Small pyrolysis machine is a cost-effective solution for efficient waste management. Through pyrolysis technology, the machine can realize resource utilization and treatment of waste such as plastics, oil sludge, and tyres. The end products such as pyrolysis oil and carbon black obtained by the machine can be applied in many fields. At present, small scale pyrolysis equipment has become the choice of many investors for waste recycling projects.
What is Small Pyrolysis Machine?
Small pyrolysis machine uses an intermittent production mode of “one furnace per day”. Each batch of raw materials (such as plastic, oil sludge and tyre) undergo pyrolysis reaction for a specific time. After the reaction stage is over, the overall operation of the machine enters the cooling stage. Finally, discharge by-products and reload new materials for the next cycle. Typically, small scale pyrolysis equipment includes feeding system, reactor, condenser, discharger and waste gas treatment system.
Basic Parameters of Beston Small Pyrolysis Machine for Sale
| Model | BLJ-6 | BLJ-10 | BLJ-16 | |
|---|---|---|---|---|
| Capacity | 4-6t/d | 8-10t/d | 12-16t/d | |
| Working Process | Batch | Batch | Batch | |
| Reactor Size | φ2200*6000mm | φ2600*6600mm | φ2800*7100mm | |
| Reactor Material | Q345R | Q345R | Q345R | |
| Drive System | 400 reducer+5.5kw drive motor | 400 reducer+5.5kw drive motor | 500 reducer+7.5kw drive motor | |
| Land (L*W*H) | 30m*12m*8m | 30m*13m*8m | 33m*13m*8m | |
| Power | 37.85kw | 44.3kw | 55.6kw | |
| Burner | 2*300,000 kcal | 2*300,000 kcal | 2*400,000 kcal | |
| Total Weight of Shipped Materials | About 24.5t | About 28t | About 34.5t | |
| Number of Containers | 1*40FR+1*40HQ+1*20 GP | 1*40FR+2*40HQ | 1*40FR+2*40HQ | |
| Noise (dB) | ≤60 | ≤60 | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | |||
| Condensing System | Vertical Condenser | φ630*3600 Single piece condensing area 17.8m2 | φ630*3600 Single piece condensing area 17.8m2 | φ820*3600 Single piece condensing area 35.6m2 |
| 3-in-1 Condenser | 5800*2260*2500 Condensing area 35.85m2 | 5800*2260*2500 Condensing area 35.85m2 | 8000*2260*2500 Condensing area 49.5m2 |
|
From Trash to Treasure: Raw Materials for Small Pyrolysis Plant
Waste Plastic
Oil Sludge
Waste Tyre
- Source: waste plastic recycling center management, urban domestic waste disposal, plastic product manufacturers, etc.
- Type: pure plastic, such as PE, PP, PS, ABS, etc. Waste plastic products, such as plastic packaging, plastic cables, agricultural mulch, etc.
- Pyrolysis Products: pyrolysis oil, carbon black, syngas.
Note:
- PET and other oxygen-containing plastics do not produce oil during pyrolysis. Moreover, such plastics release oxygen during pyrolysis, which does not meet the anaerobic reaction conditions of plastic to oil machine.
- PVC and other chlorine-containing plastics produce hydrogen chloride after pyrolysis, which corrodes pipelines. In addition, the finished oil contains chlorine. Burning this oil releases dioxins, a carcinogen.
- Source: Oil drilling, transportation and refining, ship repair and manufacturing, oil waste management.
- Type: Oil-based drilling cuttings, oil-contaminated soil, oil tank bottom sludge, refinery sludge and other industrial oily wastes.
- Pyrolysis Products: pyrolysis oil, sand, syngas.
Note:
- Oil sludge has complex composition. We recommend that customers send samples for testing and then confirm the process plan of small oil sludge pyrolysis plant.
- Source: Tire recycling, fleet transportation, heavy industrial machinery production.
- Type: Passenger tyre, commercial tyre, OTR tyre.
- Pyrolysis Products: pyrolysis oil, carbon black, steel wire, syngas.
