HK Makine manufactures industrial plastic pyrolysis plants. Pyrolysis oil, carbon black and synthesis gas from waste PE, PP, PS and mixed plastics. Custom capacity from 1 to 50 tonnes per day. Turnkey installation across Turkey from our Gaziantep factory for the recycling, chemical and energy sectors.
A plastic pyrolysis plant is a thermal conversion system that heats waste plastic and tyres in an oxygen-free environment at high temperatures (350–550°C), breaking molecular bonds to produce pyrolysis oil, carbon black and combustible gas. This process converts non-recyclable waste plastics into valuable energy resources.
HK Makine plastic pyrolysis plants are delivered as fully integrated production lines comprising a shredder, pyrolysis reactor, cooling and condensation system, gas purification unit, carbon black collection system and automation panel.
Why plastic pyrolysis? Disposing of dirty or mixed non-recyclable plastics is a major environmental challenge. Pyrolysis converts this waste into industrially usable fuel while reducing the environmental burden and delivering an economic return to the investor.
Pyrolysis oil is obtained in varying yields depending on the feedstock. It is used as a diesel substitute, industrial fuel or refinery feedstock. Its calorific value is approximately 9,500–10,500 kcal/kg.
Between 2% and 35% carbon black is recovered depending on feedstock (particularly tyres). It is used in paint, ink, rubber and construction material manufacturing.
The combustible synthesis gas released during pyrolysis is typically fed back to the reactor's own heating system as fuel, reducing the plant's energy costs.
The type and quality of plastic directly affects pyrolysis yield. The table below shows average yield ranges measured under typical laboratory and field conditions.
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| Feedstock Type | Oil Yield (%) | Carbon Black (%) | Gas (%) | Oil Calorific Value | Typical Source |
|---|---|---|---|---|---|
| PE (Polyethylene) | 80% – 95% | 2% – 5% | 5% – 15% | ~10,200 kcal/kg | Bags, packaging, pipe waste |
| PP (Polypropylene) | 80% – 90% | 2% – 5% | 5% – 15% | ~10,000 kcal/kg | Crates, furniture, carpet waste |
| PS (Polystyrene) | 70% – 85% | 10% – 15% | 5% – 10% | ~9,800 kcal/kg | Foam, packaging, electrical boxes |
| ABS | 40% – 60% | 10% – 20% | 10% – 20% | ~9,500 kcal/kg | Electronic housings, toys |
| Mixed Plastics | 50% – 70% | 5% – 15% | 10% – 25% | ~9,200 kcal/kg | Unsorted waste plastic |
| Waste Tyres / Rubber | 40% – 50% | 30% – 35% | 10% – 15% | ~9,600 kcal/kg | Vehicle tyres, industrial rubber |
| Yields may vary by ±5–10% depending on feedstock quality, moisture content and reactor operating conditions. PVC-containing plastics are not accepted as they generate corrosive chlorine gas. | |||||
Incoming waste plastics are weighed, cleaned of PVC and other harmful materials, and sorted by type where necessary.
Large pieces are shredded to 3–5 cm by a shredder, making feeding into the reactor easier and ensuring uniform pyrolysis.
Plastics are heated to 350–550°C in a rotary or fixed reactor under an oxygen-free atmosphere, breaking molecular bonds and releasing volatile hydrocarbon compounds in gas form.
Hot gases from the reactor are cooled in multi-stage condensers (primary and secondary), converting them into liquid pyrolysis oil that is transferred to storage tanks.
Non-condensable combustible gases pass through a gas purification system and are fed back to the reactor burner, minimising external fuel requirements.
Solid residue (carbon black) remaining in the reactor is cooled and discharged by mechanical systems. Optionally milled to standard carbon black particle size in a ball mill and packaged in big bags.
Pyrolysis oil is stored in storage tanks and carbon black in big bags or silos, ready for sale.
HK Makine plastic pyrolysis plants are manufactured in different configurations according to capacity, feedstock type and automation level.
The reactor shell is manufactured from P355GH or equivalent quality pressure vessel steel rated for high temperatures. Fixed (batch) reactors use a cylindrical shell; rotary reactors use an inclined rotating drum. The reactor interior is lined with heat and wear-resistant alloy steel. Operating temperature is 350–550°C at atmospheric or slightly negative pressure.
Reactor heating is provided by a modulating burner running on natural gas, diesel or synthesis gas. Once the process stabilises, synthesis gas recovered from pyrolysis is fed back to the reactor burner, minimising external fuel consumption. The heating system is controlled automatically via PLC.
High-temperature hydrocarbon gases leaving the reactor are cooled gradually in multi-stage condensers (primary and secondary). Different boiling-point fractions are separated at each stage and collected in separate tanks as heavy oil and light oil. The condensation system is made from stainless or carbon steel.
Non-condensable combustible gases pass through a dust trap, acid gas scrubber and water seal before being recycled to the burner. An emergency flare system is provided for safe gas disposal. CO and HC sensors perform continuous measurement and trigger automatic shut-down in the event of a leak.
Carbon black accumulating in the reactor is cooled by a screw conveyor or rotary cooler, then removed by vacuum or mechanical system. Optionally ground in a ball mill to N220–N330 equivalent carbon black particle size and packaged with a big-bag filling system.
The standard automation package includes a PLC control unit, touchscreen HMI panel, temperature and pressure transmitters, level sensors and an emergency stop system. Optional SCADA integration, remote access and GSM alarm system can be added. All process data is recorded.
HK Makine plastic pyrolysis plants are available in custom production for all capacities from 1 to 50 tonnes per day.
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| Capacity | Reactor Type | Daily Oil Output* | Automation | Estimated Price (Excl. VAT) | Lead Time |
|---|---|---|---|---|---|
| 1 – 2 T/Day | Fixed (Batch) | 800 – 1,900 lt | Semi-Automatic | 800,000 – 1,500,000 TRY | 45-60 days |
| 3 – 5 T/Day | Fixed (Batch) | 2,400 – 4,750 lt | PLC Control | 1,500,000 – 3,000,000 TRY | 55-75 days |
| 5 – 10 T/Day | Semi-Continuous | 4,000 – 9,500 lt | PLC + HMI | 2,800,000 – 5,500,000 TRY | 70-90 days |
| 10 – 20 T/Day | Semi-Continuous | 8,000 – 19,000 lt | PLC + SCADA | 5,000,000 – 9,000,000 TRY | 90-110 days |
| 20 – 50 T/Day | Rotary Kiln | 16,000 – 47,500 lt | Full Auto SCADA | 8,500,000 – 15,000,000 TRY | 100-120 days |
| *Daily oil output is calculated on a PE/PP feedstock basis. Yield varies for mixed plastics or tyre processing. Pipe installation and electrical works are priced separately. | |||||
HK Makine prepares custom engineering projects for the following situations:
80–95% pyrolysis oil yield with PE/PP feedstock
Oil, carbon black and synthesis gas from the same process
Custom design and manufacturing from 1 to 50 t/day
Fully integrated system from shredder to storage
Synthesis gas burned in reactor reduces external fuel costs
Gas purification system keeps emissions below legal limits
15+ year service life with high-quality steel reactor
Installation, commissioning and annual maintenance from Gaziantep
Waste Plastic to Fuel | PE / PP / PS / Tyres | Turnkey Installation Across Turkey from Gaziantep
+90 536 037 3281Copyright 2026 HK Makine — Nizip / Gaziantep. All Rights Reserved.
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