Plastic Pyrolysis Plant

China’s leading plastic pyrolysis machine manufacturer helps customers convert waste plastics into usable energy, with a recovery rate of 30%–70%.

What Is a Plastic Pyrolysis Plant?

A Plastic Pyrolysis Plant is an industrial system that converts waste plastics into usable fuel products through thermal decomposition in an oxygen-free environment. It allows factories and recycling companies to turn plastic waste into pyrolysis oil, reusable gas, and solid carbon residue, creating both environmental and economic value.

PyrolysisUnit’s plastic pyrolysis plants are designed to process 1 to 35 tons of plastic per day, with an oil yield of 30%–70% depending on plastic type and operating conditions. The systems can handle most common plastics such as LDPE, HDPE, PP, and PS, while PVC and PET are excluded due to their low oil yield and harmful emissions.

A complete plastic pyrolysis plant includes a feeding system, pyrolysis reactor, condensation unit, gas recycling system, and emission control modules, ensuring stable operation, high oil recovery, and compliance with environmental standards. The non-condensable gas produced during pyrolysis is reused to heat the reactor, reducing fuel consumption and operating costs.

PyrolysisUnit offers small, batch, semi-continuous, and fully continuous plastic pyrolysis plants, allowing customers to choose the right capacity and automation level for pilot projects, commercial recycling, or large-scale industrial operations.

What Types of Plastic Can Be Processed?

Selecting the right plastic type is crucial for ensuring efficient pyrolysis, stable product quality, and operational safety. Different plastics vary in their suitability for pyrolysis due to differences in chemical composition and thermal stability. The following table clearly outlines the pyrolysis suitability of common plastic types:

Plastic Type	Pyrolysis Suitability
PE / LDPE / HDPE (Polyethylene / Low-Density Polyethylene / High-Density Polyethylene)	★★★★★
PP (Polypropylene)	★★★★★
PS (Polystyrene)	★★★★★
Mixed plastic (PE/PP/PS blends)	★★★★☆
PVC (Polyvinyl Chloride)	Needs pretreatment
PET (Polyethylene Terephthalate)	Not recommended

Key Explanations:

★★★★★ (Highly Suitable): PE, LDPE, HDPE, PP, and PS are ideal for pyrolysis. They have high hydrocarbon content, decompose stably at 450–650℃, and yield high-quality fuel oil (up to 80% for pure plastics) with minimal harmful emissions.
★★★★☆ (Suitable with Minor Limitations): Mixed plastics (composed of PE/PP/PS) can be processed directly without complex sorting. However, the fuel oil yield may decrease slightly (by 5–10%) compared to pure plastics, and the product quality remains stable for industrial use.
Needs Pretreatment (PVC): PVC releases toxic hydrogen chloride (HCl) during pyrolysis, which corrodes equipment and violates environmental standards. If processing is necessary, strict pretreatment (e.g., dechlorination) and enhanced flue gas purification systems are required to ensure compliance and safety.
Not Recommended (PET): PET has high thermal stability and requires extremely high temperatures (over 700℃) for decomposition, which increases energy consumption significantly. Additionally, its pyrolysis yields low-value products and may generate harmful byproducts, making it economically and environmentally unviable for pyrolysis.

Plastic Pyrolysis Plant Capacity & Output

What Products Do You Get from Plastic Pyrolysis?

Plastic pyrolysis converts low-value plastic waste into three core high-commercial-value products, which are widely used in industrial production and energy supply, realizing the transformation of waste into profitable resources. The specific product types, yield ranges and commercial applications are as follows:

Fuel Oil (Yield: 40–80%): As the primary high-value product, it has excellent combustion performance and can directly replace diesel, furnace oil and boiler fuel. It is widely used in industrial boilers, thermal power generators, heavy machinery and other equipment. Its stable supply and cost advantage (lower than traditional fossil fuels) can effectively reduce the energy expenditure of enterprises.

