How do you produce fossil oil from plastic waste?

The global plastic waste crisis is in urgent need of innovative recycling solutions. Plastic waste—composed of hydrocarbon polymers derived from crude oil—can be converted into fossil oil (pyrolysis oil) through a controlled thermal process called pyrolysis. Companies like DOING specialize in providing the plastic to fossil oil pyrolysis equipment, solution and project installation expertise required for such conversions.

DOING waste plastic pyrolysis equipment

This article provides a detailed step-by-step guide to the fossil oil generation process, focusing on how DOING waste plastic pyrolysis equipment optimizes each stage for efficient, safe, and economical fossil oil production.

Step-by-step guide to producing fossil oil from plastic waste

1.Pretreatment:Strict pretreatment is essential because PVC, PET, wet or heavily contaminated plastics will reduce efficiency, damage equipment, reduce fossil oil quality, and risk harmful emissions. Waste plastics (primarily PP, PE and PS) are sorted to remove contaminants such as metals, paper, food residues and PVC. The plastics are then washed and dried to reduce their moisture content to less than 15%.

Fossil oil from plastic waste production process

2.Pyrolysis (thermal cracking): The treated plastics enter an oxygen-free reactor. Externally heated to between 260°C and 280°C, the long-chain polymer molecules are thermally broken down into smaller hydrocarbon molecules. This produces a vapor mixture of hydrocarbon gases.

3.Condensation: The hot vapor flows into a multi-stage condensation system. When the vapor cools below the dew point, the condensable hydrocarbons liquefy into pyrolysis oil and are collected in a storage tank.

Post-processing and product utilization:

1.Liquid oil (fossil oil/pyrolysis oil): The oil (40-90% of the input) can be used in industrial boilers/ brick factories, glass factories, gypsum factories, cement factories, steel factories/ heavy oil generators or be further refined into higher-value diesel for diesel generators, trucks, tractors, ships, and other heavy machinery.

2.Solid residue (carbon black): Mineral-rich carbonaceous solids (5-20% of the input) remaining in the reactor will be removed. This coke can be processed into carbon black for rubber products, coatings, building materials or as solid fuel.

Fossil oil from plastic waste application

3.Non-condensable gases (synthesis gas): Light gases (methane, ethane, ethylene, hydrogen, etc.) that are not liquefied (usually 10-30% of the input) are critical. DOING emphasizes that these light gases can be effectively reused as fuel to heat the reactor, thereby significantly reducing external energy requirements. Any excess gas or final emissions must be treated by an environmental protection system (exhaust treatment unit, flue gas purification unit, combustion chamber) to meet emission standards before they can be discharged.

Advantages of DOING waste plastic pyrolysis equipment:

1.High oil yield: The oil yield of pure PP, PE or PS materials is as high as 90%. For mixed plastic waste, the oil yield remains at a practical level of 40-60%.

2.Energy self-sufficiency: The system uses by-product syngas (about 10%) to fuel the reactor, significantly reducing operating fuel costs.

DOING waste plastic pyrolysis equipment environmental system

3.Environmental focus: The process diverts plastics from landfill/incineration. DOING emphasizes integrated pollution control systems (for waste gases, wastewater and solids residues) to minimize emissions and prevent secondary pollution, which is very different from open-air incineration or landfill.

4.High Quality: The plastic pyrolysis reactor is equipped with DOING patented dewaxing device and is constructed of national standard materials Q245R and Q345R, with customizable 304/306/314-316 stainless steel materials available upon request. The equipment can withstand high temperature and high pressure and is not easy to crack. And for the recycling of plastics like PE, DOING has patented dewaxing devices and anti-sticking and coking devices to make equipment operation smoother. Its lifespan is estimated to be 4-8 years.

Waste plastic pyrolysis oil yield

Producing fossil oil from plastic waste via pyrolysis is a sustainable, profitable solution—made efficient by DOING waste plastic pyrolysis equipment. Whether you’re a small recycler or a large waste management firm, DOING system turns plastic pollution into a steady revenue stream while meeting global environmental standards. Welcome to contact us to learn more about DOING plastic pyrolysis equipment.