIn for more information about Beston pyrolysis reactor for sale.