Continuous Pyrolysis Plant

Industry Status

  • Equipment blockage and frequent interruptions make it difficult to achieve scale profitability.
  • High energy consumption and low thermal energy utilization rate lead to high operating costs.
  • Difficult to meet emission standards, facing compliance difficulties and fine risks.
  • High work intensity and frequent manual intervention lead to high labor costs.
  • The quality of oil & carbon black varies, affecting sales prices.

Why Upgrade BLL-30

It recycles 6,000 tons plastic, 10,000 tons tyres and 12,000 tons oil sludge annually, contributing to both sustainable development goals and stable profitability.

  • 30 days of continuous non-blocking operation, no more downtime
  • Energy consumption reduced by 55%, significantly reducing fuel costs
  • Exhaust emissions reduced by 50%, meeting EU emission standards
  • Manual intervention reduced by 80%, only 2 operators required
  • ±10℃ precise temperature control, high quality oil & carbon black acquisition

3 Technical Breakthroughs of BLL-30 Continuous Pyrolysis Plant

Oil Gas Anti-polymerization Condensation Technology

30 days continuous running

This technology uses spray direct mixing condensation to rapidly reduce the temperature of oil gas. It prevents the secondary polymerization of olefin compounds, which can clog the oil gas pipelines.

Hot Flue Gas Recirculation + Air Preheating Technology

↓ 55% fuel consumption & ↓ 50% emission

Hot Flue Gas Recirculation: About 80% of flue gas is redirected to the combustion zone and mixed with 1000–1300 °C hot air to heat the reactor.

Air Preheating Technology: The remaining 20% flows to a waste heat recovery unit to preheat combustion air.

Reactor Automatic Temperature Control Technology

±10℃ Precise Temperature Control

This technology adjusts fuel mixing ratios in real time. It reduces 80% labor cost and operation complexity of pyrolysis plant. It ensures optimal pyrolysis conditions, boosting oil yield and carbon black quality.

Convert Plastic/Tyre/Oil Sludge to Value – BLL-30 Continuous Pyrolysis Plant

With large capacity and stability, fully automatic pyrolysis plant is ideal for industrial-scale plastic & tire recycling. The following are specific recyclable raw materials and pyrolysis products:

Acceptable plastics types: PP, PE, PS, and others without chlorine and oxygen (Note: PET/PVC can not be pyrolyzed)

Pyrolysis products: Pyrolysis oil, industrial residue (including a small amount of carbon black), syngas

Acceptable tyres types: Passenger tires, commercial tires, OTR tires, etc.

Pyrolysis products: Pyrolysis oil, carbon black, steel wire, syngas

Acceptable oil sludge types: Landing oil sludge

Pyrolysis products: Pyrolysis oil, industrial residue, syngas

Diverse Applications of Pyrolysis Products

Pyrolysis oil

Pyrolysis oil can be used as fuel in kilns, furnaces, and boilers for factories with high energy consumption.

Pyrolysis oil can be processed into non-standard diesel, which can be used in heavy oil generators and heavy machinery engines.

Pyrolysis oil can also be processed into naphtha, which is used in plastic manufacturing, as a solvent, and as a gasoline blending component.

rCB

Carbon black can be directly used in the production of cement, asphalt, inks, coatings, and other industrial materials.

The rCB (Recovered Carbon Black), kind of eco-friendly material is a key ingredient in the manufacture of eco-friendly tires.

Parameter of BLL-30 Continuous Pyrolysis Equipment

Model BLL-30
Manufacturer BESTON
Time to Market 2025
Motor Brand Chinese brand
Suitable Raw Materials Waste plastics; Tires; Oil sludge
Input Capacity (Max.) Waste plastic pellets: 0.8-1.05t/h
Rubber powder: 1.25-1.5t/h
Oil sludge:1.8-2.3t/h
Working Method Fully Continuous
Final Oil Quality Pyrolysis oil
Pyrolysis oil with wax or naphtha
Reactor Materil 304/310S Stainless steel
Reactor Life Span (Years) 5-8
Guarantee (Months) 12
Delivery Time (Calendar Days) 60-90
Land Space Required (L*W*H*m) 70*20*10
Packing 20*6*3m in bulk+13*40HQ
Installation Period (Calendar Days) 60-90

 

Technological Highlights of BLL-30 Continuous Pyrolysis Plant

Double Anti-Coking Protection

  • Coking Intervention: Hot air heating ensures uniform heat distribution in the reactor, preventing uneven heating and coking.
  • Mechanical De-coking: The decoking chain cleans the inner wall of the pyrolysis reactor directly by friction, preventing coking.