Wood Vinegar

Syngas (Yield: 10–20%): The by-product is mainly composed of combustible gases such as hydrogen and methane. It is fully recycled to heat the pyrolysis reactor, which significantly reduces the demand for external energy sources (such as natural gas and coal) and lowers the daily operating costs of the plant. The closed-loop energy utilization model further enhances the economic benefits of the project.

Pyrolysis of combustible gas

Carbon Black (Yield: 10–15%): It has good reinforcing and coloring properties, and is widely used in rubber production (as a reinforcing filler for tires and rubber products), asphalt modification (improving road performance), and pigment manufacturing. It can also be used as an industrial filler, with a stable market demand and providing an additional revenue stream for pyrolysis projects.

carbon black

All three products have clear industrial application scenarios and market channels, ensuring that plastic pyrolysis projects have reliable profit support, making it a practical waste-to-value business solution.

Is Plastic Pyrolysis Oil Usable as Diesel?

Plastic pyrolysis oil is not directly usable as automotive diesel due to differences in key properties (e.g., viscosity, cetane number, sulfur content) that do not meet the strict standards for vehicle engine fuels. However, it is a high-value industrial fuel with clear practical applications, and can be upgraded to diesel fractions through further processing.
Direct Applications of Plastic Pyrolysis Oil: Without additional refining, it is fully compatible with industrial combustion equipment, serving as a cost-effective alternative to traditional fuels:

Industrial burners: Widely used in manufacturing processes requiring thermal energy (e.g., metal processing, chemical production), with stable combustion and high heat value.

Industrial burners

Boilers: Suitable for industrial boilers and heating systems in factories, commercial buildings, or power plants, reducing reliance on furnace oil and lowering energy costs.

Industrial boilers

Generators: Can power industrial generators to meet on-site electricity needs, especially valuable for off-grid or backup power scenarios in waste management facilities or industrial parks.

fuel generator

Upgrading to Diesel Fraction: Through a distillation and refining process (e.g., hydrotreating, dewaxing), plastic pyrolysis oil can be converted into diesel fractions that meet industrial or even automotive fuel standards. This upgraded diesel fraction can be used directly in diesel engines or blended with conventional diesel, further enhancing the commercial value of the pyrolysis product.

Plastic Pyrolysis Process

0) Feedstock Strategy & Applicable Scope

Suitable Plastics: Primarily PE, PP, PS (typically delivering higher and more stable oil yields).
Unsuitable: PVC, PET (Reasons: PVC produces acidic gases; PET has low oil yield and poor oil quality).
Daily Processing Capacity: 1–35 t/day depending on production line configuration.
Target Oil Yield: 30%–70% (determined by plastic mix ratio, temperature control, and condensation strategy).

1) Feedstock Pre-treatment

Sorting: Remove PVC, PET, as well as metals, glass, stones, and other contaminants.
Size Reduction: Compress or shred blocky or film materials into particles or briquettes suitable for stable feeding.
Uniform Blending: Maintain a consistent formula (e.g., PE/PP ratio) to stabilize oil yield and quality.

2) Feeding & Sealing

Small/Batch/Semi-Continuous: Hopper → Sealed feeding port (or screw conveyor) → Reactor; check gaskets and fasteners.
Continuous: Feeding silo → Variable frequency screw/pressurized feeding → Airlock device → Continuous reactor.
Key Checks: Door seals, valve positions, return pipelines, cooling water circulation, burner interlocks.

3) Heating & Pyrolysis (Oxygen-Free / Oxygen-Deficient)

Atmosphere: Maintain oxygen-free/low-oxygen conditions, recommended slight negative pressure to prevent flashback or leakage.
Heating Strategy: Gradual multi-stage heating to avoid rapid thermal shock that causes coking/wax blockages.
Preheat Zone: Remove residual moisture and light volatiles.
Main Pyrolysis Zone: Operate in the ~300–500 °C range (optimum varies by feedstock):
- ~400–450 °C: Favors higher condensable oil gas yield (boosting the upper end of the 30%–70% target).
- ~300–380 °C: Produces more heavy waxes/heavy oil.
Agitation/Rotation: Improves heat transfer uniformity and reduces coking risk.
Key Process Values: Furnace temperature, reactor slight negative pressure, oil-gas mainline temperature/pressure, reflux valve position, combustible gas flow.

