What is the pyrolysis plant?-TDU Thermal Desorption Unit

Pyro=heat. Lysis=break down. Pyrolysis is a thermo-chemical reaction, which involves molecular breakdown of larger molecules into smaller molecules in presence of heat. Therefore, pyrolysis plant is also called thermal desorption/decomposition unit(referred to TDU).

DOING waste pyrolysis plant/thermal desorption unit

Pyrolysis Working principle

Pyrolysis plant is the machine(reactor vessel) designed to handle specific pyrolysis conditions. The process begins by loading the selected raw material into the reactor. The reactor is then heated to a precise pyrolysis temperature, for cracking different raw materials a, typically ranging from 400°C to 600°C. Crucially, this heating occurs in an oxygen-deficient environment to prevent combustion.

Under these controlled thermal conditions, the complex organic molecules within the feedstock break down, and finally get different valuable products.

Raw material Recycled by Pyrolysis Plant

The raw materials that can be processed by pyrolysis plant are highly adaptable to a wide range of organic waste materials. Common feedstocks for pyrolysis plant include:

Thermal desorption unit pyrolysis feedstocks

Waste Rubber, Used Tires: This is a primary application of pyrolysis technology, by recycling used car tires, truck tyres, rubber materials, yielding fuel oil, carbon black, and steel wire.

Waste Plastics: Various types of plastics (e.g., PP, PE, PS) can be converted into plastic fuel oil and carbon black. Simply put, in addition to PVC and PET, a variety of plastic products and even composite products can be cracked and recycled, including municipal domestic waste, medical plastic waste, paper mill waste, aluminum-plastic composite products, etc.

Oil Sludge: Industrial or municipal oily sludge, oil-based drill cutttings, coal tar oil residues, etc. can also be processed in specialized pyrolysis plant(namely thermal desorption unit). The products obtained from oil sludge are regenerated fuel oil, char;

Biomass: Materials like wood, bamboo, nut shell, agricultural residues (e.g., cassava meal, sawdust, rice husk, palm shell), and other organic matter can be processed into bio-oil, biochar, and syngas.

Biomass pyrolysis plant for biochar production

Other Materials: Acrylic, resin powder, fiberglass, epoxy resin, photovoltaic panels, fan blades/‌wind turbine blade‌s, rosin, diatomaceous earth, oil-containing catalyst filter cake, etc. If you have other raw materials that you would like to process with the cracking equipment, Henan Doing Company welcomes you to contact us for a customized solution and send us raw materials for trial operation.

This thermal decomposition process yields three primary products:

• Pyrolysis Oil (Fuel Oil): A liquid regenerated fuel that can be used in various industrial burners or further refined into diesel by pyrolysis oil distillation machine.

Waste pyrolysis fuel oil usages

• Syngas (Synthesis Gas): A mixture of combustible gases (like hydrogen, carbon monoxide, and methane) that can be used as fuel to sustain the pyrolysis process or for power generation.

• Char (Carbon Black/Biochar): A solid residue, rich in carbon, with applications in various industries, including tire manufacturing, pigment production, and soil amendment.

Pyrolysis plant recovered carbon black uses

The specific composition and yield of these products vary significantly based on the pyrolysis conditions (temperature, heating rate, residence time) and the type of raw material processed. For instance, processing waste tires yields not only fuel oil and carbon black but also steel wire.

With its wide range of raw material applicability and practicability of product solutions, pyrolysis plant is not only, widely used as an environmentally friendly and pollution-free waste treatment and management way, but also produce alternative heating fuel. The arrival of pyrolysis plant has truly turned waste materials into money.

Pyrolysis Plant For Sale

While pyrolysis beginners enter the industry and select suitable equipment, you may find there are so many choices and their costs vary a lot. So what are the classification of pyrolysis plant? Henan Doing Company will give you a detailed introduction.

Pyrolysis plant can be classified according to the processing of raw materials, their function and operation.

A. According to the processing of raw material pyrolysis plant can be divided into scrap plastic pyrolysis system, waste rubber tire pyrolysis machine, waste oil sludge treatment pyrolysis plant, oily sludge thermal pyrolysis unit, biomass pyrolysis plants. This division of the pyrolysis plant, is only for the customer main purpose to buy our pyrolysis equipment. In fact, as mentioned above, our pyrolysis plant can be used to deal with different substances, to achieve the purpose of one equipment with multi-usages.

