Shangqiu Aotewei Environmental Protection Equipment Co., Ltd. is one of the leading manufacturers and suppliers of small pyrolysis plant in China. We are committed to providing high quality customized products with competitive price. If you're going to buy ISO certified small pyrolysis plant, welcome to get quotation from our factory.
Products Description
Small Pyrolysis Plant
The Small Pyrolysis Plant is an economical batch-type pyrolysis unit developed by Aotewei for medium-and-small-scale solid-waste resource-recovery demands. It features small footprint, low investment and quick return-on-investment. Adopting an integrated compact layout, four core modules including pyrolysis reaction, oil-gas separation, condensation recovery and tail-gas treatment are assembled on one single base frame. It can convert carbon-containing solid waste such as waste tyres, waste plastics, waste rubber and oil sludge into usable products including fuel oil, carbon black and combustible gas. Requiring no large-scale workshop or heavy civil foundation, the plant can be placed on ordinary hardened ground. It is especially suitable for start-up recycling enterprises, county-level solid-waste stations and small-and-medium-sized processing factories to carry out on-site resource-recovery business. It serves as a cost-effective option for entering the solid-waste pyrolysis industry with limited capital.
Price Note: Quotation is subject to steel-market fluctuation, configuration grade and international exchange rates. The reference price for the standard 2-ton-per-day small pyrolysis plant is USD 28,000 / set (excluding sea freight, import duties and on-site installation & commissioning costs).
| Technical Parameter of the Pyrolysis plant | |||
| 1 | Suitable Raw Materials | Rubber/Plastic Products etc | Rubber/Plastic Products etc |
| 2 | Structure | Horizontal Rotation Type | Horizontal Rotation Type |
| 3 | Reactor Size | φ2600×6600mm φ2800×8000mm φ3000×8800mm |
φ1500×2000mm φ1800×4000mm φ2000×600mm |
| 4 | Capacity for One Batch | 8-10Mt; 12-15Mt; 18-20Mt | 1Mt; 3Mt; 5Mt |
| 5 | Oil Yield from Tyres | 38%~45% | 38%~45% |
| 6 | Work Pressure | Normal Pressure | Normal Pressure |
| 7 | Reactor Rotation Speed | 0.4R/M | 0.4R/M |
| 8 | Fuels Choice | Coal, Wood, Gas, Oil | Coal, Wood, Gas, Oil |
| 9 | Power | 15~22kw/h | 8~15kw/h |
| 10 | Cooling Method | Cycling Water | Cycling Water |
| 11 | Type of Drive | External Annular Gear | External Annular Gear |
| 12 | Heating Method | Direct Heating | Direct Heating |
| 13 | Type of Installation | Without Foundation | With Foundation / Integrated Base |
| 14 | Noise dB (A) | ≤ 85 | ≤ 85 |
| 15 | Operating Mode | Intermittent Operation | Intermittent Operation |
| 16 | Total Weight (MT) | 25~50 | 10~25 |
Features
① Integrated compact base design with small footprint
The unit adopts an integrally welded base frame. The pyrolysis main furnace, condensation system, oil-gas-liquid separation tank and electric-control cabinet are all fixed on the same base, with internal pipelines pre-connected before factory delivery. The whole plant only occupies 40-100 ㎡, greatly cutting site and civil-construction investment for customers.
② Circular-feeding batch-mode process for small-batch multi-run production
It applies batch-type pyrolysis with single-furnace cyclic feeding. Single-batch processing capacity can be flexibly adjusted. Full-load production or small-batch operation according to incoming raw-material volume are both available. The unit can standby when raw materials are insufficient, suiting small-and-medium-size operators with unstable raw-material supply and batch-based waste collection.
③ Smokeless sealed pyrolysis system for low-emission operation
Full-process sealed negative-pressure pyrolysis is adopted with fully sealed leak-proof oil-gas pipelines. A one-stop integrated spray-dust-removal and desulfurization tail-gas-treatment unit is provided as standard. Flue gas generated from pyrolysis and combustion is discharged after washing and adsorption treatment. It runs without obvious black smoke or pungent odor and meets basic environmental-inspection requirements for small-and-medium-sized projects.