4) Primary Gas–Solid Separation

Cyclone or wire mesh demister at reactor outlet to capture dust/char powder, protecting downstream condensers and pumps.

5) Multi-Stage Condensation & Fractional Oil Recovery

First Stage (High Temperature): Capture heavy oil/wax; controlled reflux to reactor if further cracking is needed.
Second/Third Stage (Medium–Low Temp): Recover light/middle pyrolysis oil.
Oil–Water Separation: Gravity separation tank; drain water regularly to stabilize final product oil.
Finished Product Storage: Fractional tanks or storage tanks by grade for downstream use matching.

6) Non-Condensable Gas Recovery & Utilization

Purification/buffer unit (gas–liquid separation, basic dust/char mist removal).
Reuse as heating fuel for furnace, prioritizing self-sufficiency; excess is sent to a separate burner/flare for safe disposal.
Goal: Minimize external fuel use while ensuring stable and safe flame.

7) Solid Residue Discharge & Handling

Mainly carbon residue and minor char powder (compared to tire pyrolysis, lower solids, no steel wire).
Batch/Semi-Continuous: Cool to safe temperature, then discharge via sealed outlet or screw conveyor.
Continuous: Bottom continuous discharge via enclosed conveying.
Post-Treatment: Screening, pelletizing, or reuse as industrial fuel/filler as required.

8) Tail Gas & Odor Control

Maintain fully sealed system + slight negative pressure.
Combustion tail gas is treated (dust removal/adsorption) before compliant discharge; activated carbon adsorption at condensation area if needed for odor reduction.
With PVC/PET excluded, acidic gas load is significantly reduced.

9) Online Quality Control & Process Adjustment

Oil: Appearance, density, water content, viscosity, initial/final boiling point (to fine-tune condensation temperature zones and reflux ratio).
Non-Condensable Gas: Flow rate and stable flame observation for adjusting heat input and auxiliary fuel use.
Energy/Output Dashboard: Track per-shift/daily oil yield (against 30%–70% target) and external fuel percentage.

10) Operating Modes – Key Points

Small Pyrolysis Units: Compact footprint, flexible start/stop, ideal for trials/training/distributed recycling.
Batch Pyrolysis: Batch feeding/discharge, clear process, suitable for multi-type switching.
Semi-Continuous: Reduced start-stop loss, smoother oil output, balanced investment vs. efficiency.
Continuous Pyrolysis: Continuous feed and oil-gas production; capacity up to 1–35 t/day, better for maintaining high, stable oil yields near the 30%–70% range.

11) Safety & Interlock (Core Checklist)

Over-Temperature/Over-Pressure: Automatic fire reduction/shut-off.
Oxygen Over-Limit: Interlocked furnace shutdown / combustible gas cut-off.
Cooling Water Failure: Divert oil-gas to safe combustion unit.
Flame Loss Detection: Activate backup burner or shut down.
Leak Detection: Gas-tight alarm + emergency shut-off valves.

PyrolysisUnit Global Cases

Plastic Pyrolysis Solution Guide

As a leading manufacturer specializing in plastic pyrolysis technology with over a decade of engineering experience, we understand that investing in plastic pyrolysis equipment requires comprehensive clarity on technology, profitability, compliance, and after-sales support. This guide is tailored for global investors, entrepreneurs, and enterprise decision-makers interested in plastic pyrolysis—covering core questions from material adaptability to project implementation, and highlighting how our factory-direct solutions and full-cycle technical services can help you achieve successful project operation.

