What are the additional equipment for pyrolysis plant and their cost?

In the pyrolysis process, the pyrolysis reactor is the core equipment. However, to ensure the smooth operation of the entire pyrolysis process and improve the quality of the final products, a series of additional equipment is required. The specific cost for it depends on the additional equipment configuration scheme.

Below is an introduction to the common additional equipment and their purposes:

Pre-processing Equipment

Shredder/Crusher: The feedstock for pyrolysis (e.g., waste tires, plastics) often varies in size and shape. By shredding or crushing it into smaller pieces, the feedstock can be uniformly fed into the reactor, thereby enhancing pyrolysis efficiency.

DOING pyrolysis plant waste-pretreatment machines

Drying System: Wet feedstock (e.g., wet oil sludge) may affect the pyrolysis process. A drying system removes excess moisture from the feedstock, improving pyrolysis efficiency and ensuring the smooth progress of the pyrolysis reaction.

Magnetic Separator: In applications like waste tire pyrolysis, the feedstock may contain metal impurities such as steel wires. A magnetic separator can effectively remove these metals, preventing damage to the reactor and improving the purity of the pyrolysis products.

Feeding System: To ensure continuous and stable operation of the pyrolysis reactor, a feeding system (e.g., screw conveyors, hydraulic feeders, or sealed hoppers) is required. This system feeds the pre-processed feedstock into the reactor at a controlled rate, enabling automated and continuous pyrolysis operations.

DOING pyrolysis plant feeding system

Post-processing Equipment

Condensing System: During pyrolysis, a large amount of pyrolysis gas is generated. A condensing system (e.g., tube condensers, spray towers) cools the pyrolysis gas, converting it into liquid oil. This is a critical step in recovering pyrolysis oil.

DOING pyrolysis plant water tank cooling system

Oil Purification System: The pyrolysis oil produced often contains impurities and moisture, which can affect its quality and applications. An oil purification system (e.g., distillation units) refines the pyrolysis oil, improving its quality and broadening its range of uses.

DOING waste oil distillation plant

Gas Scrubbing System: The syngas generated during pyrolysis may contain harmful gases such as hydrogen sulfide (H₂S) and hydrogen chloride (HCl). A gas scrubbing system removes these impurities, reducing environmental pollution and enabling the reuse of syngas (e.g., as fuel for the pyrolysis reactor).

DOING pyrolysis plant gas scrubbing system

Carbon Black Processing Equipment: In pyrolysis processes involving waste tires or plastics, carbon black is a byproduct. Carbon black processing equipment (e.g., grinding, pelletizing, or bagging systems) processes the carbon black into a marketable and usable form, enhancing its economic value.

DOING waste pyrolysis plant carbon black processing equipment

Gas Recovery Systems

Gas Burner: Gas burners utilize non-condensable gases produced during pyrolysis to fuel the reactor, reducing the plant's reliance on external energy sources and lowering operating costs.

DOING pyrolysis plant gas recovery systems

Automation and Control Systems

PLC Control Panel: The pyrolysis process involves complex operations and parameter adjustments. A PLC control panel monitors critical parameters such as temperature, pressure, and feeding rate in real time, enabling automated control of the pyrolysis process and improving operational stability and reliability.

Temperature and Pressure Sensors: Accurate temperature and pressure monitoring is essential for ensuring safe and efficient pyrolysis operations. Temperature and pressure sensors provide real-time data, helping operators adjust process parameters promptly.

Emergency Shutdown System: In the event of equipment malfunctions or emergencies, the emergency shutdown system can quickly halt the pyrolysis process, preventing accidents and ensuring the safety of personnel and equipment.

DOING waste pyrolysis plant PLC system

Auxiliary Power Systems

Generator: In some cases, the pyrolysis plant may require a backup power supply. A generator provides emergency power to ensure the plant's operations are not disrupted.

Cooling Tower: The condensing system generates hot water during the cooling process. A cooling tower cools this hot water, enabling its reuse in the condensing system and improving energy efficiency.

Additional equipment costs

The specific equipment configuration for a pyrolysis plant is influenced by a variety of factors.

Plant Scale (Batch or Continuous):

Batch Pyrolysis Plant: This type of plant processes feedstock in batches. The equipment configuration is relatively simple and may include a single pyrolysis reactor that is loaded, heated, and then unloaded after the process is complete. The feeding system is typically designed for intermittent operation, and the post-processing equipment may have lower capacity requirements since processing occurs in discrete batches.

DOING batch type pyrolysis plant

Continuous Pyrolysis Plant: Continuous plants process feedstock continuously, requiring more complex equipment configurations. The feeding system must be capable of delivering a steady supply of feedstock, and post-processing equipment like condensers, oil purification systems, and gas scrubbing systems need to be designed for continuous operation to handle the ongoing output of pyrolysis products.

DOING continuous pyrolysis plant

Feedstock Type:

Waste Tires: Pyrolysis of waste tires may require additional equipment such as shredders to reduce tire size before processing, magnetic separators to remove steel wires from the tire shreds, and specialized carbon black processing equipment to handle the carbon black produced.

Plastic Waste: Different types of plastic waste may need to be sorted and cleaned before pyrolysis. Some plastics may require specific pre-treatment steps to remove contaminants or additives. The pyrolysis oil produced from plastic waste may also require more advanced purification systems to meet quality standards for its intended applications.

Oil Sludge: Oil sludge feedstock, such as that from petroleum refining or oil-contaminated soil, may have varying moisture contents. A drying system might be necessary to reduce moisture levels to an optimal range for efficient pyrolysis. Additionally, the particle size of oil sludge can affect pyrolysis efficiency, so shredders or grinders may need used to achieve a uniform particle size.

DOING pyrolysis plant waste-pretreatment machines

Local Environmental Regulations:

Emission Standards: Stringent air quality regulations may necessitate advanced gas scrubbing and cleaning systems to remove harmful gases and particulate matter from the syngas before it is released into the atmosphere or reused. This could include equipment for removing hydrogen sulfide (H₂S), hydrogen chloride (HCl), and other volatile organic compounds (VOCs).

Waste Disposal Requirements: Regulations regarding the disposal of solid residues like carbon black or char may influence the equipment used for processing and handling these materials. For example, if landfill disposal is restricted, additional equipment for carbon black recovery, pelletizing, or other forms of utilization may be required.

DOING waste pyrolysis plant environment protection devices

The specific equipment configuration for a pyrolysis plant depends on factors such as the plant's scale (batch or continuous), feedstock type, and local environmental regulations. If you want to learn more about the additional equipment for pyrolysis plants and their prices, please feel free to contact us for a customized pyrolysis equipment configuration scheme and get an estimated cost.