Beston skid-mounted pyrolysis plant, known for its compact containerized design, is a versatile solution for recycling waste materials, such as plastics, tires, and rubber, into valuable resources like fuel oil, combustible gas, and carbon black. This machine is designed for easy transportation, installation, and operation, making it ideal for small-scale and mobile waste management projects. Consult Beston Group for customized solutions.
What Is A Skid-mounted Pyrolysis Plant?
A skid-mounted pyrolysis plant is also called a containerized pyrolysis plant, mini pyrolysis machine, portable pyrolysis machine, and mobile pyrolysis unit. This machine combines a containerized design suitable for transportation with waste-to-resource pyrolysis technology. Here breaks down the meaning in detail:
1. “Skid-Mounted” Design
Imagine a metal frame or platform that functions as the base. This base is often called a “skid.” The key components of a mobile pyrolysis plant, like the reactor, condenser, and more, are securely pre-assembled on this skid. This creates a self-contained, portable pyrolysis unit, which can be easily transported and installed as a single piece.
2. “Pyrolysis” Principle
Pyrolysis is a thermal decomposition process that occurs in the absence of oxygen. It involves heating organic materials to high temperatures and breaking them into simpler substances. This is different from burning (combustion) which requires oxygen.
Basic Parameters of Beston Skid-mounted Pyrolysis Plant
| Model | BLJ-3 | |
|---|---|---|
| Capacity | 1-3t/d | |
| Working Process | Batch | |
| Reactor Size | φ1400*4900mm | |
| Reactor Material | Q345R | |
| Drive System | 350 reducer+4kw drive motor | |
| Land (L*W*H) | 18m*4.2m*6m | |
| Power | 16.65kw | |
| Burner | 2*200,000 kcal | |
| Total Weight of Shipped Materials | About 18t | |
| Number of Containers | 1*40HQ | |
| Noise (dB) | ≤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 |
| 3-in-1 Condenser | 3000*2200*2250 Condensing area 17.51m2 |
|
Application Fields of Mobile Pyrolysis Unit in Recycling
| Input Raw Materials | Applicable Types | Feeding Capacity | Output End Products |
|---|---|---|---|
| Waste Plastics | PP, PE, PS, ABS, etc.; | ≤1T/D | Fuel oil, solid residues, combustible gas; |
| Whole Tires | Car tires, truck tires, OTR tires, motorcycle tires, bicycle tires, etc.; | ≤3T/D | Fuel oil, carbon black, steel wire, combustible gas; |
| Rubber Powder | Rubber cable sheath, rubber soles, and all the other kinds of rubber sheets; | ≤2t/d | Fuel oil, carbon black, combustible gas; |
| Oil Sludge | Oil-based cuttings, tank bottom oil sludge, refinery oil sludge, crude oil sludge, etc. | ≤3T/D | Fuel oil, sand, combustible gas; |
How to Get Profit from Pyrolysis Products?
Different raw materials yield different finished products through skid-mounted pyrolysis plant, and the proportions of these products also vary. Here’s how you can profit from each of the main pyrolysis products:
Pyrolysis Oil
- Sell as Alternative Fuel: Supply energy-intensive factories with pyrolysis oil as an alternative fuel, reducing their operational costs and providing a consistent revenue stream for you.
- Sell to Oil Refineries: Partner with oil refineries to have the pyrolysis oil further processed into higher commercial value fuel like standard diesel, tapping into a lucrative market.
Carbon Black
- Enhance Quality: Process the carbon black into higher quality grades, such as N330 carbon black, which increases your profit margins.
- Sell as Additives: Market carbon black as an additive for asphalt mixtures, printing inks, black dyes, and paints, leveraging its value in various industrial applications to boost your profits.
Steel Wire
- Sell to Tire Manufacturer: Sell steel wire back to tire manufacturers, providing them with a cost-effective raw material.
- Reprocess for Sale: Reprocess the steel wire into other metal products, expanding your product range and tapping into different markets for increased revenue.
Sand
- Produce Permeable Bricks: Use the sand to manufacture permeable bricks, capitalizing on the growing demand for sustainable construction materials.
- Oil Well Applications: Reprocess the sand into anti-collapse materials for oil wells, creating additional revenue streams from the sale of these items.