Usage of End Products Obtained from Small Scale Pyrolysis Unit
The end products produced by small pyrolysis machine of each raw material are different. In particular, the reaction of each raw material produces syngas. It is reused in the pyrolysis reaction. The remaining products have a wide range of applications in various fields.
Pyrolysis Oil
- Used as alternative fuel for energy-intensive factories such as steel mill, cement plant, and power plant;
- Further distilled into non-standard diesel with higher commercial value for sale;
- Non-standard diesel is used as fuel for heavy oil generator sets to generate electricity.
Carbon Black
- Further processed into higher quality carbon black, such as N330 carbon black;
- Used as an additive for asphalt mixtures, printing inks, black dyes, paints, etc.
Steel Wire
- Reused in tire production;
- Reprocessed into other metal products for sale.
Sand
- Used to produce permeable bricks;
- Reprocessed into oil well anti-collapse materials.
Working Process Description of Small Pyrolysis Machine
01Preheating (3h)
Use a burner to preheat the small pyrolysis reactor. Generally, natural gas, diesel, and heavy oil are used as preheating fuels.
02Feeding (2-3h)
03💡Reaction (7-11h)
When the temperature of the reactor reaches 180℃, the reaction begins. When the reaction reaches 280-350℃, the reaction tends to stabilize. The entire reaction involves the following processes:
- Pyrolysis: Under the thermal desorption process, high molecular weight hydrocarbon polymers in the raw materials undergo chain scission into small molecule gaseous hydrocarbons. These high-temperature gaseous hydrocarbons are oil gas.
- Condensation: Oil gas enters the manifold first. After separating the heavy oil and impurities, the high-temperature oil gas enter the condenser. Condensable components are condensed to form pyrolysis oil, which is collected by the oil storage tank.
- Syngas Reuse: Non-condensable components in oil gas, namely syngas, first enter the water seal for purification. Later, it enters the combustion system through the pipeline as fuel to provide energy for the reaction.
- Exhaust Gas Discharge: Flue condenser and spray tower cool down and remove dust from exhaust gas. Finally, chimney discharges the exhaust gas.
04Cooling (5-6h)
When the oil yield decreases and the oil turns dark brown, the oil extraction process is essentially complete. After the reaction is completed, the equipment is cooled down. This is to prepare for the subsequent discharging.
05Discharging (2-3h)
Diverse Configuration Scheme for Batch Pyrolysis Plant
Small pyrolysis machine adopts flexible component layout and modular design. Therefore, you can customize the configuration according to site conditions and production requirements. For the supporting facilities of different systems, you can choose additional equipment to expand the pyrolysis production line. By the way, these configuration options are an important part of small pyrolysis plant cost.
Feeding System
The feeding system of batch machine can be divided into three categories according to working efficiency: manual, hydraulic and screw feeding:
| Feeding Method | Feeding Size | Working Efficiency |
|---|---|---|
| Manual | less than 1.2m | low |
| Hydraulic | less than 1.2m | high |
| Screw | less than 5cm | high |
Furnace Material
The main furnace of a small scale equipment is the core component for the reaction. Also, it is main factor affecting small pyrolysis reactor price. According to the characteristics of different pyrolysis raw materials, the main furnace needs to be made of different materials. For example, the pyrolysis reaction temperature of plastic is higher, and the high temperature resistance of the material is higher. The following are three commonly used main furnace materials.
| Furnace Material | Features | Suitable Raw Materials |
|---|---|---|
| 310S Stainless Steel | Can withstand high temperature of 1035℃; High temperature oxidation corrosion resistance; Acid corrosion resistance. |
waste plastic |
| 304 Stainless Steel | Can withstand high temperature of 600-700℃ | oil sludge, scrap tyre |
| Q345R Steel | Can withstand high temperature of 450℃ | oil sludge, scrap tyre |
Discharging System
After the reaction is over, the temperature of the solid residue needs to be cooled. The discharge system of the small scale pyrolysis equipment uses a water-cooled screw conveyor to cool the solid residue. You can choose a 1 or 3 screw conveyor. The latter has a shorter cooling time for the main furnace and faster cooling of the solid residue.
| Discharging Method | Furnace Cooling Temperature | Cooling Time | Solid Residue Temperature |
|---|---|---|---|
| 1 screw conveyor | 50-60℃ | long | 100-150℃ |
| 3 screw conveyors | 150℃ | short | 50-80℃ |
Additional Equipment for Small Pyrolysis Machine
Catalytic Tower
For small plastic pyrolysis machine, catalytic tower can solve the problem of wax oil blocking pipeline during pyrolysis process. Thus, it improves reaction efficiency and oil quality.