Sealing Protection

  • Main Furnace Sealing: Combined high-temperature flexible dynamic sealing technology greatly enhances sealing performance of reactor of fully continuous pyrolysis plant.
  • Discharge Sealing: The slag tank is equipped with a material seal to prevent leakage of high-temperature oil and gas during continuous slag discharge.

Precise & Safe Feeding

  • “Gram” Level Weighing: Electronic weighing system not only control the feed amount to the “gram” level but also allow real-time monitoring and phase statistics.
  • Oxygen-Deficient Protection: Nitrogen generator over 95% purity replaces the air in the sealed silo, maintaining an oxygen-deficient environment inside the reactor.

EU Emission Standards

  • Chemical Treatment: Exhaust gas flows into an SCR denitration tower to eliminate NOₓ. Then it proceeds to a desulfurization tower to eliminate sulfur compounds.
  • Physical Treatment: Exhaust gas passes through electrostatic precipitator to remove large particulates. Finally, it enters activated carbon device to adsorb fine particulates.

Benchmark Project of BLL-30 Continuous Pyrolysis Plant

Continuous Plastic Pyrolysis Project in Morocco
– Fuel Cost Reduction

Project Goals

  • Obtain pyrolysis oil: Convert waste plastics into fuel oil;
  • Cut energy costs: Power the factory with the oil to cut energy costs;
  • Stable operation: Ensure stable operation for long-term gains.

Project Status

  • Development Started 2024 | Installation Completed | Operating

Project Outcomes

  • High oil yield: Continuously convert plastic into fuel oil, the oil yield achieves approximately 65%.
  • Reduce production costs: Use the obtained pyrolysis oil instead of diesel, greatly reducing production costs.

Continuous Pyrolysis Project in North Africa
– Solves Oil Sludge Treatment Challenge

Project Goals

  • Project Compliance: Meet AU and local emission standards through sludge pyrolysis process. Obtain project EIA certification.
  • Cost Reduction: Self-built treatment center improves oil sludge treatment capacity, significantly reducing costs.

Project Status

  • Development Started 2024 | Installation Completed | Operating

Project Outcomes

  • Emissions Meet Standards: The treated oil sludge fully meets AU and local environmental protection standards.
  • Improved Processing Capacity: After the equipment is put into operation, large-scale processing capacity is stably guaranteed.
  • ROI Improvement: Reduce external processing expenses, obtain sales revenue of pyrolysis products, and improve ROI.

Continuous Pyrolysis Project in the Netherlands
– Build a Greener Plastics Value Chain

Project Goals

  • Achieve large-scale plastic recycling and promote EU circular economy.
    Meet stringent NOx emission standards.
  • Solve the risk of wax oil clogging machine in pyrolysis

Project Status

  • Development Started 2023 | Installation Completed | Operating

Project Outcomes

  • Equipment is operating smoothly with no blockages, minimal downtime.
  • Annually recycle 24,000 tons of plastic waste, and reduce 93,000 tons of CO₂ emissions.
  • Supply pyrolysis oil for new plastic production, enabling a true circular economy.

Workflow of  Continuous Pyrolysis Machine

PTGS  provides an on-site demonstration video to help you better understand the components and operational 