ROI Analysis of BLJ-3 Mini Pyrolysis Plant
Yearly Income
Payoff Period
ROI
Note: Taking waste plastics as feeding materials, the following analysis is just for your reference; the detailed analysis varies according to many factors, and you can contact us for customized analysis.
| Return on Investment of BLJ-3 Waste Plastic Pyrolysis Project in the USA | ||||||||
|---|---|---|---|---|---|---|---|---|
| Introduction | According to the market data of USA, the estimated ROI report, the various expenses are as follows: | |||||||
| Fixed Investment Cost | Item | Details | Unit | Unit Price/USD | Quantity | Amount/USD | Total Amount | Remark |
| Equipment | BLJ-3 | Set | 47375.00 | 1.00 | 47375.00 | |||
| Transportation | From China to USA | Set | 12700.00 | 1.00 | 12700.00 | |||
| From Sea Port to Site | Set | 0.00 | 1.00 | 0.00 | ||||
| Customs tax | 15% | Set | 7106.25 | 1.00 | 7106.25 | |||
| Installation | Beston technician’s salary | Day | 350.00 | 15.00 | 5250.00 | |||
| Round -trip airtickets | Ea | 3820.00 | 2.00 | 7640.00 | ||||
| Visa | Ea | 750.00 | 1.00 | 750.00 | ||||
| Local welder | Day | 160.00 | 15.00 | 2400.00 | 2 welders are needed | |||
| Local plumber | Day | 160.00 | 10.00 | 1600.00 | ||||
| Local labor | Day | 160.00 | 15.00 | 2400.00 | ||||
| Crane forklift | Day | 160.00 | 10.00 | 1600.00 | ||||
| Materials | nstallation materials ready | Set | 3000.00 | 1.00 | 3000.00 | Foundation, pipe, etc. | ||
| Licenses | / | Ea | 0.00 | 1.00 | 0.00 | Environmental, firefighting, etc. | ||
| Workshop | 100 | ㎡ | 0.00 | 100.00 | 0.00 | |||
| US$91,821.25 | ||||||||
| Operating Cost | Raw Materials | Waste plastic | Ton | 0 | 1.00 | 0 | ||
| Water | / | m³ | 22.50 | 1.00 | 22.50 | |||
| Electricity | / | KWH | 0.13 | 256.00 | 32.38 | 22hours | ||
| Fuel | Fuel oil | Liter | 0.00 | 120.00 | 0.00 | Fuel oil produced by own plan | ||
| Labor | / | People | 160.00 | 4.00 | 640.00 | |||
| Maintenance | / | Day | 20.00 | 1.00 | 20.00 | |||
| Depreciation | 8 years | Day | 19.74 | 1.00 | 19.74 | |||
| Tax | 0% | 0 | ||||||
| US$734.62 | ||||||||
| End Products Price | Plastic oil | 70% | Ton | 1190 | 0.7 | 833.00 | 70% of input | |
| Carbon black | 30% | Ton | 162 | 0.3 | 48.60 | 30% of input | ||
| Subsidy | Ton | 100 | 1 | 100.00 | ||||
| US$981.60 | ||||||||
| Daily Income | US$246.98 | |||||||
| Monthly Income | Working day | Day | 25 | US$6,174.41 | ||||
| Yearly Income | Working day | Day | 300 | US$74,092.93 | ||||
Instructions of Beston Skid-mounted Pyrolysis Plant
The instructions for the BLJ-3 mini pyrolysis machine will assist customers in operating the production line. Alternatively, customers can consult us online. Our technicians are always ready to answer your questions.
1. Installation
2. Operation
3. Maintenance
4 . Documentation and Reporting
1.1 Site Preparation
- Choose a site with adequate space for the portable pyrolysis plant. The site should be accessible for transportation and have necessary utilities like water, and electricity. Follow local regulations regarding the installation of industrial facilities.
1.2 Foundation Construction
- Placement: There is no need to establish an additional concrete base or other parts. Just position the mobile pyrolysis unit in the proper location according to the layout plan provided by Beston Group.
- Commissioning: Conduct initial operational tests and adjustments under engineer guidance to commission the skid-mounted pyrolysis machine effectively.
2.1 Pre-Operation Checklist
- Machine: Conduct a thorough machine inspection, including all connections, fittings, and safety devices.
- Fuel Supply: Ensure the correct type and amount of fuel is supplied to the plant.
- Feedstock: Verify that materials (plastic, tires, rubber, etc.) meet feeding requirements and are free of non-pyrolyzable contaminants.
2.2 Startup Pyrolysis
- Feeding: Input materials into pyrolysis reactor by manual work or automatic screw feeder. Avoid overloading.
- Preheating: Activate the burner to heat the reactor to the required temperature (according to Beston’s recommended temperature settings for different materials).
- Pyrolysis: Wait for the pyrolysis process to generate oil gas. Continuously monitor process parameters and adjust settings as needed to maintain optimal conditions.
