Plastic to oil machines use pyrolysis technology to convert waste plastics (PE, PP, PS, etc.) into usable oil. This offers a sustainable alternative to landfilling. These machines are available in various scales, from small batch systems to large, continuous industrial plants. They can handle 6,000 tons annually or smaller sizes. This solution benefits both sustainable economic development and environmental preservation.
Plastic to Oil Process: Step by Step Guide
01 Feeding
Feed plastic waste into the pyrolysis reactor via an airtight screw feeder or hydraulic ram. A nitrogen purging system displaces atmospheric oxygen inside the reactor to prevent combustion, ensuring thermal decomposition occurs instead of burning.
02 Preheating
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.
03 Catalytic Pyrolysis
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.
04 Condensing
Then the high-temperature oil gas enters the vertical tube condenser, condenses into liquid oil, and enters the storage tank. 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.
05 Discharging
Close the burners after the reaction. The main reactor and the draft fan still operate normally. After cooling, the slag can be discharged by auto screw discharger and water-cooling discharger.
06 Flue Gas Dedusting
The high-temperature flue gas from the catalytic tower mixes the high-temperature flue gas from the main reactor then enters the flue condenser for cooling treatment, and enters the spray tower for spraying dust removal, then discharged through the chimney to the atmosphere.
Catalytic Pyrolysis: Core Technology Advantage of Plastic to Oil
Improve Oil Quality – ISCC Certify
Using catalysts significantly reduces the wax content in the oil produced during the plastic pyrolysis process, resulting in a higher-quality end product. This means the oil is purer and performs better, making it suitable for a wider range of industrial applications.
Improve 200% Production Efficiency
With the reduction of wax in the pyrolysis oil, the risk of pipeline blockages is greatly minimized. This directly reduces downtime due to cleaning and maintenance, significantly lowering maintenance costs and improving operational efficiency.
Improve Operation Safety
Wax accumulation causes pipeline blockages and leads to increased internal pressure within plastic pyrolysis equipment, posing safety risks. Catalytic dewaxing prevents this from occurring, ensuring stable and safe operation of plastic to oil machine.
Plastic Types Analysis: Suitability for Pyrolysis and Oil Yield
| Types of Plastic | Applicability to Pyrolysis | Oil Yield (Lab Test) | |
|---|---|---|---|
 |
Polyethylene Terephthalate | × | low |
 |
High-Density Polyethylene | √ | 80%-95% |
 |
Polyvinyl Chloride | × | low and dangerous |
 |
Low-Density Polyethylene | √ | 80%-95% |
 |
Polypropylene | √ | 80%-90% |
 |
Polystyrene | √ | 80%-90% |
 |
Other Plastics without chlorine and oxygen | Plastics without chlorine and oxygen: √ Plastics with chlorine and oxygen: × |
/ |
Laboratory Pyrolysis to Oil Test Reports
Between 2024 and 2025, different plastic samples were sent to Beston Group’s manufacturing base in Jiaozuo, China, for testing. In our laboratory, we conducted a series of experiments to determine the oil yield from various types of plastic waste, specifically focusing on HDPE, LDPE and PP. The pyrolysis reactions were performed under controlled conditions to simulate real-world applications, and the data collected is summarized below:
Data Interpretation and Analysis
The data suggests that HDPE provides the highest yield, with over 80% of the feedstock converted into oil. Polypropylene followed closely, with a yield of 75%, while polystyrene yielded the least, around 60%. The reason for these differences lies in the varying chemical bonds within the plastics, with HDPE and PP being more thermally stable and thus more readily converted into pyrolysis oil.
Expert Insights
Plastic pyrolysis is a rapidly developing field, and ongoing research continues to refine the conditions for optimal yield. These laboratory results align with existing studies in the field, which have shown similar yields for HDPE and PP under comparable conditions. By optimizing the pyrolysis process, it is possible to increase the yield further, improving the efficiency of plastic waste recycling.
3 Plastic Pyrolysis Oil Products to Get and Apply
Light Oil
Light oil is sourced from integrated pyrolysis + distillation technology. Main applications:
- Used as a steam-cracking feedstock for producing ethylene and propylene.
- Applied in the chemical industry for the manufacture of plastics, synthetic rubber, and solvents.
- Partially substitutes conventional fossil-based naphtha, supporting plastic circular economy initiatives.
Non-Standard Diesel
Non-standard diesel is sourced from integrated pyrolysis + distillation technology. Main applications:
- Used as fuel for industrial boilers, kilns, and heating systems.
- Applied as fuel for self-use generators in mining areas and industrial plants.
- Can be further upgraded to standard diesel through deep hydrotreating.
Gasoline Blending Components
Gasoline blending components are recovered from surplus non-condensable combustible gas. Its aromatic hydrocarbon content reaches 65%. Main application:
- Used as a high-octane component for commercial gasoline blending to improve performance.