1.What Types of Plastic Can Be Pyrolyzed?
2.Plastic Pyrolysis Oil Yield & Output Expectation
3.Batch vs Semi-Continuous vs Continuous Systems
4.Economic Feasibility & Profit Considerations
5.Environmental Compliance & Emission Control
6.Safety Design & Risk Control
7.Application Scenarios & Typical Projects
8.Why Our Plastic Pyrolysis Solution
9.Engineering Expertise & Global Support
10.FAQ on Plastic Pyrolysis

1. What Types of Plastic Can Be Pyrolyzed?>>>

Plastic pyrolysis converts waste plastics into valuable fuels (pyrolysis oil), carbon black, and syngas through oxygen-limited high-temperature cracking. Not all plastics are suitable for pyrolysis, and our equipment is engineered to optimize the conversion efficiency of compatible materials while ensuring stable operation. Here are the main types of pyrolyzable plastics and our technical adaptations:

Polyolefins (Highly Recommended): Including polyethylene (PE, e.g., plastic bags, bottles, film), polypropylene (PP, e.g., plastic buckets, caps, automotive parts). These are the most ideal raw materials, with high oil yield (70-85%) and low impurity content. Our equipment is equipped with a customized feeding and sorting pre-treatment system to handle various forms of PE/PP waste (crushed or whole).
Polystyrene (PS): Such as foam plastic, disposable lunch boxes, and packaging materials. PS has a high oil yield (60-75%) and can be processed directly with our equipment without additional modifications. We provide specialized temperature control programs for PS to avoid excessive carbonization.
Mixed Plastics (With Limitations): Mixed plastics (excluding non-pyrolyzable types) can be processed by our equipment, but the oil yield will vary (50-65%) depending on the proportion of high-quality plastics. Our technical team will conduct raw material testing for you and customize the equipment’s cracking parameters to maximize output value.
Non-Pyrolyzable Plastics (Strictly Prohibited): Plastics containing chlorine, fluorine, or other harmful elements, such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), and plastic containing heavy metal additives. These will produce toxic gases (e.g., hydrogen chloride) during pyrolysis, damaging equipment and violating environmental regulations. We provide professional raw material identification training to help you avoid operational risks.

2. Plastic Pyrolysis Oil Yield & Output Expectation>>>

Oil yield and output are core concerns for investment returns, and they are determined by raw material quality, equipment technology, and operational parameters. As a manufacturer, we commit to transparent data and customized solutions to ensure your output meets expectations:

Key Factors Affecting Oil Yield

Raw Material Purity: Pure PE/PP can reach an oil yield of 70-85%; mixed plastics with 50% PE/PP have an oil yield of 50-65%; contaminated plastics (with soil, water, or other impurities) will reduce the oil yield by 5-15%.
Equipment Technology: Our patented multi-stage cracking technology and precise temperature control (380-450℃) ensure full cracking of plastics, increasing oil yield by 8-12% compared to ordinary equipment. The built-in oil-gas separation system also reduces oil loss during condensation.
Raw Material Pretreatment: Drying (moisture content ≤10%) and crushing (particle size 2-5cm) of raw materials can improve oil yield. We provide matching pre-treatment equipment (dryers, crushers) to form a complete production line.

Output Expectation (Factory-Standard Equipment)

Equipment Type	Daily Raw Material Processing Capacity	Estimated Daily Oil Output (Pure PE/PP)	Suitable Project Scale
Small Batch Unit	5-10 tons	3.5-8 tons	Startups, small-scale waste disposal stations
Medium Semi-Continuous Unit	10-30 tons	7-25.5 tons	Medium-sized recycling enterprises, regional waste treatment projects
Large Continuous Unit	30-100 tons	21-85 tons	Large-scale energy companies, industrial waste recycling parks

Note: The above data is based on standard operating conditions. Our technical team will conduct on-site surveys and provide personalized output forecasts according to your local raw material conditions.