Tire/Plastic/Oil Sludge thermal desorption unit

B. According to the action, the pyrolysis plant can be roughly divided into several types: fluid conveying equipment, heating equipment, heat exchange equipment, mass transfer equipment, reaction equipment and storage equipment.

C. According to the machine operational mode, it is divided into batch, semi-continuous and fully continuous/automatic pyrolysis plant.

Batch pyrolysis plants:

Batch pyrolysis plant for sale

Processing Capacities: 100/500KG, 1TPD/2TPD/5TPD/10TPD/12TPD/15TPD/18TPD/20TPD.

Features: Simple structure, high flexibility in operation, and adaptability to various feedstocks. They are well-suited for small to medium-scale operations.

Process: The reactor is loaded, heated, run through the pyrolysis cycle, cooled, and then discharged. This cycle is repeated for each batch.

Pros: Lower initial cost, easier to operate and maintain, ideal for learning and smaller production needs.

Cons: Higher labor intensity, potential for longer overall processing times due to loading/unloading, and generally lower throughput per unit of energy consumed compared to continuous systems.

Note: Some parts of the batch pyrolysis systems can be installed in the frame, it’s called the skid-mounted pyrolysis unit, which is easy for transportation and installation.

Semi-Continuous Pyrolysis Plants:

Semi-continuous pyrolysis machine for sale

Processing Capacities: 5TPD/10TPD/12TPD/15TPD/18TPD/20TPD.

Features: A hybrid approach, often involving continuous feeding but batch or semi-continuous discharge. This offers a balance between batch simplicity and continuous efficiency.

Process: Materials are fed continuously, and the solid residue can be discharged periodically at high temperatures.

Fully Automatic/Continuous Pyrolysis Plants:

Fully automatic continuous pyrolysis plant

Processing Capacities: 15TPD/20TPD/30TPD/40TPD/50TPD

Features: Designed for high throughput and maximum efficiency. They involve continuous feeding of raw materials and continuous discharge of products.

Process: Utilizes sophisticated feeding mechanisms and discharge systems, often incorporating advanced automation (e.g., PLC control) for precise temperature management, full cracking, and optimal oil yield.

Pros: Higher productivity, more consistent product quality, reduced labor, and better energy efficiency.

Cons: Higher initial investment and higher requirements for continuous pyrolysis technologies and machine qualities.

A whole set of pyrolysis production line consists of many devices: raw material pre-treatment machine, feeding system, heating burners, pyrolysis reaction kettle/pyrolysis furnace, buffer tank, oil gas cooling system, oil and gas separator, water separator, dust removal device, deodorization device, multiple-stage exhuast gas purification systems, oil tanks, carbon black collection system and vacuum device (safety device). If you have higher requirements for the fuel available and want to further purify it, we also offer pyrolysis oil to diesel fuel refining equipment. Besides that, Henan Doing Company also supplies carbon black refining and briquette machine.

Pyrolysis system production line equipment configurations

Key Application Industries for Pyrolysis Technology

Pyrolysis is a versatile technology with significant applications across various sectors:

Waste Management & Recycling: Diverting waste from landfills, creating value from problematic waste streams.

Energy Production: Generating alternative fuels (fuel oil, syngas) for industrial heating, power generation, or even heavy machinery fuel after refining.

Chemical Industry: Producing high-purity carbon black for tire manufacturing, rubber products, and as a pigment. Biochar can be used in agriculture for soil improvement.

Environmental Protection: Reducing the volume of waste and mitigating pollution associated with traditional waste disposal methods like incineration or landfilling.

For beginners, starting with a small-scale batch or a skid-mounted pyrolysis plant offers an accessible entry point into this vital industry. For organizations seeking alternative energy sources for stable heating raw materials, recycling companies, and environmental protection organizations, the establishment of medium- to large-scale cracking projects is more recommended.

DOING thermal pyrolysis plant operation sites

Interested in exploring the potential of waste-to-energy through pyrolysis plant/TDU thermal decomposition unit? Contact us today to learn more about our compact and efficient pyrolysis plant solutions, suitable for various feedstocks and operational scales.