- Condensation: Wait for the oil gas to condense, liquefy, and store in the oil tank.
- Dedusting: The flue gas dedusting system begins to work to ensure it meets flue gas emission standards.
- Cooling: Wait for the reactor to cool down naturally. Shut off the main power supply.
- Collection and Cleaning: Collect the pyrolysis oil and solid products, properly label and store them. Clean the reactor and other components to prepare for the next operational cycle.
3.1 Routine Maintenance
- Inspections: Conduct regular inspections of all components of the skid-mounted pyrolysis machine. Look for signs of wear and tear, leaks, or other issues.
- Cleaning: Periodically clean the reactor and other components to prevent blockages.
- Lubrication: Lubricate moving parts according to the manufacturer’s recommendations to ensure smooth operation.
3.2 Troubleshooting
- Common Issues: Be prepared to address common issues such as feedstock blockages, temperature fluctuations, and gas leaks. Refer to the troubleshooting guide provided by Beston for specific solutions.
- Technical Support: Contact Beston Group’s technical support team for assistance with any unresolved issues or for guidance on complex maintenance tasks.
4.1 Record Keeping
- Logs: Retain detailed logs of all operations, maintenance activities, and any issues encountered.
- Reports: Prepare regular reports on plant performance, production output, and any incidents or maintenance tasks.
4.2 Compliance
- Regulatory Requirements: Keep all necessary documentation to demonstrate compliance with local, state, and federal regulations.
- Audit Preparation: Prepare for audits and inspections by maintaining organized records and ensuring the plant meets all regulatory standards.
Production Time of Beston Portable Pyrolysis Machine
Take oil sludge as raw material, a BLJ-3 mini pyrolysis machine needs production time:
- Feeding: 1h;
- Preheating: 2-3h;
- Reaction: 7-9h;
- Cooling naturally: 4-5h;
- Discharging: 1-2h.
Note: Referring to the processing time of oil sludge, using waste tires as raw materials will reduce pyrolysis reaction time by 3-4 hours; using waste plastics as raw materials will increase the pyrolysis reaction time by 3-4 hours.
Configuration and Customize Choice of BLJ-3 Mobile Pyrolysis Plant
Basic System Configuration
The whole skid-mounted pyrolysis plant has been equipped with the following modules. All components work together to realize efficient pyrolysis.
- Reactor module: including pyrolysis reactor, casings, reactor base, thermal insulation, drive;
- Manifold module: soft connector, manifold, sludge oil tank;
- Oil condenser module: oil condensers, oil storage tank, hydro-seal, water pump;
- De-dusting module: spray tower, water tank, draft fan, flue condenser, chimney;
- Heating module: flame arrester, exhaust gas burner, blower;
- Control: control cabinet;
- Other: accessories.
Customizable Configuration
Customers can choose custom modules to improve efficiency or adapt to local conditions. Below are the customization options available for the BLJ-3 machine configuration. Please let us know if you need these services as soon as possible.
01 Feeding Methods
Customers can choose one of the following methods:
- Manual: suitable for materials with a diameter of up to 1200mm.
- Hydraulic: suitable for materials with a diameter of less than 600mm.
- Screw: suitable for materials with a diameter of less than 50mm.
02 Main Reactor Material
The standard configuration for the BLJ-3 model adopts Q345R. Customers can also customize. Options include:
- Q345R: withstand high temperatures up to 450℃; 1-2 years lifespan.
- 304S: withstand high temperatures of 600-700℃; 5-8 years lifespan.
- 310S: withstand high temperatures of 1035℃; acid corrosion resistance; 8-10 years lifespan.
03 Discharging Methods
Customers can choose how to collect pyrolysis solid products. Discharging system has two options:
- Front slag discharge design: convenient operation; easy maintenance
- Rear screw slag discharge design: enhancing the machine’s overall operational efficiency.
04 Catalytic Tower
For plastic pyrolysis, customers can opt for a catalytic system. This can effectively solve the problem of wax oil blockage, improving the yield and quality of pyrolysis oil. It also helps prevent safety hazards associated with increased gas pressure.
Reasons for Popularity of Skid-mounted Pyrolysis Machine
Easy to Install
Because the BLJ-3 machine’s production and almost 90% of assembly work are completed in the factory, it only needs minimized on-site installation workload. It can work only by completing the connection of the interface pipeline and the external electrical connection.
Easy to Migrate and Transport
Because all the functional components are integrated into a whole base, the containerized pyrolysis unit can be moved as a whole. It just needs a 40-foot-high cube for transportation. It can reach most remote areas.
