Plastic pyrolysis process explains how waste plastics are turned into valuable pyrolysis oil. Each step helps people interested further know specific principles. Beston Group clarifies detailed plastic pyrolysis process steps. This offers insights that reflect both the technical precision and the transformative potential of this technology.
What Is the Principle of Plastic Pyrolysis Process?
Pyrolysis is a thermal decomposition process that involves breaking down organic materials (waste plastics, etc.) at high temperatures and low/no oxygen conditions, not combustion. During the process, long-chain polymeric materials decompose into simpler, smaller molecules, forming new solid, liquid, or gaseous products.
Beston plastic pyrolysis plant employs catalytic pyrolysis, operating at temperatures between 280-350°C, to enhance the breakdown of plastic waste. This method is specifically designed to maximize the yield of pyrolysis oil by promoting efficient molecular decomposition and optimizing the conversion process.

Plastic Pyrolysis Process Steps: Catalytic Pyrolysis Technology
Feed plastic waste into plastic pyrolysis reactor. In the video, the batch plastic to oil machine adopts a hydraulic feeder. Remove the hydraulic feeder after feeding. The door must be closed and locked.
Start the main reactor rotation and preheating. Wait for the main furnace to reach the desired temperature. The fuel can be diesel, natural gas, heavy oil or pyrolysis oil. To save fuel consumption, we design syngas recycling.
When the main reactor’s temperature reaches about 100℃ after 2-3h, it begins to produce oil gas. The high-temperature flue gas generated during pyrolysis is heated in the jacket layer of the catalytic tower, and the oil gas passes through the catalytic tower.
Then high-temperature oil gas enters the vertical tube condenser, condenses into liquid oil, and enters the storage tank for storage. Non-condensable pyrolysis gas enters the water seal and is recycled for reactor heating. The excess pyrolysis gas enters the exhaust chamber for burning out.
Close the burners after the reaction. The main reactor and the draft fan still operate normally. After 7-8h of natural cooling, the slag can be discharged by auto screw discharger and water-cooling discharger.
The high-temperature flue gas from the catalytic tower and the main reactor enters the flue condenser for cooling treatment and enters the spray tower for spraying dedusting. This gas is discharged through the chimney to the atmosphere, finally achieving EU environmental standards.
What Plastic Types Suit Plastic Pyrolysis Process?
The success of the plastic waste pyrolysis process relies heavily on selecting the right types of waste plastics as raw materials. Different plastics have unique chemical compositions, influencing pyrolysis efficiency, safety, and output.
What Is the Output of Plastic Pyrolysis Process?
The pyrolysis process for plastics focuses on producing liquid pyrolysis oil, which can be used as an alternative to traditional fossil fuels or further refined to diesel or gasoline. Oil yield for reference:
What Factors Affect Plastic Pyrolysis Process?
Several factors significantly influence the efficiency and output of the plastic pyrolysis process. Optimizing these factors helps maximize the yield of expected end products and minimize environmental impact. Key considerations include the following:
- Meaning: the heat level inside the reactor during pyrolysis, typically measured at °C.
- Influence: It significantly influences pyrolysis efficiency and end product type. Higher temperatures accelerate reactions, but excessively high temperatures can cause unwanted side reactions and energy inefficiencies.
- Example: To get a high oil yield, recommend 300-400℃. To maximize syngas yield, recommend 500-1300℃.
- Meaning: the speed at which the temperature increases during the plastic pyrolysis process, typically expressed at °C/min.
- Influence: A high heating rate typically results in a higher yield of combustible gas and less solid residue. A slower heating rate may bring more liquid fuel oil and solids.
- Meaning: the force exerted by gases or vapors on a unit area within a reactor, typically expressed in pascals (Pa) or atmospheres (atm).
- Influence: Pressure inside the reactor also affects the composition of the products. Maintaining proper intracranial pressure is also a means to ensure the safety of plastic pyrolysis process steps.
- Example: Beston Group’s pyrolysis plant maintains a micronegative pressure in the reactor to ensure safety.
- Meaning: the average amount of time that reactants spend in a reactor, typically measured in seconds (s) or minutes (min).
- Influence: Balancing residence time is important – too short may result in incomplete conversion, while too long may lead to the formation of undesirable by-products. A shorter residence time typically produces more liquid products. A longer residence time leads to more gas formation.
- Meaning: the different kinds of equipment or vessels used for conducting pyrolysis reactions. Common types include fixed-bed reactor, fluidized-bed reactor, rotary kiln reactor, and more.
- Influence: Different types of reactors have varying mixing and heat transfer characteristics, which can impact the efficiency of the pyrolysis process and the distribution of products.
- Example: Beston Group utilizes rotary kiln reactor design, which offers uniform reaction and high thermal efficiency.
- Meaning: a substance that accelerates a decomposition reaction, usually not consumed in the process, remaining unchanged after the reaction.
- Influence: An appropriate catalyst can increase the yield of desired products and reduce the overall energy input of the process. The proportion of the same catalyst (the ratio of catalyst to plastic) can also have different effects on pyrolysis.
- Example: The ZSM-5 catalyst can reduce impurities like solid residues, sulfur, nitrogen, and phosphorus in the liquid oil produced. For example, when the ratio of kaolin to WPP plastic is 1:2, the oil yield reaches its highest at 80.75 wt%.
What Equipment Is Involved in Plastic Pyrolysis Process?
Executing the plastic pyrolysis process requires a specialized apparatus – the plastic pyrolysis machine. This plant typically encompasses a feed system, a pyrolysis reactor, a combustor, a condensation system, a dedusting system, and units for the collection of final products. Beston Group has designed three types of models: skid-mounted-type, batch-type, and continuous-type. These machines are engineered to withstand high temperatures and maintain an oxygen-free environment, ensuring the success of the pyrolysis process.
- Model: BLJ-16;
- Capacity: 12-16t/d;
- Small land occupied;
- Short ROI cycle;
- No special requirements for raw materials.
- Model: BLL-30;
- Capacity: 4-6t/d; 8-10t/d; 12-16t/d;
- Automatic feeding and discharging;
- Continuous work for 3-6 days;
- Intelligent PL control& IOT monitoring.