How Does Pyrolysis Plant Work?

The pyrolysis plant is a recycling machine that can convert waste plastic/tyre/oil sludge/coal tar oil to fuel oil. The final product of the pyrolysis plant is mainly fuel oil (can be further refined into diesel), carbon black, and signal gas. (Steel wire for waste tyre). The prolysis plant is a renewable and environmental equipment that deals with the waste and changes the waste into energy.

Goto Sihai Energy to know more.

Waste plastics/tyres/oil sludge to fuel oil plant

◆ The principle of the pyrolysis plant is as below:

When the raw material waste tyre/plastic heated in the reactor, then raw material will generate some oil gas. When the oil gas goes into the condenser, the oil gas will be condensed into liquid fuel oil. The oil gas which cannot be condensed will be recycled to the burner to heat the reactor. So just little energy is required to run the pyrolysis plant. It's quite energy saving.

◆ Pyrolysis Plant Working Process:

Next, let's take the waste plastic pyrolysis plant as an example to see how the pyrolysis plant works.

1. Use the feeding machine to send the waste plastic into the pyrolysis reactor, and then heat the pyrolysis reactor with fuel;

2. When the temperature of the pyrolysis reactor reaches a certain temperature, oil gas will be produced, and the oil gas will be cooled down into pyrolysis oil through the cooling system.

Uncondensable but combustible gas can be recycled by industrial pressure vessel to heat pyrolysis reactor;

3. After the pyrolysis reaction is over, wait for the temperature of the pyrolysis reactor to drop below 40 degrees, and then open the carbon black discharge port of the pyrolysis reactor to discharge carbon black.

4. Collect the carbon black with the carbon black discharge device.

Workflow of continuous waste plastic pyrolysis plant

◆ Pyrolysis Plant Running Videos:

◆ The application of pyrolysis plant final products

1. Fuel oil.

Fuel oil is a good heating fuel, which can be used in many industries, such as steel factories, boiler heating, heavy oil generator, cement factories, etc. Besides, fuel oil can be refined by waste oil distillation machine into diesel fuel, which can be used in diesel generator, heavy machinery or diesel fuel for heating. The current market price of waste tire pyrolysis oil is about US$500 per ton, and the price is still rising. Therefore, waste tire pyrolysis oil can bring huge profits to customers.

Fuel oil application

2. Carbon black.

Carbon black can be made into pellets for burning and heating, just like coal, or refined into different standards, used as additives for paints, pigments, rubber products, etc. Many of our customers have obtained huge profits from carbon black, which has solved the problem of carbon black shortage in the market to a certain extent.

Carbon black application

◆ Different types of Pyrolysis Plant For Sale:

Doing Group provides two types of waste tire/plastic pyrolysis plant: batch waste tire/plastic pyrolysis plant and continuous waste tire pyrolysis plant. The daily capacity of our pyrolysis plant is between 100KG to 50+T.

1. Batch Type:

①Skid-mounted Pyrolysis Plant: 100KG, 500KG

The company is the world’s best Vacuum Distillation Plant supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Features: Free installation, easy for transportation and handling. Suitable for trial running or sciences experiment uses.

②Common Batch Pyrolysis Plant: 1-15TPD

Features: Cost effective, multiple uses, popular choice of most customers

2. Continuous Type:

①Semi-continuous Pyrolysis Plant: 1-15TPD

Features: Equipped with feeding system, labor&energy saving. Higher configuration of batch common batch pyrolysis plant.

②Fully continuous Pyrolysis Plant: 15-50+TPD

Features: 24/7 hours running, high professing efficiency, high profits. Suitable for customers who want to dispose of waste in a large quantity.

Different type pyrolysis plant

DOING Group's pyrolysis plants have been on hot sale in more than 100+ countries and regions, and in good running. By virtue of their stable operation, environmental protection and brilliant performance, our pyrolysis plants won good recognition.If you want to know more information about waste tires/plastic pyrolysis plants, welcome to consult us.

What is Pyrolysis?

Introduction     Our Research     What Is Pyrolysis?     Bio-Oil     Researchers

Facilities     Our Partners     Publications     In The News     Links

What Is Pyrolysis?

Biomass

Lignocellulosic biomass is the most abundant renewable carbon source on Earth.  Available biomass sources include forest residues, crop residues, purpose grown energy crops (e.g. grasses), animal wastes and food wastes.  These materials are the fibrous structural parts of plants and are largely made of cellulose, hemicellulose and lignin.  Compared with so called 1st generation bio-feedstocks such as sugars, starches and vegetable oils, nature has made these parts of the plants difficult to deconstruct to chemical building blocks, making utilization of this carbon source a challenge for scientists and engineers.   Biorefineries are facilities where biomass is converted to a variety of products.  Our target products included advanced hydrocarbon biofuels that are indistinguishable from fossil-based gasoline, diesel or jet fuels along with bio-based chemicals and materials.  Technologies need to be developed to more efficiently convert this renewable carbon source so that renewable bio-products from biomass can be made economically competitive with those produced from fossil resources.

