Factor 1 - LRP (Liquid, Rubber, and Plastics)

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Application Area

The unit processes a wide range of feedstock:

• Oil sludge and petroleum sediments
• Used lubricating oils
• Acid tar, bitumen, fuel oil (including M-100)
• Crude oil residues, technical fluids
• Mixtures containing up to 20% water
• Processing 25-30 tons of waste daily 

Working Principle

A multi-level pyrolysis system:

• Upper zone: up to 360°C — degassing and drying
• Middle zone: 360–380°C — deep cracking
• Lower zone: 430–460°C — maximum carbon yield

Heat is supplied via a refractory-lined chamber with a staggered brick design to prevent local overheating. Inside the retorts are screw conveyors ensuring even heating and feed movement.

Unit Design

• Three levels of retorts, 2 per level (Ø225 mm)
• Built-in screw conveyors at every stage — from feed to output
• Retort length — approx. 4 meters
• Thermal circuit lined with firebrick (up to 920°C)
• Heated by pyrolysis gas or diesel fuel (during startup)

Performance and Specifications

| Capacity | up to 1250 kg/h |

| Power supply | 380 V, 50 Hz |

| Power consumption | 40 kWh (startup), 20 kWh (operating) |

| Thermal power | ≥ 1000 kW |

| Reactor pressure | up to 150 Pa |

| Flue gas temperature | up to 1100°C |

| Dimensions | 6200 × 2200 × 3600 mm |

| Weight | up to 20 tons |

| Service life | 15 years |

| Maintenance | 2 days/month |

| Water consumption | up to 5 m³/year |

Liquid Fuel Composition (Pyrolysis Oil)

• Fractional composition:
• Gasoline — up to 35%
• Diesel — up to 60%
• Fuel oil — up to 5%
• Flash point: ≥ 0°C
• Pour point: down to –15°C
• Viscosity at 80°C: ≤ 60 mm²/s
• Water and impurities: ≤ 1%
• Sulfur content: ≤ 2%

Pyrolysis Product Yield

Feedstock Type / Pyrolysis Oil Yield / Other Fractions 

Fuel oil M-100  / 60–85%  / coke, pyro gas 

Used oils           / 75–90%  /           —            

Oil sludge          / 20–70%  /           —            

Crude oil residues  / 70–80% /      —            

Dry Carbon Residue (Coke)

• Calorific value: ≥ 27,250 kJ/kg
• Density: ≤ 430 kg/m³
• Ash content: ≤ 17%
• Moisture: ≤ 3%
• Specific surface area: ≥ 7.5 m²/g
• Sulfur content: ≤ 2.6%

Example Chart: Pyrolysis Oil Yield by Feedstock

| Feedstock Type | Min. Yield | Max. Yield |

|------------------------------|------------------|------------------|

| Fuel oil M-100       | 60%            | 85%           |

| Used oils                | 75%            | 90%           |

| Oil sludge               | 20%            | 70%           |

| Crude oil residues | 70%            | 80%           |

Advantages of FACTOR 1 LRP

• Fully automated operation
• Self-sufficient — uses its own pyro gas
• Handles feedstock of any viscosity
• Reliable lining and overheating protection
• Low operating costs
• High environmental performance — no emissions or wastewater discharge
• Compact design and easy installation

Environmental and Regulatory Benefits

• Zero atmospheric emissions
• Closed-loop water treatment system
• No waste burial
• Compliance with international standards (EU, CIS, Asia)
• Safety: emergency shutdown, sensors, explosion protection

Contact and Customization for Your Project

We offer tailored solutions:

• Component selection for specific feedstock
• ROI model based on your tariffs, energy sources, and logistics
• Support with environmental compliance procedures