Connect With Us
Connect With Us

Biochar & Sustainable Processing Lines

Home > Product > Oil Sludge Pyrolysis Plant

Oil Sludge Pyrolysis Plant 

Enquire Now
Download Brochure

Introduction

Oil Sludge Pyrolysis Plants are state-of-the-art thermal treatment plants with the aim of transforming the dangerous oil sludge. One of the most frequent byproducts of the petroleum refining, drilling and storage processes is useful products such as fuel oil, carbon black, and syngas by means of a controlled pyrolysis process. These plants can decompose the sludge in complex hydrocarbons without any combustion, and in an oxygen-free environment (400-600°C), the process reduces emissions and environmental impact. Kerone advanced systems have powerful rotary kilns or screw reactors that do not require pre-treatment of oil containing high-viscosity sludges but achieve a recovery rate of over 85% of reusable oil and a production of non-condensable gases that are used as a self-sufficiency energy source. This is an environmentally friendly solution that is able not only to solve the problem of waste disposal but also to convert liability into profit for oil and gas industries across the globe.

Why Choose Kerone Oil Sludge Pyrolysis Plant

Kerone is a reliable thermal processing solution provider, which has designed its Oil Sludge Pyrolysis Plants to be of high efficiency, reliability, and adherence to high standards such as the EU ATEX directives and the Indian CPCB standards. Having more than 45 years of experience in designing and supplying custom industrial heating and pyrolysis systems, we also offer turnkey plants, which can be simply integrated into the existing refineries or wastewater plants, with full after-sales support in the form of remote monitoring and predictive maintenance through IoT-enabled control systems. Our plants are also safe with automatic food feeders and multi-stage scrubbers, as well as explosion-proof designs, and guarantee no discharge operations and high ROI due to high oil production and low operation costs; therefore, Kerone is the perfect company to partner with in ensuring sustainable sludge management.

Types and Features of Oil Sludge Pyrolysis Plant

Oil Sludge Pyrolysis Plants are available in batch, semi-continuous, and fully continuous types, depending on various scales, such as small 5-ton/day plants to large 50-ton/day plants, with modular designs, which are easily scaled. Some of the important characteristics are vacuum-assisted pyrolysis to provide high separation of oil, chambers of catalytic cracking to upgrade heavy oils into light fuels and an inbuilt condenser system to collect 75-90 per cent of the pyrolysis oil with low content of wax. The higher-end models have AI-based temperature monitoring to optimise processes accurately, automatic slag discharge systems to avoid downtime, and energy recycling systems that use syngas to drive 60-80% of the operations that operate on alloys which resist corrosion due to the presence of acidic sludge compositions.

Key Features

  • Excellent oil recovery efficiency

    • Recovers 80-90 per cent of usable fuel oil directly off oil-laden sludges and the distillation process is automated to refine the quality.

  • Eco-Friendly Emissions Control

    • Multi-layer scrubbers and thermal oxidizers minimize the VOCs, SOx, and NOx in excess of 99 percent, exceeding the international EPA requirements.

  • Modular and Scalable Design

    • Configured capacities ranging 3-100 tons/day, with plug-and-play modules that are easily installed and expanded.

  • High-tech Safety

    • There is Explosion-proofing, auto-shut systems, and negative pressure to avoid leakage or any danger.

  • Energy Self-Sufficiency

    • The plant uses Syngas combustion to reduce the external fuel use up to 70 percent and reduce OPEX.

  • Durable Construction

    • The high-grade stainless-steel reactors are resistant to sulphur and chloride corrosion in sludge.

  • Easy-to-Use Automation

    • PLC-based HMI with real-time data recording, and remote diagnostics and mobile applications.

  • Zero-Waste Output

    • Uses residue to make carbon black to be used in industries, which removes dependency on landfills.

Powered by AI, ML & IoT

Future-Ready Engineering Driven by AI & IoT

Our advanced AI, ML, and IoT technologies, this solution delivers smarter automation, real-time insights, and predictive intelligence to enhance efficiency and drive future-ready growth.

Real-Time Monitoring & Control

Continuous tracking of process parameters with instant adjustments.

Predictive Maintenance

Intelligent fault detection to prevent failures before they occur.

Adaptive Process Optimization

Dynamic tuning of operations for maximum output and efficiency.