Parameters of Plastic to Oil Machine for Sale
Continuous Type: Blackgold P30
- Process 6,000 tons of plastic waste annually
- 30-day continuous pyrolysis operation
- High automation: 4 operators required
- Get light oil & non-standard diesel
- Policy support and incentives
- Easy to get environmental compliance and approval
Blackgold P30
BLJ-20
BLJ-16
| Model | Blackgold P30 | BLJ-20 | BLJ-16 Standard | BLJ-16 WAX | BLJ-16 CAT | BLJ-16 ULTRA |
|---|---|---|---|---|---|---|
| Manufacturer | BESTON | BESTON | BESTON | BESTON | BESTON | BESTON |
| Time to Market | 2026 | 2025 | 2013 | 2022 | 2022 | 2022 |
| Motor Brand | Chinese brand | Chinese brand | Chinese brand | Chinese brand | Chinese brand | ABB Explosion-proof |
| Suitable Raw Materials | Waste plastics; Tires; Oil sludge | Waste plastics; Tires; Oil sludge | Whole tire<120cm; Tire blocks<15cm; Oil soil with liquid content<30% | Waste plastic bales (Max.0.9*0.9*1.6m) | Waste plastic bales (Max.0.9*0.9*1.6m) | Waste plastics; Tires; Oil sludge |
| Input Capacity (Max.) | Waste plastic pellets: 0.8-1.05t/h; Rubber powder: 1.25-1.5t/h; Oil sludge:1.8-2.3t/h | Waste plastic pellets: 12-13t/d; Tire: 18-20t/d; Oil sludge:20-25t/d | Whole tire <120cm or Tire blocks<15cm: 10-12t/batch; Sidewall removed tire: 15-16t/batch; Oil soil: 16-18t/batch | 8-10t/batch | 8-10t/batch | Waste plastic bales: 8-10t/batch; Whole tire <120cm or Tire blocks<15cm: 10-12t/batch; Sidewall removed tire: 15-16t/batch; Oil sludge: 16-18t/batch |
| Working Method | Fully Continuous | Batch | Batch | Batch | Batch | Batch |
| Final Oil Quality | Pyrolysis oil; Pyrolysis oil with wax or light oil; Gasoline blending components | Pyrolysis oil; Light oil and non-standard diesel | Pyrolysis oil | Pyrolysis oil with wax | Pyrolysis oil with light oil | Pyrolysis oil; Pyrolysis oil with wax or light oil |
| Reactor Material | 304/310S Stainless steel | Q345R Boiler steel and 304/316L/310S Stainless steel | Q345R Boiler steel | 304 Stainless steel | 304 Stainless steel | 304 Stainless steel |
| Reactor Life Span (Years) | 5-8 Years | Q345R Boiler steel: 2-3 Years; 304/316L Stainless steel: 5-8 Years; 310S Stainless steel: 8-10 Years | 2-3 Years | 5-8 Years | 5-8 Years | 5-8 Years |
| Guarantee (Months) | 12 | 12 | 12 | 12 | 12 | 12 |
| Delivery Time (Calendar Days) | 60-90 | 60 | 45 | 60 | 60 | 90 |
| Land Space Required (L*W*H*m) | 50*20*10 | 40*13*8 | 33*13*8 | 33*13*8 | 33*13*8 | 33*26*8 |
| Packing | 20*6*3m in bulk+13*40HQ | 1*40FR+4*40HQ | 1*40FR+3*40HQ | 1*40FR+3*40HQ | 1*40FR+3*40HQ+1*20GP | 1*40FR+8*40HQ |
| Installation Period (Calendar Days) | 60-90 | 45 | 45 | 45 | 45 | 60 |
Global Plastic to Oil Projects
Technical Breakthrough in Blackgold P30 & BLJ-20 Plastic to Oil Machine
0 Clogging & Minimize Coking: 30 Days Non-stop Operation
- Smart Wax Collection System: 100% Eliminates the risk of condenser blockage
- Mechanical Decoking Structure: Minimizes coke formation inside the furnace and ensures continuous and stable operation for 720 hours.
Collect Light Oil & Non-Standard Diesel
Light & heavy oil fractionation system uses an advanced oil-gas spray system to separate different fractions.
- Maximizes classified and high-value utilization of oil products.
- Saves distillation equipment capital costs.
- Reduces energy consumption.
High Automation & Safety Upgrade
Automatic temperature control, automatic weighing feeding, self-adjusting sealing technology, and a self-cleaning system ensure stable, efficient equipment operation.
- Reduces manual intervention, boosting production efficiency by 60%.
- Lowers skill requirements for workers.
- Ensures full safety compliance.
One Step to Get Light Oil & Non-standard Diesel
Fractional distillation technology separates light oil and non-standard diesel at a 200°C distillation point. Long-term benefits:
- Increase oil product purity and market value.
- Reduce operational costs (water, electricity, labor, and additional distillation investment).
