Oil Sludge Pyrolysis Plant

GEMCO oil sludge pyrolysis plant not only offers customers an efficient and environmentally friendly solution for waste disposal but also, through the effective recovery of resources, generates sustainable economic and environmental benefits for businesses.

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Sludge Pyrolysis Technology

The pyrolysis of sludge provides a novel and effective approach for the reduction, harmlessness, and resource utilization of sludge disposal. In recent years, this technology has attracted increasing attention and become an emerging thermal treatment process for sludge. The pyrolysis process exploits the thermal instability of organic matter, causing it to undergo thermal decomposition under anaerobic or oxygen-deficient conditions, resulting in the formation of gas, liquid, and solid residues.

oil sludge pyrolysis equipment

Rotary Kiln Pyrolysis System

GEMCO oil sludge pyrolysis process adopts an indirect-fired rotary kiln as the pyrolysis reactor. It heats oil-containing sludge under anaerobic or oxygen-deficient conditions to temperatures ranging from 300 to 600℃. This process disrupts the high molecular bonding state of organic matter, breaking it down into low molecular substances. Simultaneously, the heated organic matter volatilizes to form pyrolysis gas and solid residue. This equipment is suitable for treating various oil-containing waste generated during oilfield drilling, transportation, and petroleum refining processes (such as oil-based cuttings, land-based oil sludge, oil-contaminated soil, refining sludge, dye and paint waste, etc.), as well as for the treatment of organic pollutants.

waste oil sludge

Transform Waste Sludge into Multiple Products

The high-temperature pyrolysis gas generated from the oil sludge in the pyrolysis reactor produces mineral oil and non-condensable gas containing a significant amount of propane, butane, methane, carbon monoxide, and other combustible components after condensation. The mineral oil can be recovered and reused, while the non-condensable gas can serve as supplementary fuel directly reused for combustion to provide heat for the pyrolysis system. The solid residue can be utilized as road base material.

gemco oil sludge treatment solutions

Various Flexible Options Available

GEMCO’s oil sludge pyrolysis system offers multiple configurations for users to choose from. We can also customize different equipment solutions based on the specific needs of customers. Options include continuous feed rotary pyrolysis equipment, batch feed rotary pyrolysis equipment, continuous feed multiple hearth furnace pyrolysis equipment, and more. Additionally, depending on on-site utility conditions, different energy sources such as natural gas, diesel, or electric heating can be selected.

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GEMCO Sludge Pyrolysis Plant Advantages

Modular Design

The equipment adopts a sled-mounted and modular integrated design, occupying a small footprint, facilitating transportation, and enabling rapid installation. Multiple module combinations can flexibly increase production output according to requirements.

Environmentally Friendly Design

Utilizing indirect anaerobic heating technology ensures that materials do not come into contact with air, effectively suppressing the generation of harmful gases such as dioxins, thereby enhancing environmental performance.

Wide Applicability

By adjusting the kiln’s tilt angle or rotational speed, the equipment can adapt to the processing of different types of materials, making it widely applicable.

High Safety Degree

The equipment is equipped with multiple safety measures such as nitrogen protection, gas monitoring, and safety release to ensure safe operation.

Resource Recycling

The non-condensable gas is reused as auxiliary fuel, and the heat energy from the pyrolysis kiln exhaust gas is recovered, increasing resource utilization efficiency and reducing system operating costs.

User-Friendly Interface

The equipment adopts program control, safety interlocking, and a user-friendly human-machine interface. Real-time monitoring and alarm, automatic data collection, and wireless remote transmission can be achieved, enhancing operational convenience and safety.

GEMCO Sludge Pyrolysis Plant Design

the designed structure of GEMCO oil sludge pyrolysis plant
1. Crushing & Feeding System
2. Pyrolysis Reactor
3. Buffer Air Bag
4. Condenser
5. Water Seal
6. Gas Generator Set
7. Oil Tank
8. Circulating Water Tank
9. Fuel Tank
10. Wire Separator
11. High Voltage Electrostatic Precipitator
12. Spray Deacidification Tower

Sludge Pyrolysis Plant Working Principle

Sludge pyrolysis oil production utilizes the thermal instability of organic matter in sludge to convert it into fuel. Dehydrated sludge, after removing moisture through drying, enters the pyrolysis reactor. Under atmospheric pressure (or high pressure) and oxygen-deficient conditions, the sludge is heated to a high temperature. With the catalytic effect of alumino-silicates and heavy metals (especially copper) contained in the sludge, lipids and proteins in the sludge are transformed into hydrocarbon compounds. Through dry distillation and thermal decomposition, the sludge is ultimately converted into high-value fuel oil, reaction water, non-condensable gas (NCG), and char. The products possess advantages such as easy storage, transportability, and convenience of use.

Oil-containing sludge is stored in oil sludge tanks and lifted to the pretreatment system via a feeding system. After pretreatment, the material is fed into the pyrolysis system, and after pyrolysis, the material is discharged from the system after cooling via a cooling spiral. The process gas produced from pyrolysis is washed and condensed, with the non-condensable gas treated by the tail gas treatment system before being returned to the pyrolysis equipment as auxiliary fuel. The condensed liquid undergoes oil-water separation, with waste oil recovered for reuse and wastewater entering the water treatment system.

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GEMCO Sludge Pyrolysis Plant Parameters

Raw Materialsoil-based cuttings, land-based oil sludge, oil-contaminated soil, refining sludge, dye and paint waste, etc.
End ProductsFuel oil, reducing soil
Processing Capacity1-40 t/d
HeatingAdjustable constant temperature heating
Working Pressure<100Pa
Pyrolysis TemperatureThermostatic cracking Low temperature catalytic pyrolysis, temperature can be adjusted according to different materials (300~600℃)
Automation level.Fully automatic intelligent control, with low labor intensity
Service Life>10 years
Reduced soil oil content<0.3%
oil containing sludge pollution

Hazards of Waste Oil Sludge

Oil containing sludge has a large volume. If left untreated and discharged directly, it not only occupies a large amount of farmland, but also causes pollution to the surrounding soil, water, and air, accompanied by the production of foul odors. The sludge contains a large amount of pathogenic bacteria, parasites (eggs), copper, zinc, chromium, mercury, and other heavy metals, as well as salts, which contain a large amount of benzene series, phenols, polychlorinated biphenyls, dioxins, anthracene, etc Toxic substances with a foul odor, such as pyrene, and toxic and harmful substances that are difficult to degrade, such as radioactive isotopes. Arbitrary landfill can lead to serious pollution of groundwater and serious damage to natural ecosystems such as food crops, trees, and vegetation.

With the help of scientific and reasonable processes and stable and reliable equipment, GEMCO’s sludge pyrolysis solutions can effectively reduce and harmless oil containing sludge, contributing to the sustainable development of human society.

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