Safe Assurance
The mobile pyrolysis unit has multiple security assurances: alarm of over temperature or pressure; mechanical pressure and temperature gauge, combustible gas anti-back-burning device (water seal); automatic pressure relief valve (airbag), etc.
Environmental Compliance
Multiple dedusting treatment measures prevent air pollution. The fully enclosed design prevents dust from flying, better for workers’ health.
Combustible Gas Energy-Saving Design
The pyrolysis process produces large amounts of combustible gas. The mobile pyrolysis plant is designed with combustible gas recycling technology, saving fuel consumption.
Highly Standardized
All the products from Beston Group have passed CE, ISO, and SGS certificates, which have lower loss and lower failure rates.
Small Floor Space
The mini pyrolysis machine has a compact structure, which reduces floor space. Moreover, the small compact design helps reduce packing and shipping costs of the machine.
Low Investment Cost and High ROI
The machine has an affordable price. And it consumes low labor costs (1-2 workers are enough). It has a promising profit (details in the above profit analysis).
Short Stocking Cycle and Fast Delivery
It only takes about 30 working days to complete the production of a skid-mounted pyrolysis plant. Compared with continuous pyrolysis plant, it is a short period.
Warranty Service and Other After-sales Service
Free warranty for mobile pyrolysis unit for 12 months. Not only that, Beston Group offers quality spare parts service, technical consulting service, and more throughout its service life.
Which Customers Can Consider Investing in Mini Pyrolysis Machine?
Customers dealing with small quantities of raw materials
The BLJ-3 model has a relatively smaller processing capacity, making it suitable for projects handling limited amounts of materials at a time. For example, small-scale manufacturers or waste treatment companies with limited production scales and raw material supplies can benefit from this equipment to efficiently manage waste and recover resources.
Customers with limited budgets.
Compared to larger pyrolysis equipment, BLJ-3 mini pyrolysis plant requires a smaller investment. This makes it an ideal choice for customers with limited funds but who are eager to enter the environmental protection industry. These customers can start operations with a lower capital investment and gradually scale up as they achieve profitability.
Customers who are new to the pyrolysis field.
For beginners, choosing a skid-mounted pyrolysis plant can reduce initial investment risks. The machine is easy to operate and maintain. This allows new customers to quickly grasp pyrolysis technology and gain experience, laying a solid foundation for future business expansion.
Choose Reliable Manufacturer to Buy Mini Pyrolysis Machine
In terms of buying this machine, you need to know that not every pyrolysis plant manufacturer is effective at designing and manufacturing this type of plant. Although it is a small-scale design, it does not always mean you can easily adjust the configuration of all the components or consistently achieve the expected yield. Therefore, choosing an experienced and professional manufacturer is crucial.
Beston Group has specialized in the designing and manufacturing of pyrolysis plant for years. Perfect one-stop service, 200,000㎡ factory areas, and 10+ years of industry experience all expect to support your pyrolysis project. Just leave your demand to us.
Worldwide Customer Cases of Beston Mobile Pyrolysis Units
More FAQS on BLJ-3 Skid-mounted Pyrolysis Plant
1. What Is The Rotation Speed of The Pyrolysis Reactor of BLJ-3?
0-0.72 RPM.
2. How about The Fuel Consumption of BLJ-3?
The standard configuration of BLJ-3 includes two 20W large-calorie burners, which consume 46 liters of heavy oil or diesel or 46 cubic meters of natural gas per hour. For each batch, with a heating duration of 4 hours, the total consumption is 184 liters of heavy oil or diesel, or 184 cubic meters of natural gas.
3. How about The Total Power of BLJ-3 Mobile Pyrolysis Machine?
The BLJ-3 standard configuration (excluding the heating system) has a total power of approximately 13.5 kW. It operates under three-phase 380V/50Hz and single-phase 220V/50Hz voltage, with a total current of approximately 28.5A. The recommended cable type for the main power supply is 5*6mm².
4. What Is The Volume of 3-in-1 Condenser in BLJ-3 Mini Pyrolysis Machine?
The volume of the oil storage tank in the 3-in-1 condenser is 3.5m³.
Contact Us for Skid-mounted Pyrolysis Plant
Beston skid-mounted pyrolysis machine, with the latest pyrolysis technology and the top configuration, has become a hot product in the international market. If you are looking to start a small pyrolysis project, the mini mobile pyrolysis machine will be the best choice. Contact us for a price list now or follow us on YouTube/Facebook/LinkedIn/Pinterest.