Mingjie industrial plastic pyrolysis plant is a waste plastic processing and recycling line, designed for waste municipal plastics, marine plastics, and medical plastics. As a leading Chinese manufacturer of pyrolysis technology and equipment, Mingjie Group boasts an advanced pyrolysis technology R&D and equipment manufacturing industrial park.
We are committed to developing comprehensive, environmentally friendly continuous pyrolysis solutions. Our industrial plastic pyrolysis plants have been used in solid waste pyrolysis projects in multiple countries.
The entire industrial plastic pyrolysis plant consists of eight major systems: feeding, pyrolysis, heating, condensation, separation, slag removal, purification, and electronic control system. The industrial plastic pyrolysis plant produces high-value-added products, such as pyrolysis oil, carbon black, and syngas. It is suitable for large-scale commercial operations.
Continuous Industrial Plastic Pyrolysis Plant Workflow
Feeding Process
The feed system pushes the material into the pyrolysis reactor, which is then ignited and begins pyrolysis.
Heating Process
The combustion chamber uses syngas for combustion and heating, raising the temperature. The industrial plastic pyrolysis plant is started using diesel or natural gas, taking approximately one hour. The pyrolysis equipment is equipped with a digital temperature controller, which automatically controls the furnace temperature at 400-450°C.
Pyrolysis Process
The pyrolysis process of industrial plastic pyrolysis plant proceeds layer by layer, from the outside in. The plastic pyrolysis products are gas and solid phases: the gas phase consists of hydrocarbons with varying carbon numbers, while the solid phase consists of residual carbon from high-carbon organic matter.
The gas phase exits the furnace chamber due to the pressure differential caused by the temperature difference between the inside and outside of the pyrolysis furnace. It is then condensed in the condensation stage as pyrolysis gas, and the remaining carbon residue is cooled and packaged as the product.
The continuous industrial plastic pyrolysis plant allows continuous pyrolysis, and the pyrolysis gas in the main furnace is drawn out of the furnace under a slightly negative pressure process. Carbon black is conveyed by the screw propeller into the carbon black slag discharge system.
Product Separation Process
The pyrolysis oil and gas exiting the pyrolysis reactor enter a gas separator, where gravity sedimentation removes fine dust from the oil and gas. It then enters a condenser, where most of the remaining gas in the system is extracted. The condensable portion is converted into liquid and passed through a separator tank to an oil storage tank, while the non-condensable portion enters a purification system.
The condensation system of industrial plastic pyrolysis plant utilizes a tube condenser, cooled by water. Cooling water is supplied by a circulating water tank.
Oil Gas Separation
The oil and water are separated in the separator tank, producing a small amount of oily wastewater. Fuel oil is stored in an oil storage tank. The non-condensable gas is evacuated to a vacuum in the buffer tank by a vacuum pump. Under the vacuum pressure, the non-condensable gas passes through the condenser, enters the alkaline cleaning and purification unit.
The remaining exhaust gas after condensation is primarily low-carbon hydrocarbon flammable gas. After passing through two safety devices, a water seal and a flashback arrester, it is fed into the cracking furnace combustion chamber as fuel. It is fully burned at the furnace bottom to provide the required energy for the cracking furnace.
The combustion flue gas is treated by environmental protection facilities and then discharged through the chimney after meeting the standards.
Carbon Black Collection
The carbon black is conveyed by a spiral slag cooler into carbon black packaging bags. Circulating cooling water is introduced through the outer wall of the slag cooler, reducing the carbon black temperature to below 40°C during the spiral conveying process. The carbon black slag discharge is fully enclosed.
Safety Monitoring
The pyrolysis furnace, steam drum, and settling tank are equipped with temperature control systems and pressure gauges. The separation tank is also equipped with a pressure gauge. Both the temperature control system and pressure gauges are remotely monitored.
They monitor the pressure and temperature of the main processor and key systems. Automatic alarms are generated in the event of any abnormality, ensuring the safety of the plastic-to-fuel oil process.
Flue Gas Treatment System
The post-combustion flue gas first passes through a heat exchanger to dry the waste plastic. It then enters a comprehensive flue gas treatment system to achieve standard discharge.
The industrial plastic pyrolysis plant utilizes a special emission purification system, including water spray dust reduction, alkali wash spray tower, UV photolysis, activated carbon adsorption.
The alkali spray absorbs acidic gases, while the activated carbon adsorbs organic gases. Liquid spraying inherently reduces dust, eliminating the need for additional dust removal equipment. The treated flue gas, once meeting standards, is discharged through the chimney.
Advantages of Plastic Pyrolysis Plant
The industrial plastic pyrolysis plant offers unmatched advantages over traditional treatment methods in terms of resource recycling and environmental protection. It provides a viable solution for the harmless and resource-efficient treatment of plastic waste.
Conventional landfilling simply buries plastic waste underground. These plastics are difficult to degrade in the soil, which not only consumes valuable land resources but also wastes the chemical energy and raw materials they contain. According to statistics, the value of plastic waste lost to landfills globally each year reaches billions of dollars.
While incineration can reduce the volume of plastic waste, most of the energy is released directly as heat, making it impossible to effectively recycle. It also produces large amounts of harmful gases and ash, causing secondary environmental pollution.
Waste Resource Utilization
The industrial plastic pyrolysis plant transforms plastic waste into valuable resources, achieving resource recycling. The pyrolysis oil produced by pyrolysis can be used directly as fuel. It can also be further refined to produce high-quality fuel oils such as gasoline and diesel.
- Pyrolysis technology can convert 1 ton of plastic waste into approximately 0.7-0.8 tons of pyrolysis oil, with an energy density comparable to traditional fossil fuels.
- Pyrolysis produces combustible gases, such as hydrogen and methane. These gases are important clean energy sources and can be used for power generation and heating, providing a new energy source.
- The solid carbon black produced during pyrolysis can also be used as an industrial raw material in industries such as rubber, inks, and coatings.
Harmless Treatment
The industrial plastic pyrolysis plant operates under oxygen-free or oxygen-deficient conditions, effectively reducing the production of harmful gases. During the pyrolysis process, organic matter in the plastic is broken down into small molecules, avoiding the generation of harmful substances such as dioxins due to incomplete combustion during incineration.
At the same time, the syngas produced by pyrolysis can be purified to remove impurities and pollutants, ensuring they meet environmental emission standards before being released, significantly reducing environmental pollution.
Furthermore, industrial plastic pyrolysis plant can reduce the land occupied by plastic waste, alleviating land resource constraints.