Cloud Dashboards & Analytics

Unified access to real-time insights and performance trends.

Energy & Resource Savings

Smarter utilization of energy to cut costs and reduce waste.

Secure IoT Connectivity

Encrypted data flow with seamless integration across plant systems.

Applications of Oil Sludge Pyrolysis Plant

Oil Sludge Pyrolysis Plants are widely applied in Oil Sludge industries whereby Kerone has provided sustainable solutions in waste-to-energy. Common uses are:
    • Refineries: Sludge on the bottom of the processing tanks and API separator waste is also processed to extract fuel oil and save on the cost of disposal.
    • Oil Drilling Rigs: The toxic drilling muds and cuttings that are contained with oil are treated so that the site can be remedied in both offshore and onshore operations.
    • Wastewater Treatment Plants: Sludge disposal Waste generated during the primary clarifier, oily sludge, can be converted from a part of the hazardous waste to useful resources.
    • Oil Storage Terminals: Handling of sludge which has accumulated in the storage tanks and the maintenance of the same so that it is in line with the environmental laws.
    • Chemical and Petrochemical Plants: Pre-treatment of the oily residues of the production process to obtain the energy and recycle the material using the pyrolysis process.
    • Environmental Clean-up Sites: Cleaning up of contaminated soils and old oil spills using mobile pyrolysis units.
By investing in the Oil Sludge Pyrolysis Plant of Kerone, the environmental issues will be transformed into economic benefits that will offer unparalleled pyrolysis performance, regulatory merits, and long-term profitability to the oil and waste management industries. These plants enable businesses to achieve their ESG objectives without compromising their performance by pioneering zero-waste technology that recovers high-value products and also reduces their carbon footprints. Achieve an upgraded version of your sludge management by collaborating with Kerone today to develop a tailored solution capable of future-proofing your operations to meet the changing waste standards and increasing energy requirements. Contact us to transform your sludge management.

Seamless Export Connections Global & Local

Our Global Footprint in Industrial Excellence

Delivering world-class industrial and process solutions across countries with precision, innovation, and reliability.

PeruPeru
ChileChile
ArgentinaArgentina
MexicoMexico
ColombiaColombia
BrazilBrazil
USAUSA
CanadaCanada
United KingdomUnited Kingdom
FranceFrance
GermanyGermany
SpainSpain
ItalyItaly
NetherlandsNetherlands
SwedenSweden
SwitzerlandSwitzerland
PolandPoland
PortugalPortugal
IrelandIreland
CzechiaCzechia
RomaniaRomania
HungaryHungary
AustriaAustria
GreeceGreece
KazakhstanKazakhstan
UzbekistanUzbekistan
TurkmenistanTurkmenistan
AlgeriaAlgeria
EgyptEgypt
NigeriaNigeria
KenyaKenya
South AfricaSouth Africa
Saudi ArabiaSaudi Arabia
UAEUAE
IsraelIsrael
RussiaRussia
IndiaIndia
ChinaChina
JapanJapan
South KoreaSouth Korea
ThailandThailand
VietnamVietnam
MalaysiaMalaysia
SingaporeSingapore
IndonesiaIndonesia
PhilippinesPhilippines
AustraliaAustralia
New ZealandNew Zealand

Pan-India Presence. Local Expertise.

Raipur
Bilaspur
Panaji
Vasco da Gama
Gandhinagar
Ahmedabad
Surat
Chandigarh
Gurgaon
Shimla
Manali
Bengaluru
Mysore
Kochi
Pune
Mumbai
Thane
Navi Mumbai
Hyderabad
Chennai
Coimbatore
Kolkata
Lucknow
Jaipur
Udaipur
Jodhpur
Dehradun
Haridwar
Bhubaneswar

Product Gallery

Frequently Asked Questions (FAQ)

  • It is a thermal processing unit, which heats up oil sludge under an oxygen-free atmosphere to break down the sludge into fuel oil, syngas and carbon black as an alternative to clean and alternative to incineration or landfilling of the waste.

Get Expert Assistance

Pyrolysis Plants

Categories

Get a Custom Quote Today

Kerone’s custom-designed heating and processing solutions are built to meet the demands of your growing operations. Whether you’re upgrading equipment, expanding production, or need a tailor-made solution

Get a Quote

Contact Us

Please enable JavaScript in your browser to complete this form.
Let's chat