What equipment can we select to set up a continuous pyrolysis machine project?

Setting up a continuous pyrolysis machine project involves a range of equipment and systems that work together to efficiently process waste materials (such as tires, plastics, rubber, medical waste, construction waste, e-waste, etc.) into useful by-products like fuel oil, carbon black, and syn-gas. Below is a comprehensive list of the equipment you will need to set up a continuous pyrolysis machine: 

1. Pyrolysis Reactor

The core component of a continuous pyrolysis machine:

Material: Typically made of carbon steel or stainless steel, resistant to high temperatures and corrosive environments.

Type: Continuous reactor, where feedstock is continuously fed into the system and processed in a continuous flow.

Capacity: Continuous systems can range in capacity from 15 tons/day to 50 tons/day, depending on your production requirements.

Heating Method: indirect heating systems.

Design: The reactor is equipped with advanced thermal insulation to retain heat and enhance energy efficiency.

2. Feeding System

For continuous processing, an efficient feeding system is necessary to ensure that the waste material is added in a consistent and controlled manner.

Automatic Feeding System: Includes an automatic screw feeder or conveyor system to load the waste material continuously into the reactor.

Hopper: Holds the waste material before it is transported into the reactor.

Feeding Conveyor: A conveyor belt or screw conveyor transports the material from the hopper to the reactor.

3. Condenser and Cooling System

The gas produced during pyrolysis must be cooled and condensed into liquid oil, so a reliable cooling system is essential:

Buffer Tank: A system to slow the flow speed of oil gas to ensure the full cooling oil gas;

Oil-Water Separator: A system to separate fuel oil from water that may be condensed along with the pyrolysis gas.

Tube Cooling System/Water Tank Cooling System: Realize industrial cooling system to get high oil yield.

4. Gas Collection and Purification System

The pyrolysis gas produced in the reactor can be used as fuel to heat the reactor after purifying or stored for other purposes. To make it safe and reusable, it needs to be purified:

Tail-gas cleaning system: purify the tail gas produced from the pyrolysis process;

Desulfurization tower: purify the exhaust gas to meet the emission standards in various countries.

5. Carbon Black Processing System

The solid residue produced in the pyrolysis process is carbon black, which can be collected and processed for sale or further use.

Carbon Black Discharge System: Collects and discharges the carbon black from the reactor.

Carbon Black Processing (Optional): A carbon black grinder or milling machine can be added to grind the carbon black into finer particles if necessary.

6. Control System and Electrical Equipment

A reliable and automated control system is essential for managing the continuous operation of the pyrolysis plant.

PLC Control System: A Programmable Logic Controller (PLC) is used to monitor and control all aspects of the pyrolysis process, including the feeding system, reactor temperature, gas collection, and safety systems.

Control Panel: A user-friendly interface for operators to monitor the plant's performance and adjust settings as needed.

Temperature & Pressure Sensors: Sensors to monitor the temperature and pressure inside the reactor, which are critical for safe operation.

7. Safety Features

Pyrolysis involves high temperatures and pressures, so safety is a primary concern. Key safety features include:

Pressure Relief Valve: Prevents the buildup of excessive pressure within the reactor, ensuring safe operation.

Fire Protection System: Includes automatic fire extinguishers, fire alarms, and sprinklers to reduce the risk of fire.

Emergency Shutdown System: An automated system that can shut down the plant safely in the event of an emergency.

Over-temperature Protection: Systems to prevent overheating in the reactor and other parts of the plant.

Negative pressure vacuum device: keep safe operation.

8. After-Sales Services and Support

After setting up your pyrolysis plant, reliable after-sales support is crucial to ensure smooth operations:

Installation and Commissioning: Professional installation and testing of all equipment to ensure everything is working as expected.

Training: On-site or online training for operators and maintenance staff to ensure they can operate and maintain the system effectively.

Maintenance and Spare Parts: Regular maintenance services and access to replacement parts are important for minimizing downtime.

These components form the basic infrastructure required to run a continuous pyrolysis plant. The exact specifications of each piece of equipment will depend on factors such as the type of feedstock, the plant capacity, and your specific business needs. It's essential to work with a reliable manufacturer like DOING  who can customize the equipment based on your project requirements. For more machine information, just feel free to contact us directly:

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