3. Batch vs Semi-Continuous vs Continuous Systems>>>

Choosing the right system type is critical to matching your project scale, raw material supply, and investment budget. We offer all three types of systems and provide professional selection guidance based on your actual needs. Here is a detailed comparison:

Comparison Dimension	Batch System	Semi-Continuous System	Continuous System	Our Recommendation
Operation Mode	One-time feeding → cracking → discharging, cyclic operation	Continuous feeding, batch discharging	Fully automated continuous feeding, cracking, and discharging	–
Daily Capacity	2-10 tons	10-30 tons	30-100+ tons	–
Investment Cost	Low (entry-level)	Medium	High (large-scale investment)	Startups: Batch; Growing enterprises: Semi-continuous; Large projects: Continuous
Labor Requirement	3-5 people/shift	2-3 people/shift	1-2 people/shift (fully automated)	We provide automated upgrade solutions for batch/semi-continuous systems
Raw Material Adaptability	Strong (suitable for small batches of mixed plastics)	Medium (stable raw material supply required)	High (requires continuous and stable raw material supply)	Customize system parameters according to your raw material stability
Energy Efficiency	Medium (heat loss during feeding/discharging)	High (reduced heat loss from continuous feeding)	Excellent (waste heat recycling, low energy consumption)	All systems are equipped with our patented waste heat recovery technology

4. Economic Feasibility & Profit Considerations>>>

As a factory, we help you control costs from the source and maximize profits through professional technical support. The economic feasibility of plastic pyrolysis projects mainly depends on four core factors, and we provide full-cycle profit optimization services:

Core Cost Components (Factory-Direct Advantages)

Equipment Cost: Factory direct sales, no middlemen markup. We provide flexible payment plans (installment payment, L/C) and customized equipment configurations to avoid over-investment.
Raw Material Cost: The main cost driver (accounting for 40-60% of total costs). We help you identify local low-cost raw material channels (waste plastic recycling stations, industrial waste discharge enterprises) and provide raw material procurement standards.
Operational Cost: Including energy, labor, and maintenance. Our equipment’s energy efficiency is 15-20% higher than industry average, and the simplified maintenance design reduces maintenance costs by 30%. We also provide free operator training to improve work efficiency.

Profit Sources & Optimization

Main Product: Pyrolysis Oil: Can be sold as industrial fuel (for boilers, generators) or further refined into diesel (with additional refining equipment). Our technical team provides oil quality improvement solutions to increase the selling price of pyrolysis oil by 10-15%.
By-Products: Carbon Black & Syngas: Carbon black can be sold to rubber, pigment, or battery industries; syngas can be recycled as fuel for the pyrolysis furnace, reducing energy costs by 25-35%.

Typical Profit Forecast (Medium Semi-Continuous System, 20 Tons/Day Raw Material)

Assuming raw material cost: $150/ton; pyrolysis oil selling price: $600/ton; carbon black selling price: $300/ton; daily operational cost: $2,000. Daily profit = (14 tons oil × $600 + 3 tons carbon black × $300) – (20 tons raw material × $150 + $2,000) = $8,400 + $900 – $3,000 – $2,000 = $4,300. The payback period is usually 8-18 months (varies by region and raw material cost). We provide customized profit calculation reports based on your local market conditions.

5. Environmental Compliance & Emission Control>>>

Global environmental regulations are becoming increasingly strict, and compliance is a prerequisite for project sustainability. Our equipment is designed in accordance with international standards (EU ETS, US EPA, CE, ISO 14001) and is equipped with a full-set emission control system to ensure your project meets local environmental requirements:

Key Emission Control Technologies

Flue Gas Treatment System: Three-stage purification (dry dust removal → wet scrubbing → activated carbon adsorption) to remove dust, sulfur dioxide, nitrogen oxides, and volatile organic compounds (VOCs). The emission concentration of particulate matter is ≤10 mg/m³, which is far below the global mainstream standards.
Wastewater Treatment: The small amount of wastewater generated during the process is treated by a closed-loop system (coagulation → sedimentation → filtration) and reused for cooling, realizing zero wastewater discharge.
Odor Control: Sealed production line + activated carbon deodorization device to eliminate odor pollution during feeding and discharging.

We provide local environmental compliance consulting services, helping you obtain relevant permits and pass environmental inspections. All our equipment comes with environmental protection test reports to ensure compliance and worry-free operation.

