Continuous pyrolysis
complexes production

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1. Could you provide the environmental analysis and certification to ensure safety of the pyrolysis technology and complex equipment for waste recycling?
2. What is the minimal capacity of the equipment complex?

The min. capacity of Pyrolysis unit is 1.5 t of waste materials per hour (36 t/day or 13 000 t/year). The layout of the model with capability 1.5 t/hour is absolutely balanced in accordance with amount of downloading raw materials, output products and economic effectiveness of the process.

3. Which types of raw materials can be processed with the Pyrolysis units?

The Pyrolysis plants based on continuous pyrolysis technology allows treatment of almost all types of waste, except of demolition waste.
Recyclable materials list includes:

  • municipal solid waste,
  • biomass, agricultural waste (harvest residues, products of animals vital activity),
  • RDF (refuse derived fuel);
  • medical and toxic waste,
  • sewage sludge (moisture content > 15%),
  • all types of plastic,
  • car tire casings and other rubber products,
  • wood waste,
4. What is the appropriate moisture content and size of raw materials?

The equipment complexes are designed individually in accordance with raw materials characteristics. Equipment modules for raw materials sorting, sifting, crushing, separating depends on the waste mass content. In accordance with type of waste the pieces fraction differ from 10*10 mm to 20*30 mm. Moisture content of the prepared to the pyrolysis process raw materials is 15-20%.

5. Could the equipment complex be adapted to the other type of waste later on?

It is possible to adapt the installation to another type of waste. But it is not economically successful. The equipment complex reengineering is realized by the manufacturer and not included into the lump sum price. To start the reorganization of the complex it is necessary to interrupt the continuous pyrolysis process. The fuel and energy exchange for renewed unite startup will be equal to the previous starting exchange.

6. How long is the period of equipment complex designing and installing?

The period of the constructing and delivering is 6-8 months (it depends on our busy conditions at the moment of the entering into a contract).
The period of installing, setting into operation and staff training is less than 1 month after transportation.

7. What are the size and footprint of the equipment complex?

The entire pyrolysis system is placed in container having a volume of 40 cubic feet. The footprint of the pyrolysis equipment is 600-900 m2 (staff, subsidiary and housekeeping constructions are not included).

Requirements to the pyrolysis facility location:

  • It should be distanced for more than 500 m from living apartments;
  • Electric power substation or functioning boiler room located next to the pyrolysis facility, are preferable for the further pyrolysis products application.
  • The transport links, storage places, staff office room and cover to the pyrolysis equipment are also required.

8. Which exploitation expenses are provided after the launch of the continuous pyrolysis process?

The appropriate amount of the exploitation expenses are:

  • Electricity supply – 60 kW/hour (average);
  • Water supply – 3-5 m3 of water per month (the water circulate through the pyrolysis system per a month, and it is changed during the monthly service);
  • Staff required – 3 day shifts, 2-3 operators per day;
  • Fuel – 500-1 500 l (depends on the pyrolysis machine capacity). Fuel is required for the launch of the process, further the pyrolysis products are used to maintain the continuous thermal destruction inside the pyrolysis reactor chamber;
  • Space heating – the excess heating power is used to heat the staff office and storage places.

9. Is the pyrolysis process environmental and safe for health?

Waste treatment based on continuous pyrolysis technology eliminates the emission of hazardous substances into the atmosphere. Disintegration of the materials into particles occurs without access of oxygen at low temperature in the closed reactor chambers. This factor ensures environmental and operational safety of the pyrolysis process.

10. What is the average output of MSW, biomass or sewage sludge recycling?

Low temperature pyrolysis installation produces the pyrolysis gas, pyrocarbon and liquid pyrolysis fuel. Pyrocarbon and pyrolysis liquid fuel are gasificated to generate the maximum amount of the electricity with one pyrolysis unit. In this case the pyrogas output is about 900 m3 from one ton of MSW (waste amount counted after the drying, sorting and separating). 900 m3 of pyrolysis gas is enough to generate 1-1.2 MW of electricity.

Average output of the pyrolysis products from 1 t of MSW:

  • pyrogas – 0.275 t or 425 m3 (caloric value 3 500-6 000 kcal/m3);
  • fuel for boilers – 0.3 t (caloric value 9 000 kcal/kg);
  • pyrocarbon – 0.425 t (caloric value 6 000 kcal/kg).

Biomass recycling installations based on continuous pyrolysis technology may be oriented toward one of two types of preferable output products: biochar production or synthetic gas for space heating or electric energy production.
Average output of the pyrolysis products from 1 t of biomass (in case of synthetic gas production):

  • pyrogas – 0.45-0.55 t or 650-700 m3 (caloric value 3360 kcal/m3);
  • fuel for boilers – 0.15 t;
  • pyrocarbon – 0.3-0.4 t (coincides with coal coke characteristics).