④ High-efficiency tubular condenser module for high oil-gas recovery rate
Equipped with multi-stage double-inlet & double-outlet tubular condenser. Heat-exchange tube layout and cooling-water flow rate are optimized for oil-gas flow characteristics of small-size units. Condensable fractions in combustible gas are fully liquefied. The fuel-oil recovery rate increases by 8%-10 % compared with simple units of the same specification. Produced crude oil features low moisture and low impurities and can be directly sold as industrial fuel.
⑤ Simplified and reliable control system with low operation threshold
It adopts simplified electric-control design combining push-buttons and digital displays. Core parameters (furnace temperature, oil temperature, cooling-water temperature) are displayed in real-time with automatic over-temperature alarm. Control logic is streamlined without complex multi-linked automatic configurations. Ordinary workers can independently complete the full workflow including startup, heating, shutdown and slag discharge after short-term training, eliminating the need for high-salary professional technicians.
Advantages
① Low initial investment with accessible entrepreneurship threshold
Compared with standard 5-10 ton tyre pyrolysis plants, the purchase cost is greatly reduced, together with savings on large workshops and heavy civil foundations. It enables individual entrepreneurs and small recycling workshops to launch businesses without huge one-off capital expenditure.
② Flexible raw-material tolerance adapting to scattered-recycling mode
Stable large-volume tyre supply is not mandatory. Production starts after accumulating a batch of waste tyres and stops when feedstock is scarce, avoiding equipment idling and investment waste. It matches the actual operation of scattered waste-tyre recycling in counties and towns.
③ Simple installation and fast commissioning-to-production cycle
Most modules are pre-assembled in factory. On-site work mainly covers pipeline connection and electric debugging. With remote technical guidance from experienced technicians, full installation, commissioning and trial-production can be finished within 7-10 days, greatly shortening project preparation lead-time.
④ Easy operation & maintenance with low requirements for technical staff
Streamlined overall structure and simplified control-system logic without complex multi-linked advanced configurations. After short-term training, ordinary recycling-station workers can complete startup, production, shutdown and routine maintenance, removing the need for high-salary professional chemical operators.
⑤ Flexible business model supporting later-stage upgrading Produced crude pyrolysis oil can be sold directly to oil-refinery purchasers for quick capital recovery. When business expands later, an independent distillation-and-refining module can be externally connected to produce diesel without replacing the whole main unit, thus protecting previous equipment investment.
Application Scenarios
- Small-town tyre-recycling workshops: For county-level and township-level waste-tyre-recycling stations to locally process collected passenger-car and light-truck tyres. Crude pyrolysis oil, steel wire and carbon black are produced for direct sale, cutting long-distance outbound logistics costs for waste tyres.
- Pilot projects for start-up recycling enterprises: Used by newly-founded environmental-recycling companies for small-scale commercial trials to verify local waste-tyre supply, product sales channels and business models. Large-capacity equipment can be purchased after market validation to lower entrepreneurial trial-and-error risks.
- Centralized-disposal sites for auto-repair chains: Jointly built by multiple auto-repair shops to centrally treat waste car tyres replaced from each outlet. Waste is converted into saleable products instead of paying third-party hazardous-waste-disposal fees.
- Supporting projects for small-scale solid-waste transfer stations: Serve as tyre-disposal units attached to garbage and solid-waste transfer stations for sorting and processing collected waste rubber tyres and improving the station's resource-recovery profits.
- Simple solid-waste-disposal points in remote villages and towns: Deployed in hard-to-reach townships with extremely high outbound-transport costs for waste tyres. Local waste tyres are processed on-site and finished products are sold in nearby markets.
Packing & Shipping
Packing Method:
The pyrolysis reactor receives anti-rust paint coating and is wrapped by rain-proof tarpaulin, with pre-installed lifting lugs and transport locking fixtures. Precision components such as electric-control cabinet, temperature-pressure instruments and valves are packed in shock-proof wooden cases with moisture-proof cushioning. Pipes, flanges, sealing gaskets, disassembly-assembly tools and wearing-part spares are sorted and palletized. Bilingual simplified operation manuals, assembly sketches and packing lists are provided.
Shipping Method:
The complete small-scale unit can be fully loaded into one 40HQ container for sea export. Extra-large components will be split for multi-container shipment. For inland destinations, flat-bed truck land-transport is available for direct delivery to the site.
Delivery Lead Time:
For standard configurations, production, no-load testing and shipment will be completed within 45-60 working days upon advance payment. Lead time will be extended if optional upgraded accessories (enhanced flue-gas treatment, liquid-level-monitoring assemblies) are added. Real-site photos and operation-test short videos will be provided pre-shipment to help customers prepare the site in advance.