Increase Processing Capacity by 50%
Large-capacity pyrolysis reactor (ø2800*10000) runs one batch per day, each recycling 15–16 tons of waste plastics. Long-term benefits:
- Greater scalability to larger-scale projects.
- Consistent supply of high-value oil products to meet market demand.
- Faster return on investment (ROI).
High Safety Factor
Thermal dynamic sealing and flexible high-temperature insulation technology enhance project safety. Long-term benefits:
- Lower risk of accidents.
- Ensure full compliance with safety regulations.
- Reduce downtime and maintenance costs.
- Strengthen corporate reputation and investor trust.
Unique Designs of Beston Plastic to Oil Machine
Floating Seal Technology
The main reactor combined floating sealing technology uses carbon fiber + high-temperature soft filler combined sealing. Compared with the traditional graphene packing sealing technology, it has good high-temperature resistance, corrosion resistance and wear resistance.
EU-standard Dedusting System
Combined with the higher exhaust gas treatment and wastewater discharge requirements of European clients, it can provide semi-dry or fully dry desulfurization, denitrification and de-dusting system to meet European emission standards.
Hot Air Heating System
Hot air heating method is safer, more uniform in heating, and more precise in temperature control. The most important thing is that waste heat can be recycled, energy saving and emission reduction can save 20-30 % of energy consumption.
Overpressure Alarm System
If overpressure occurs in the main furnace, the safety valve will automatically activate to relieve pressure. This can ensure the safety of both the equipment and personnel.
Torch Safety System
To address overpressure and storage risks from surplus pyrolysis gas and potential emergencies like power outages, a safe, highly automated torch system is installed as an emergency safeguard.
Nitrogen System
Nitrogen is introduced to reactor to replace air before ignition and slag discharge. It prevents flash explosions in the reactor and ensures safe and stable operation of the plastic to oil plant.
Why Plastic-to-Oil Makes Sense: A Comparative Outlook
Current plastic disposal and recycling methods remain limited in both scope and efficiency. Given that plastic bags are made from petroleum, they can be converted back into their original liquid oil form. In this context, plastic pyrolysis-to-oil solutions offer clear and compelling advantages.
Burning/Incineration
- Environment pollution: Burning waste plastics releases around 850 million metric tons of greenhouse gases annually and may emit harmful chemicals.
- Not achieve resource recycling: Burning waste plastics creates non-reusable ash while producing new plastic consumes 8-10% of the world’s petroleum.
Landfill or Leaked into Oceans
- Land/Ocean pollution: Landfill occupies large amounts of land and pollute the soil. Leaking into oceans pollutes oceans and endangers the survival of marine life.
- Slow natural degradation: It takes 20- 500 years or more for a plastic bag to degrade in a landfill. It can’t meet the increasing need for plastic disposal.
Mechanical Recycling
- Limited recycling times: Plastics are not infinitely mechanically recyclable (washing, grinding, pelletizing, etc.). Most plastics can only be recycled 3 to 7 times.
- Reduced plastic quality: Recycled plastics may not perform as well as new ones, impacting market demand and the feasibility of large-scale recycling.
Plastic Pyrolysis into Oil
- Better environmental compliance: Operates in low-oxygen conditions, minimizing toxic emissions like dioxins. Emission control systems further reduce environmental risks.
- Resource recovery: Recycle oil from plastic waste, saving non-renewable petroleum resources.
- High efficiency and scalability: Suit industrial application and solving the challenge of complex plastic waste streams.
Turning Plastic into Oil: A Step Towards Sustainable Development
SDG 12: Responsible Consumption and Production
Plastic-to-oil technology supports the goal of reducing waste by converting plastic waste into useful products instead of letting it accumulate in landfills or pollute the environment.
It contributes to sustainable production processes, as it promotes recycling and helps decrease the demand for virgin plastic production, reducing the environmental impact associated with plastic manufacturing.
SDG 13: Climate Action
By recycling plastic waste into oil, this technology helps reduce greenhouse gas emissions compared to traditional waste management methods such as incineration.
The technology can also lower the carbon footprint of plastic production by providing an alternative to petroleum-based products.
Additionally, the conversion process can reduce landfill methane emissions—a potent greenhouse gas produced by decomposing plastic.
SDG 7: Affordable and Clean Energy
Plastic into fuel machine generates pyrolysis oil, which can be refined into usable fuel or energy. This helps in diversifying energy sources and offers a more sustainable, clean alternative to fossil fuels.
This energy production can be more localized, potentially reducing the need for long-distance transportation of energy resources, leading to reduced carbon emissions.
Start Plastic-to-Oil Project Now
Beston Group has years of experience in researching and manufacturing plastic to oil machines, delivering reliable and efficient solutions worldwide. We look forward to partnering with forward-thinking leaders like you! More updates on Facebook/YouTube/Linkedin/Pinterest.