Average output of the pyrolysis products from 1 t of the sewage sludge (moisture content – 5%, fraction – 20*30 mm):

  • pyrogas – 0,427 t (caloric value 1500-6000 kcal/ m3);
  • fuel for boilers – 0,15 t (caloric value 4000-8000 kcal/kg);
  • pyrocarbon – 0,423 t (caloric value 1500-6500 kcal/kg).

Alternative output of the sewage sludge recycling using the pyrolysis complex (capacity 60 t/hour):

  • 10.25 Gcal/h of the heat power (total heat effect from fuel products combustion);
  • 2010 kW of the electric power (using 1005 m3 of pyrogas);
  • 14.3 t of the steam per hour (in case of the treatment of all manufactured fuel products).
11. What is the fuel products yield/electrical energy output from the different types of raw materials?

The comparative table of the pyrolysis products output from different types of raw materials

Type of feed (raw materials) Pyrolysis products, by weight %
Pyrolysis liquid substance (synthetic oil with water content < 0.01%) Pyrogas Pyrocarbon (include bottom ash) Pyrowater (filtered from the pyrolysis liquid substance)
Municipal solid waste (humidity – 10%) 20-50 18 25 15
Rubber (tires) 40-60 12 34 3
Wood waste 25 20 30 20
Brown coal 15 25 25 35
Straw, husk 15 25 28 12
12. How could the pyrolysis products be realized?

Pyrolysis liquid (synthetic oil) and pyrogas may be transformed into heat power for space heating or into electric power (using turbines and other additional equipment). 2.5 m3 of pyrogas (synthetic gas) is an equivalent to 1 m3 of natural gas.

Pyrocarbon be gasificated to produce maximum quantity of the electric power with one pyrolysis machine. Among the popular fields of pyrocarbon application are also production of coal-water fuel, waste-water treatment, rubber products (tire-casings) filling, plastic and plastic dyes manufacture. It is similar to coal coke and may be used in the same way.

Biochar is the carbon residue formed in the low-temperature pyrolysis combustion of biomass. It is in demand as an effective fertilizer and animals’ feed supplement on the European market. It increases the soil productivity for 30%. Learn more about biochar here.

13. Do the Pyrolysis units generate electric power?

For electric energy generating the additional equipment modules are requirement (turbines and steam boilers) We are not producing these devices now, but we are able to design the technological layout for “turnkey”.

The appropriate quote of pyrolysis gas for 1 100-1 200 kW generating is 900 m3. To learn more about the power generating cycle, visit our YouTube channel.

14. How much fuel or electricity could I get finally?

There is the calculator for Pyrolysis installation efficiency counting here

15. What equipment modules are included into the lump sum price?

All equipment modules needed for pyrolysis process (starting from raw materials receiving and ending by pyrolysis products (liquid fuel, pyrogas and pyrocarbon/biochar) unloading) are included into the lump sum price.
The additional equipment modules (turbines and boilers) for electric energy generation may be also included into the layout.
There are not included into the price:

  • costs for additional buildings (storages, road, etc.),
  • foundation for equipment and other additional constructions for pyrolysis complex,
  • containers for pyrolysis products storage. Further service and technological support of the functioning pyrolysis installation could be realized as an additional option.
16. Is the equipment delivery included into the lump sum price?

Yes, the transporting and installing of the equipment complex are included into the final price. But the responsibility for installing place preparation is entrusted to the host party.

17. What staff is required?

The inquired staff for proper continuous pyrolysis plant functioning consists of 6-9 workers (3 day shifts, 1 engineer and 2 operators or 1 engineer and operator every day). It is discussed individually.

18. Which additional constructions and buildings are required?

It is necessary to organize the foundation for installation, drives for transports, store places for pyrolysis products and for reserve component parts, and also to build the operators' office. The complex is functioning at the open air, but it is better to protect it from precipitation with awning. Also, the containers for pyrolysis products are required.

19. Do you provide any training for operating personnel?

The staff is usually trained and instructed during the installation startup work (appropriate for a month). Staff training is included into the lump sum price.

20. Do we buy waste materials for further recycling?

Currently, the Pyrolysis project is aimed at providing the equipment complexes for pyrolysis recycling, but not for the waste buying and treating. Nevertheless, we are going to concern such a type of cooperation soon.

21. Where and when the presentations of the functioning Pyrolysis units take place?

The functioning industrial model is situated in Ukraine (Kyiv region). We usually offer our guests to test the machine and try to recycle their prepared samples of waste mass and to analyze the output products.

Also, the engineers and project coordinators are usually presented at the appointment to discuss more detailed the technological or mechanical characteristics and cooperation conditions.

Ask about the earliest presentation date here.


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