6. Safety Design & Risk Control>>>

Plastic pyrolysis involves high temperature and pressure, so safety is our top priority in equipment design. We integrate multiple safety protection technologies into the whole production process to minimize operational risks:

Core Safety Design

Pressure & Temperature Monitoring: Real-time online monitoring of the cracking chamber’s pressure and temperature, with automatic alarm and shutdown functions when parameters exceed the safety range.
Overpressure Protection: Equipped with a safety valve, rupture disk, and other overpressure relief devices to prevent equipment damage caused by excessive internal pressure.
Sealed & Fire-Proof Design: The entire production line adopts a fully sealed structure to avoid leakage of flammable and explosive gases. Fire-proof devices and fire extinguishing systems are installed in key areas.
Emergency Shutdown System: One-key emergency shutdown function, which can quickly cut off the heating source and isolate the cracking chamber in case of emergencies, ensuring the safety of personnel and equipment.

In addition, we provide comprehensive safety training (on-site or online) for your operators, covering equipment operation specifications, emergency handling procedures, etc. We also conduct regular safety inspections during the after-sales period to eliminate potential risks.

7. Application Scenarios & Typical Projects>>>

Our plastic pyrolysis solutions have been successfully applied in more than 50 countries and regions around the world, covering various application scenarios. Typical projects include:

Waste Plastic Recycling Enterprises: Converting collected waste plastics into high-value fuels and carbon black, improving the added value of recycling. Typical case: A recycling company in India (20 tons/day semi-continuous system) achieved a payback period of 10 months.
Industrial Waste Disposal: Helping chemical, plastic manufacturing, and other enterprises dispose of industrial plastic waste on-site, reducing transportation costs and environmental risks. Typical case: A plastic film factory in Germany (15 tons/day batch system) realized zero discharge of production waste.
Energy Generation Projects: Using pyrolysis oil to generate electricity for factories or local communities. Typical case: A rural energy project in Nigeria (10 tons/day semi-continuous system) supplies electricity to 200+ households.
Environmental Protection Projects: Undertaken by local governments or environmental protection companies to solve the problem of plastic waste pollution. Typical case: A waste treatment project in Southeast Asia (50 tons/day continuous system) processes 18,000 tons of plastic waste annually.

We can provide you with detailed case studies (including project videos, operation data, and profit reports) of projects in your region.

8. Why Our Plastic Pyrolysis Solution>>>

As a professional manufacturer with independent R&D and production capabilities, our core advantages lie in factory direct supply, leading technology, and full-cycle technical services—helping you avoid risks and improve project success rate:

Factory Direct Supply, Cost Control: No middlemen, direct sales of equipment at factory prices. We provide customized configurations according to your budget and needs, avoiding over-investment. Flexible payment terms reduce your capital pressure.
Independent R&D, Technological Leadership: We have a professional R&D team and 15+ patents in pyrolysis technology. Our equipment has higher oil yield, lower energy consumption, and better environmental performance than industry average. We continuously upgrade technology to adapt to global environmental regulations and market changes.
Full-Cycle Technical Services: From pre-project consulting (feasibility analysis, site planning) to during-project (equipment installation, commissioning, operator training) and after-sales (maintenance, spare parts supply, technology upgrade), we provide one-stop services. Our technical team can respond to your needs within 24 hours.
Global Compliance, Worry-Free Operation: Our equipment meets international standards (CE, ISO, EPA, etc.). We provide local environmental compliance consulting and help you obtain relevant permits, ensuring your project complies with local laws and regulations.

9. Engineering Expertise & Global Support>>>

With over 10 years of experience in plastic pyrolysis project engineering, we have established a global service network to provide you with professional and timely support:

Professional Engineering Team: Our engineers have rich experience in global project implementation, capable of providing customized engineering solutions (site layout, pipeline design, electrical configuration) according to local climate, geological conditions, and relevant regulations.
Global On-Site Support: We have service centers in Asia, Africa, Europe, and South America. Our technical engineers can arrive at the project site within 3-7 working days to provide installation, commissioning, and maintenance services.
Spare Parts Supply: We have a global spare parts warehouse, providing genuine spare parts at factory prices. Emergency spare parts can be delivered within 48 hours to ensure minimal downtime of your equipment.
Long-Term Technology Upgrade: We provide free technical upgrade guidance for life. As environmental regulations and market demands change, we help you upgrade equipment functions to maintain the competitiveness of your project.