Pyrolysis

Pyrolysis is one of the technologies available to convert biomass to an intermediate liquid product that can be refined to drop-in hydrocarbon biofuels, oxygenated fuel additives and petrochemical replacements. Pyrolysis is the heating of an organic material, such as biomass, in the absence of oxygen.  Biomass pyrolysis is usually conducted at or above 500 °C, providing enough heat to deconstruct the strong bio-polymers mentioned above.   Because no oxygen is present combustion does not occur, rather the biomass thermally decomposes into combustible gases and bio-char.  Most of these combustible gases can be condensed into a combustible liquid, called pyrolysis oil (bio-oil), though there are some permanent gases (CO­2, CO, H2, light hydrocarbons), some of which can be combusted to provide the heat for the process.  Thus, pyrolysis of biomass produces three products: one liquid, bio-oil, one solid, bio-char and one gaseous, syngas.  The proportion of these products depends on several factors including the composition of the feedstock and process parameters.  However, all things being equal, the yield of bio-oil is optimized when the pyrolysis temperature is around 500 °C and the heating rate is high ( °C/s) fast pyrolysis conditions.   Under these conditions, bio-oil yields of 60-70 wt% of can be achieved from a typical biomass feedstock, with 15-25 wt% yields of bio-char.  The remaining 10-15 wt% is syngas.  Processes that use slower heating rates are called slow pyrolysis and bio-char is usually the major product of such processes.  The pyrolysis process can be self-sustained, as combustion of the syngas and a portion of bio-oil or bio-char can provide all the necessary energy to drive the reaction. 

Schematic of the Fast Pyrolysis Process.

Bio-oil is a dense complex mixture of oxygenated organic compounds.  It has a fuel value that is generally 50 - 70% that of petroleum bases fuels and can be used as boiler fuel or upgraded to renewable transportation fuels.  The bio-oil’s composition makes it thermally unstable and therefore difficult to distill or further refine, making additional research on producing higher quality bio-oil necessary.  However, its density is > 1 kg L-1, much greater than that of biomass feedstocks, making it more cost effective to transport than biomass.   Therefore, it’s is possible to envision a distributed processing model where many small scale pyrolyzers (farm scale) covert biomass to bio-oil which is then transported to a centralized location for refining.  To test this hypothesis, our group developed and constructed a mobile one-ton per day pyrolysis demonstration unit based on a reactor design called the combustion reduction integrated pyrolysis system (CRIPS). The CRIPS unit can produce bio-oil on location and can perform fast or catalytic pyrolysis to produce partially deoxygenated bio-oil.

   ARS’s Mobile Combustion Reduction Integrated Pyrolysis System (CRIPS)

Furthermore, the bio-char produced can be used on the farm as an excellent soil amender that can sequester carbon.  Bio-char is highly absorbent and therefore increases the soil's ability to retain water, nutrients and agricultural chemicals, preventing water contamination and soil erosion. Soil application of bio-char may enhance both soil quality and be an effective means of sequestering large amounts of carbon. Use of bio-char as a soil amendment will offset many of the problems associated with removing crop residues from the land. 

Our Project

Our core project at the Eastern Regional Research Center current has four main objectives dedicated to making pyrolysis and biodiesel based biorefineries economically competitive.  They include:

1. Develop thermochemical and/or catalytic, carbon efficient biomass and waste plastic conversion processes to produce bio-oils and bio-gas containing fractions suitable for use towards advanced commercially viable bio-fuels (jet, diesel, and gasoline carbon ranges).
2. Develop pre- and post-process thermo-catalytic technologies to produce renewable chemicals and biocarbon materials from biomass, biochar, lignin and bio-oils.
3. Identify and develop new feedstocks and technologies to produce biodiesel, renewable hydrocarbon diesel and biojet fuels from fats and oils.
4. Accurately estimate the economic values of thermolysis conversion processes to produce bio-based fuels and chemicals.

Our approach to developing commercially viable pyrolysis based biorefineries is summarized in the Figure above.   We are developing catalytic pyrolysis technologies where a catalyst is used to reduce the oxygen content of the bio-oil to produce stable, low or mid-level oxygen content bio-oil that can undergo separation processes such as distillation to sperate fractions to be used for various refining processes to produce renewable chemicals in addition to biofuels. We are also developing replacements for fossil based industrial carbons such as coke and pitch that can be used in heavy carbon emitting industries such as aluminum smelting. Furthermore, we are tackling the plastic waste problem by considering waste plastic, especially the very common polyolefins, as a potential source of cheap hydrogen making up for the inherent hydrogen deficiency in biomass. Our preliminary results indicate that co-pyrolysis of biomass with plastic waste over a catalyst can increase the carbon conversion efficiency to valuable aromatic hydrocarbons.