Tyre Shredder
For tyre pyrolysis machine equipped with screw feeding, tyre need to be processed into rubber powder. The equipment can achieve tyre cutting, crushing and steel wire removal, etc.
Oil Distillation Equipment
This equipment further purifies the pyrolysis oil through distillation reaction. The pyrolysis oil is converted into non-standard diesel, which has higher utilization and commercial value.
High-end Exhaust Gas Treatment System
In order to meet the high emission standards in some regions, we provide high-end exhaust gas treatment equipment. The exhaust gas treated by this equipment can meet EU standards.
Small Pyrolysis Plant VS Continuous Pyrolysis Plant
Degree of Automation
- A fully continuous pyrolysis plant operates in a continuous manner. This includes continuous feed, uninterrupted fuel output and seamless soot discharge. There’s no requirement for shutdown during pyrolysis reactor cooling and carbon black slagging. This enables sustained operation for a span of 20-30 days without any interruption.
- For small pyrolysis unit, the process starts with the feed. Subsequently, the heating initiates the conversion of the oil vapor into fuel oil. Subsequently, the pyrolysis reactor is cooled. Finally, carbon black slagging is carried out. Each process must start after the previous process is complete.
Pretreatment of Raw Materials
- The continuous type machine handles materials like tires, rubber, and plastics. These materials must be in a clean state, and they need to undergo shredding initially. For instance, you must crush tires into 5mm rubber particles devoid of steel content. This ensures seamless material input and output, facilitating the uninterrupted operation of the continuous plant.
- The small pyrolysis machine doesn’t demand specific raw material conditions. Therefore, you can directly feed whole tires or waste plastic into the reactor. The need for cutting, cleaning, or screening is not necessary. The final feed size is determined according to the furnace door size.
Cutting-edge Technology of Beston Small Scale Pyrolysis Plant
Nitrogen System
The function of the nitrogen system is to introduce nitrogen for gas replacement before ignition and discharge. Through nitrogen replacement, the residual combustible oil and gas in the furnace can be effectively removed. This can prevent the flash explosion of the main furnace, thereby ensuring the safe and stable operation of the small pyrolysis machine.
Hot Air Heating System
Compared with burner heating, hot air heating system provides a more uniform heating effect. In addition, the temperature control of the system is more precise. Most importantly, the hot air heating system can realize the recycling of waste heat. The system can save 20-30% of energy consumption. This significantly improves energy efficiency and environmental benefits.
Floating Seal Technology
The floating seal technology adopts a sealing method that combines carbon fiber and high-temperature soft filler. Compared with the traditional graphene packing sealing technology, this combined sealing form has high temperature resistance, corrosion resistance and wear resistance. This technology can stably guarantee the sealing of the equipment for a long time.
Flare System
Excess syngas may cause safety hazards of system overpressure and storage. Emergency incidents such as power outages that may occur during equipment operation. To prevent these potential safety hazards, the flare system can be quickly activated in the event of pressure or power abnormalities. This ensures the safe discharge of syngas and prevents system overpressure.
Small Pyrolysis Machine Creates Diversified Value for Investors
Economic Benefit
- As the global demand for clean energy and alternative materials continues to increase, pyrolysis end products such as pyrolysis oil, carbon black, are highly competitive in the market. This ensures a stable sales channel and revenue source.
- Small scale pyrolysis equipment usually have a shorter investment return cycle, and investors can see economic benefits in a shorter period of time. This reduces investment risks and ensures the long-term stable operation of the project.
Sustainability Promotion
- Small scale machine significantly reduces the landfill and incineration of waste. This can not only effectively reduce the emission of harmful substances, but also the pollution risk of natural resources. This plays a positive role in the protection of the ecosystem.