01 Feeding
  • The first screw feeder conveys raw materials in a silo to the weighing machine for precise weighing.
  • The second screw feeder then delivers the accurately quantitative material into the pyrolysis reactor.
  • The raw materials enter the reactor of continuous plastic pyrolysis plant. Then, under the push of guide plate, the raw materials are fully heated from the front to the back.
  • When the temperature reaches 180 degrees Celsius, gas oil begins to generate. A significant amount of gas oil appears at temperatures between 280-350 degrees Celsius.
  • After the oil gas enter the catalytic tower, it reacts with the catalyst. This step mitigates issues related to wax deposition and liquefaction. Simultaneously, it contributes to enhancing the quality of the plastic pyrolysis oil.
  • The oil gas enters the manifold of continuous pyrolysis plant, and heavy particles of the oil gas will be liquefied and dropped into the heavy oil tank.
  • The light oil gas will be liquefied into fuel oil by the condenser and reserved in the fuel oil tank.
  • Non-condensable gas is directed to the buffer tank, water-gas separator and multiple water seals to stabilize the gas pressure.
  • The purified combustible gas is recovered and returned to the combustion chamber for combustion to produce hot air.
  • Part of high-temperature flue gas is directed to the combustion chamber. It mixes with the hot air and heats the reactor.
  • The remaining flue gas exchanges heat with the air in the air-to-air heat exchanger. The heated air provides oxygen to support closed combustion.
  • The residue is transported to the water-cooled slag box through the spiral slag discharger at the tail of the continuous waste plastic pyrolysis plant reactor.
  • Soild residue in storage tank enters multiple water-cooled slag dischargers for cooling.
  • Sampler is deployed at the tail of the reactor. Operators can periodically sample the slag to monitor its condition.
  • Exhaust gas is cooled, desulfurized, denitrified, electrostatically precipitated, and activated carbon precipitated. The chimney discharges exhaust gas that meets EU emission standards.

Stay Ahead of Policy Trends: Choose Continuous Pyrolysis Plant First

As global environmental regulations tighten, governments worldwide are driving industries toward greener, more efficient, and sustainable development. Continuous pyrolysis equipment stands out as the smart choice, especially when considering the following policy trends:

Government Bans

Many countries are phasing out traditional batch systems due to their pollution and safety risks. For example, in 2023, China’s State Council mandated the complete phase-out of non-compliant fixed-bed batch gasifiers. Continuous systems, featuring closed-loop operation and fully automated control, are cleaner, safer, and more likely to meet future regulatory standards.

Policy Incentives

Governments offer subsidies, tax breaks, and green financing for advanced, low-emission equipment. Continuous pyrolysis machine qualifies for such support due to their energy efficiency and better emission control, which helps investors reduce costs and attract ESG-driven investment.

Easier Environmental Approval

Environmental Impact Assessments (EIA) and Safety Assessments are easier to pass with continuous systems. Their steady-state operation and reliable emission control simplify compliance, speeding up the permit process and reducing project delays.

Contributions of BLL-30 Continuous Pyrolysis Equipment to Industries

As global environmental regulations tighten, governments worldwide are driving industries toward greener, more efficient, and sustainable development. Continuous pyrolysis equipment stands out as the smart choice, especially when considering the following policy trends:

Waste Management Recycling Industry

These industries need to manage high volumes of waste plastic or waste tires. By adopting continuous pyrolysis technology, they can:

  • Efficient treatment: Large amount of plastics/tyres can be processed by BLL-30 continuous pyrolysis machine. One day, it can process 35 tons tires or 25 tons plastics.
  • Qualified carbon black output: Automatic temperature control ensures toluene permeability meets standards, turning carbon black into valuable end product.

Oil and Gas Industry

Faced with substantial volumes of oil sludge, this industry benefits from continuous pyrolysis system in several key ways:

  • Waste reduction & harmless：BLL-30 can recycle oil components of waste generated in the industry, reducing waste volume and avoiding environmental risks.
  • Enhance industry influence: Investing in cutting-edge recycling technology demonstrates ESG leadership and wins recognition from society and government.

Manufacturing Industries with High Fuel Oil Demand

Heavy industries such as cement, metallurgy, and chemicals are seeking cost-effective and cleaner energy alternatives. Continuous pyrolysis plant offers:

  • Energy independence: Convert internal waste or sourced materials into fuel, reducing reliance on external suppliers and cutting fuel expenses.
  • Low-cost environmental compliance: EU industries face strict emission standards. Flue gas recirculation and air preheating help meet these requirements while keeping compliance costs down.

Launch Continuous Pyrolysis Project with Beston Group

Invest in a continuous pyrolysis plant and lead the way in cutting-edge solid waste recycling. Designed for profitability, sustainability and industrial-scale operation, it’s the smart choice for large-scale recycling projects. Share your needs, we will provide you with a customized solution. Follow us on Linkedin to stay up with latest innovations.

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