What is pyrolysis plant? - Sihai Energy Technology
What is pyrolysis plant? - Sihai Energy Technology
What is pyrolysis plant?
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.
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Waste plastics/tyres/oil sludge to fuel oil plant
◆ The principle of the waste plastic 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.
◆ 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.
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.
◆ Different types of Pyrolysis Plant For Sale:
1. Batch Type:
①Skid-mounted Pyrolysis Plant: 100KG, 500KG
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.
Small is beautiful: Pyrolysis of solid waste compatible with the need
Solid waste, usually known as trash or garbage, is a rejected and unusable residue produced in common-day activities. In this article, we are explaining the power of local sized solutions for solid waste pyrolysis.
Value out of trash: How pyrolysis of solid waste can help in local treatment process.
Introduction to solid waste.
Solid waste, usually known as trash or garbage, is a rejected and unusable residue produced in common-day activities. Depending on the industry and origin, this term can cover both: municipal and industrial waste, construction, demolition or waste-water process derived substances, combustible and fire-resistant, exposing a different range of properties and characteristics. Such a wide variety of products calls for the extensive portfolio of technologies dedicated to efficient management.
For many years, the industry has been busy developing technologies for segregation, recycling and reuse of materials. From the waste collection, through the transportation, sorting, and processing on site, hundreds of different solutions are working in service of minimising the quantity of waste that would be dumped. Although waste recycling and management systems are more and more efficient, still there is often a high quantity of calorific solid waste that cannot be recycled with available measures.
At that point, the energy recovery technologies come up with a variety of mass burn solutions that handle the mixed streams of waste. Incineration plants provide a general answer for incoming streams of waste, often managing it as low-quality fuel. Large incinerators have made their place in the industry for good, welcoming garbage transports from all the nearby regions.
Small is beautiful: Solid waste pyrolysis compatible with the need
We believe that size of technical solutions has to be associated with local environmental and economic needs. This is why we develop modular and compact plants that can be quickly set up to the available conditions and further sized up when the demand increase.
Whenever working with municipal or industrial waste manager, we focus on decentralized solutions. Because by bringing the process right to the place it is needed, waste can really become a resource for creating value and building the sustainable economy.
Do you think your industry or community could benefit from pyrolysis of solid waste? Do not hesitate to contact us
Pyrolysis Plants: Transforming Waste into Resources for a Greener Future
A pyrolysis plant or pyrolysis reactor, also called a biochar production machine, is a specialized piece of equipment used in the process of pyrolysis. Pyrolysis is a thermal decomposition process that involves heating organic materials in the absence of oxygen, resulting in the breakdown of the materials into various byproducts.
The primary purpose of a pyrolysis machine is to convert organic materials such as biomass, plastics, rubber, or waste tires into useful products like bio-oil, biochar, and syngas. The machine creates an environment with controlled temperature and absence of oxygen, typically using a rotating or fixed reactor chamber.
Pyrolysis Process
Want more information on tire pyrolysis system? Feel free to contact us.
The pyrolysis process involves three main stages:
1. Drying:
The feedstock is dried to remove any moisture present in the material. This is important to ensure efficient pyrolysis and prevent unwanted reactions.
2. Pyrolysis:
The dried feedstock is then subjected to high temperatures, typically ranging from 400 to 800 degrees Celsius (752 to degrees Fahrenheit), in the absence of oxygen. This thermal decomposition leads to the breakdown of the organic material into volatile gases, liquid products, and solid char.
3. Condensation and Collection:
The volatile gases produced during pyrolysis are condensed into a liquid known as bio-oil, which can be further refined for various applications. The solid char, known as biochar, can be used as a soil amendment or for other purposes. Syngas, a mixture of combustible gases, is also produced and can be used as a source of energy.
Pyrolysis machines are used in waste management, recycling, and renewable energy industries. They provide an environmentally friendly method of converting waste materials into valuable resources, reducing landfill waste and dependence on fossil fuels.
Build and Operate a Small-scale Pyrolysis Plant
Yes, it is possible to build and operate small-scale pyrolysis plants for farm or timber company use. In fact, small-scale pyrolysis systems are becoming increasingly popular for decentralized and localized processing of biomass or waste materials. These smaller plants can offer several benefits, including on-site waste management, energy generation, and the production of value-added products.
Small-scale pyrolysis plants are typically designed to handle lower volumes of feedstock compared to larger industrial-scale plants. They can be tailored to meet specific requirements and accommodate the available biomass or waste materials from farms or timber companies. The capacity of such plants can range from a few kilograms to a few tons per day.
Advantages of small-scale pyrolysis plants:
1. Waste Management:
Farms and timber companies generate various organic waste materials such as crop residues, wood chips, sawdust, or agricultural waste. A small-scale pyrolysis plant provides an opportunity to convert these waste materials into useful products while minimizing disposal and transportation costs.