- Through the application of advanced pyrolysis technology, the machine plays a key role in energy saving and emission and promoting resource recycling. This conforms to the strategic goals of global environmental protection and sustainable development.
Social Influence
- Operation of the pyrolysis project drives the development of local related industrial chains. The entire industrial chain ranges from supply chain to product processing, and then to sales and services. This can also provide a large number of employment opportunities.
- As the core of the emerging industry, the small pyrolysis machine has attracted a large number of investments and support from related industries and local governments. This industrial structure optimization enhances the diversity of the local economy.
Market Prospects of Small Pyrolysis Machine in Different Regions
Small Pyrolysis Plant in Europe
The main types of waste in Europe are plastics and oil sludge. The recycling status of these wastes in Europe has the following characteristics:
- Strict Waste Regulatory: European countries have a strict regulatory system for waste disposal. Taking the plastic ban as an example, many countries ban the use of disposable plastic products, further promoting the recycling of plastic waste.
- Government Support: The government implements policies to support recycling projects. It also encourages innovative waste treatment facilities such as intermittent pyrolysis plants through large amounts of funding.
- Sustainable Transformation: More and more European companies regard sustainable development and circular economy as an important part of their corporate strategy. They actively seek new methods of waste treatment and recycling.
Therefore, the prospects of small pyrolysis machine, especially plastic to fuel machine in the European market are very broad. Pyrolysis machines can effectively process wastes such as plastics and oil sludge, which meets the European market’s demand for efficient and environmentally friendly waste treatment technology. The following are successful cases of Beston Group’s pyrolysis projects in Europe:
Small Pyrolysis Plant in Middle East & Africa
The main types of waste in these regions are oil sludge and tires. The current status of waste recycling projects in the Middle East & Africa is as follows:
- Lack of Recycling Facilities: Due to the lack of professional waste recycling technology and corresponding facilities, more and more resources are being invested in the construction of waste recycling infrastructure.
- Strengthened Policy Support: Although some countries still have a long way to go in terms of waste recycling policies, more and more countries are beginning to formulate and implement more systematic waste management and recycling policies.
- Economic Opportunities Emerge: These regions have great potential for economic development. Increasing industrial activities and urbanization have driven the demand for efficient waste treatment technologies.
Currently, recyclers in these regions are in the initial stage of investing in pyrolysis projects on a small scale. In other words, it brings great potential for future project expansion. Thus, small scale pyrolysis unit is currently becomes a key option for solving waste disposal problems in these regions. The following are pyrolysis projects carried out in these regions:
Small Pyrolysis Plant in Asia
Asia is now facing the challenge of sustainable recycling of plastics, oil sludge and tires. The background of the construction of waste recycling projects in the region is as follows:
- Waste Accumulation: Rapid economic growth and urbanization in many Asian countries have led to a large amount of waste generation.The many environmental problems caused by waste accumulation have attracted attention from many parties.
- Improving Recycling System: Many Asian countries have made significant progress in waste recycling in recent years and established a relatively complete waste recycling system. All countries use market incentives to promote the development of waste resource utilization.
- Recycling Awareness Awakening: As the concept of sustainability continues to permeate, the environmental awareness of the public and enterprises in Asian countries has gradually increased. More and more investors are committed to waste recycling projects.
The Asian market has great potential for small pyrolysis machines. Rapid urbanization and large amounts of industrial waste have driven the demand for efficient waste treatment technology. Countries are also gradually realizing the importance of waste management and ecological protection. The following are successful cases of Beston Group‘s pyrolysis projects in Asia:
Profit Analysis of Small Scale Pyrolysis Unit
| 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 | ||||
Start Your Pyrolysis Project with Beston Group
If a small pyrolysis machine piques your interest, consider choosing Beston Group. Because we are professional manufacturer with professional strength and rich experience. If you want to know more about this plant before you purchase, contact us directly, contact us directly. Our project manager will provide professional solutions and designs that meet your needs. Find more information about our pyrolysis projects on LinkedIn.