FAQ
Q1: What is the maximum daily tyre processing capacity of this small scale waste tyre recycling plant?
A: The standard model is designed for 3 tons of waste passenger car / light truck tyres per day. Single batch throughput will decrease for heavy duty off the road tyres. Mass processing of thick walled engineering tyres is not recommended.
Q2: What are the hard requirements for workshop and ground conditions?
A: A standard industrial workshop is not required. Only a 40 80 m² flat hardened concrete ground plus a simple rain and sun shade shed is needed. 380V industrial power supply and circulating cooling water shall be prepared. Heavy reinforced concrete civil foundation is unnecessary.
Q3: Is there a big gap in product yield between small scale plant and large scale pyrolysis equipment?
A: They share identical pyrolysis principles. For clean passenger car tyres, oil yield reaches 40 47 %, and yields of carbon black and steel wire are close to large size units. The difference lies in lower total daily output due to smaller single batch feeding volume, while product quality remains unchanged.
Q4: Can this equipment pass local environmental inspections?
A: It comes with integrated desulfurization dust removal flue gas treatment unit for smokeless low odor operation and meets basic emission requirements for small sized projects. Customers shall complete filing formalities according to local regulations. Upgraded advanced waste gas treatment assemblies are optional for regions with stringent environmental standards.
Q5: Can workers from recycling stations operate it without previous pyrolysis experience?
A: Yes. Operation procedures are simplified. Remote graphic and video training is provided. Operators can master basic startup, shutdown, slag discharge and daily inspection work within 3 5 days. 24 hour remote technical support is available for complex failures.
Q6: Can this small size unit be modified for higher capacity when business expands later?
A: The throughput of the main reactor itself cannot be enlarged by modification. Nevertheless, external distillation and refining equipment can be connected to convert crude oil into diesel. To raise daily processing capacity, adding an extra unit for parallel operation or switching to a larger capacity model is recommended.
Q7: What wearing parts spares should be prepared?
A: Main spare parts include sealing gaskets, valve packings, spray nozzles and temperature sensors. These parts enjoy high market universality. A spare parts list will be supplied with goods and most items can be purchased from local hardware & electromechanical markets.
Production Process Flow
- Raw-material Pre-treatment: Waste passenger-car and light-truck tyres are simply sorted to remove bulky foreign objects. Deep shredding is not required. Whole tyres or roughly-cut pieces are stored in the raw-material zone for standby use.
- Feeding into Reactor: Tyres are fed into the pyrolysis reactor via a simple feeding port. Close and lock the furnace door after feeding to form a sealed oxygen-free internal environment inside the reactor.
- Batch-mode Segmented-heating Pyrolysis: The combustion chamber ignites for heating. Furnace temperature rises in multi-stage profiles. Rubber pyrolysis cracking takes place within the optimal temperature range. Rubber macromolecules break down to release oil-gas, steel wire remains intact, and rubber components convert into oil-gas and carbon-black residues.
- Oil-gas Condensation & Liquefaction: Pyrolysis-generated oil-gas flows into the multi-stage tubular condenser module for heat-exchange and liquefaction via circulating cooling water. Liquid crude pyrolysis oil flows into oil-storage tanks; non-condensable combustible gas is diverted back to the combustion chamber as heating fuel.
- Combustible-gas Recycling for Heating: Non-condensable gas from pyrolysis serves directly as heating fuel for equipment. Only a small amount of external fuel is needed for initial cold-furnace ignition to realize most energy self-sufficiency. Surplus minor gas is fully combusted before entering flue-gas-treatment procedures.
- Furnace Cooling & Sealed Slag Discharge: Stop heating after pyrolysis completion. Wait for the reactor to naturally cool down to a safe temperature. Activate the sealed slag-discharge mechanism to separately discharge intact steel wire and carbon black for respective collection and storage.
- Flue-gas Purification & Discharge: Combustion-produced flue gas enters the integrated desulfurization-dust-removal module for dust and sulfide removal and is discharged after reaching emission standards.
- Product Storage & Sales: Crude pyrolysis oil, steel wire and carbon black are inspected before direct sale. According to business plans, crude pyrolysis oil can be delivered to externally-connected distillation-and-refining equipment for further deep-processing.
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