2. Energy Generation:
The pyrolysis process generates a combustible gas called syngas, which can be used to produce heat or electricity. Farms or timber companies can utilize this energy on-site to power their operations, reducing reliance on external energy sources.
3. Biochar Production:
The solid residue known as biochar, produced during pyrolysis, can be used as a soil amendment. Biochar enhances soil fertility, water retention, and carbon sequestration, providing benefits for agricultural or forestry activities.
4. Value-added Products:
Small-scale pyrolysis plants can produce bio-oil, a liquid product with potential applications in heating, industrial processes, or further refinement into biofuels. This opens up opportunities for generating additional revenue streams.
When considering the construction of a small-scale pyrolysis plant, it is important to ensure compliance with local regulations, obtain necessary permits, and conduct feasibility studies to assess the availability and suitability of feedstock. Engaging with experts in pyrolysis technology and consulting with relevant authorities can help in the design, construction, and safe operation of a small-scale pyrolysis plant tailored to the specific needs of a farm or timber company.
Pyrolysis Plants for Wood Feedstock
For wood feedstock, the most suitable type of pyrolysis plant is typically a “slow pyrolysis” or “carbonization” plant. Slow pyrolysis is a pyrolysis process that occurs at relatively low temperatures (around 400 to 600 degrees Celsius) and longer residence times, resulting in a higher yield of solid char (biochar) and a lower yield of liquid products (bio-oil). This process is well-suited for wood feedstock due to its high carbon content and the desire to maximize biochar production.
Key features and considerations for a pyrolysis plant optimized for wood feedstock:
Fixed-bed Reactor: Slow pyrolysis plants for wood often utilize fixed-bed reactors. In this configuration, the wood feedstock is loaded into a stationary reactor chamber, and heat is applied to initiate the pyrolysis process. The fixed-bed design allows for better control of the pyrolysis parameters, such as temperature and residence time.
Controlled Oxygen Environment: Wood pyrolysis is typically performed in an oxygen-limited or oxygen-free environment to prevent combustion. This can be achieved by using a sealed reactor or by introducing an inert gas, such as nitrogen, to displace the oxygen.
Slow Heating and Longer Residence Time: The slow pyrolysis process involves gradually heating the wood feedstock over a longer period, allowing for the decomposition of the organic materials into biochar, gases, and some liquid products. This promotes the production of high-quality biochar while minimizing the yield of volatile gases.
Condensation and Filtration: Since slow pyrolysis of wood generates a lower amount of liquid products, the condensation and collection systems can be designed accordingly. These systems should be capable of capturing and recovering the produced bio-oil efficiently. Additionally, filtration systems may be required to remove any remaining solids or impurities from the bio-oil.
Biochar Collection and Handling: The produced biochar is a valuable co-product with various applications. The plant should have appropriate mechanisms for collecting, cooling, and handling the biochar. This may include a separate chamber or system for biochar quenching and storage.
It’s important to note that the specific design and configuration of a pyrolysis plant for wood feedstock can vary based on factors such as scale, desired outputs, and available resources. Consulting with experts in pyrolysis technology and considering the specific requirements and goals of the wood processing operation can help in selecting or designing the most suitable pyrolysis plant for wood feedstock.
Pyrolysis Plant Safety
Pyrolysis plants, like any industrial facility, can pose certain risks if not operated and maintained properly. However, with appropriate safety measures and adherence to regulations, the risks associated with pyrolysis plants can be effectively mitigated. Here are some factors to consider regarding the safety of pyrolysis plants:
Fire and Explosion Hazards: Pyrolysis involves heating materials to high temperatures, and some materials can be flammable. If safety protocols are not followed, there is a risk of fire or explosion. Proper equipment design, installation of safety systems (such as fire suppression systems and explosion-proof equipment), and adherence to safety guidelines can help minimize these risks.
Emission Control: Pyrolysis processes can generate emissions, including gases, volatile organic compounds (VOCs), and particulate matter. It is essential for pyrolysis plants to have effective emission control systems in place, such as scrubbers, filters, and monitoring equipment, to prevent the release of pollutants into the atmosphere.
Occupational Safety: Workers involved in operating and maintaining pyrolysis plants need to follow safety protocols, wear appropriate personal protective equipment (PPE), and receive proper training. Potential hazards include high temperatures, exposure to harmful gases and chemicals, and the handling of sharp or heavy objects. Safety measures like regular inspections, safety training, and the implementation of safety procedures are vital to protect workers.
Waste Handling and Storage: Pyrolysis plants typically handle large volumes of waste materials. Proper waste handling and storage practices are necessary to prevent spills, leaks, or other incidents that could lead to environmental contamination or pose risks to workers.
To ensure the safe operation of pyrolysis plants, it is important to comply with local regulations, obtain necessary permits, and implement appropriate safety management systems. Regular maintenance, inspections, and monitoring of the equipment are also crucial to identify and address any potential issues promptly.
It is worth noting that advancements in pyrolysis plant technology and industry best practices continually strive to enhance safety standards and minimize risks associated with these facilities.