Whether you are a startup exploring the plastic pyrolysis industry or an enterprise expanding production scale, we are committed to becoming your long-term partner. Contact us today to get a free customized project feasibility report and equipment quotation!

FAQ on Plastic Pyrolysis Plant

Can I use mixed plastic?

Yes.
A plastic pyrolysis plant can process mixed plastics as long as they are mainly:

PE (polyethylene – bags, film, bottles)
PP (polypropylene – packaging, caps, containers)
PS (polystyrene – foam, disposable boxes)

These plastics crack into oil very efficiently.

What must be excluded?

Mixed plastic must NOT contain:

Plastic	Why it is bad
PVC	Releases HCl (acid gas) → corrodes reactor + illegal emissions
PVDC	Produces chlorine & toxic fumes
PET	Very low oil yield, produces acid + wax
Brominated plastics	Toxic & dangerous

Even 5–10% PVC in mixed plastic can destroy oil quality and violate environmental rules.

This is why sorting is mandatory, not optional.

What oil yield do you get from mixed plastic?

Typical oil yield:

Feedstock	Oil Yield
Pure PE / PP	70–85%
PS	60–75%
Mixed plastic (PE+PP+PS)	50–65%
Mixed plastic with PET	30–50%
Mixed plastic with PVC	❌ Not allowed

So yes — mixed plastic works, but the more PE & PP inside, the more money you make.

Is pyrolysis oil usable as diesel?

No.

Plastic pyrolysis oil is:

A synthetic crude oil
A mix of C5–C30 hydrocarbons
Similar to light fuel oil / furnace oil

It is not diesel-grade fuel when it comes out of a pyrolysis plant.

But it can be upgraded into diesel.

How pyrolysis oil becomes diesel

To turn pyrolysis oil into real diesel, it must go through a refining process:

Step 1 — Distillation

Removes:

Heavy wax
Light naphtha
Water
Produces a clean middle-distillate fraction

Step 2 — Desulfurization (HDS)

Removes:

Sulfur
Nitrogen
Odor
Corrosive compounds

Step 3 — Polishing

Improves:

Flash point
Color
Stability

After this, the oil becomes:

In many countries it can be used in:

Diesel generators
Industrial boilers
Mining equipment
Marine engines
Heavy trucks (after proper refining)

What is the oil yield?

It depends mainly on the plastic type.

Plastic type	Typical oil yield
PE (HDPE / LDPE / film, bags)	70–80%
PP (caps, containers, packaging)	70–75%
PS (styrofoam, foam, cups)	75–90%
Mixed plastics (PE+PP+PS)	50–70%
PET	30–50%
PVC	❌ Not recommended (toxic HCl gas)

Why people say “30–70%” on websites

Because real-world feedstock is mixed.

Most recycling plants do not get pure PE or PP — they get:

Film
Packaging
Containers
Labels
Dirt, moisture, fillers

So commercial plants typically achieve:

50–70% oil from mixed plastic waste

This is what banks, EPC contractors, and serious investors use in financial models.

How much electricity does it need?

Electricity is used for:

Motors (feeding, rotation, discharge)
Pumps (oil, water, gas)
Condensers & cooling towers
Control system (PLC, sensors)

Heating is NOT electric — it is done by pyrolysis gas or fuel oil burners.

Typical power consumption

Plant size	Plastic input	Installed power	Actual running load
Small unit	3–5 tons/day	25–40 kW	15–25 kW
Medium plant	10–20 tons/day	50–90 kW	35–60 kW
Industrial line	30–50 tons/day	100–180 kW	70–120 kW
Large continuous	50–100+ t/day	180–350 kW	120–250 kW

Actual consumption is usually 60–70% of installed power because not all motors run at the same time.

What is the ROI?

For commercial-scale plastic pyrolysis plants, the ROI is usually:

8–18 months payback
60%–150% annual return