2 Catey Plastic-to-Oil Machine + Distillation Units (Plastics → Diesel)
Project Objective
A single-site industrial plastic-to-oil facility in Dakar, Senegal using 2 continuous pyrolysis lines, sized to process mixed waste plastics that are suitable for pyrolysis, with the project designed around:
One Industrial Site
A single consolidated location in Dakar, Senegal purpose-built for continuous plastic-to-oil conversion.
2 Continuous Plastic Lines
Two parallel pyrolysis processing lines for redundancy, scale, and operational flexibility.
Pre-Processing & Storage
Dedicated feedstock receiving, sorting, shredding, and buffer storage infrastructure.
Utility & Safety Systems
Full environmental controls, safety systems, and utility infrastructure integrated into the plant design.
This plan will include deep dive into equipment, shipping/logistics, installation/commissioning/training, on-site civil works, power connection, maintenance reserve, and operating capital.
Basis of Design
Plant Concept
The site will include the following integrated systems and areas:
Core Process Areas
- 2 continuous plastic pyrolysis lines
- Feedstock receiving and sorting area
- Shredding / sizing area
- Reactor and condenser area
- Syngas reuse for internal heating
- Carbon black discharge and storage
- Pyrolysis oil tank farm
Support Infrastructure
- Control room, workshop, and warehouse
- Cooling water systems
- Transformers and generator backup
- Compressed air
- Fire protection and gas detection
- Drainage and spill containment
This follows the same equipment and site logic where each plastic line includes a feeding system, continuous reactor, condensation system, gas recovery system, carbon black discharge, cooling system, and PLC-based controls.
Site Scale
Each plastics-to-oil plus distillation line needs about 2,500–3,000 m², and that total land has to be multiplied further for roads, utilities, storage, and safety buffers. For a 2-line site without a full large-scale multi-hub layout, a realistic design basis is:
m² Direct Line Footprint
2 × 2,500–3,000 m² for the two plastic-to-oil processing lines
m² Total Land Required
Roughly 2–4 acres including all support areas
Additional land requirements beyond the direct line footprint include:
Feedstock Yard
Receiving, sorting, and buffer storage for incoming plastic waste
Internal Roads
Truck maneuvering, access routes, and loading/unloading pads
Utility Yard
Transformers, generators, cooling towers, and compressed air systems
Tank Farm
Pyrolysis oil storage and carbon black silo/bagging area
Control & Admin Buildings
Control room, workshop, warehouse, welfare block, and lab room
Safety Setbacks & Green Buffer
Fire-water system, perimeter lighting, CCTV, and greenbelt
Technical Configuration
4.1 Core Process Lines
Each line should include the main components:
Feeding System
- Hopper
- Controlled feed
- Screw feeder
- Integration with pre-processing/shredder line
Core Process Components
Continuous Pyrolysis Reactor
- Insulated steel reactor
- Continuous movement of feedstock through reactor
- Designed for steady-state operation
Condensation System
- Condensers
- Gas/oil separation
- Cooling loop
Ancillary Process Systems
Syngas Recovery & Burner System
- Gas cleaning
- Gas buffer
- Reuse of syngas as process fuel
Carbon Black Discharge
- Continuous discharge
- Controlled cooling
- Handling and storage
Cooling System
- Circulation pumps
- Cooling tower
- Piping and valves
Control System
- PLC
- HMI
- Alarms
- Automatic shutdown logic
Shared Equipment
Common shared infrastructure for every block of machines, including shredders, magnetic separators, conveyors, wastewater treatment, and safety systems. For a 2-line plastic-only site, those shared systems should include:
Processing & Handling
- 1–2 industrial shredders
- Magnetic separator
- Belt conveyors and hoppers
- Startup burner / auxiliary furnace
- Carbon black silo / bagging area
- Tank farm for pyrolysis oil
Utilities & Safety
- Diesel generator backup
- Transformers and switchgear
- Wastewater/oily water separator
- Fire hydrants and extinguishing system
- Gas flare for emergencies
- Nitrogen or inerting package where needed
Capacity Statistics
6.1 Nominal Processing Capacity
A plastics line capacity of roughly 25 TPD plastics each.
With 2 lines: 50 TPD nominal installed capacity
6.2 Practical Operating Capacity
A real plant does not operate at a perfect nameplate 365 days a year. The plan will account for:
- Feedstock inconsistency
- Startup and shutdown periods
- Maintenance downtime
- Rainy season moisture and contamination effects
- Learning curve in first year
Recommended Planning Case
Year 1 — 60% Utilization
Average throughput: 30 TPD
Year 2 — 75% Utilization
Average throughput: 38 TPD
Year 3 — 85% Utilization
Average throughput: 43 TPD
For annual calculations, use 330 operating days/year to allow for downtime.
Feedstock Plan
The plan will not assume "all waste plastic" is usable. It will only target the fractions suitable for pyrolysis.
Primary Target Feedstock
- PE
- PP
- PS
Excluded or Minimized
- PVC
- PET
- High-moisture contaminants
- High-inert fractions: soil, stones, metals, glass
Feedstock Sources
The most practical sources for the site are:
- Municipal collection partners
- Transfer stations
- Landfill recovery contractors
- Informal aggregators and waste pickers
- Industrial/commercial plastic waste streams
- Market and packaging waste suppliers
Feedstock Strategy
We do not want to depend on one source. The site should be built around: % municipal/transfer station contracts, % private aggregators, % industrial/commercial waste, % emergency spot purchases / buffer sourcing.
Required Feedstock Tonnage
At 30–43 TPD operating average: annual raw plastic requirement is about ~9,900 to 14,190 tons/year. The plant should maintain: 2–4 weeks of feedstock buffer inventory.
Products & Revenue Streams
This plant has two real revenue lines in Phase 1: pyrolysis oil and carbon black / char residue. Syngas is not treated as external revenue; it is treated as an internal energy offset, which is the safer planning assumption.
7.2 Product Volumes
7.3 Sales Prices (Conservative Planning Values)
Pyrolysis Oil / Plastic-Derived Diesel
$350–$500/ton
Carbon Black
$80–$180/ton
7.4 Revenue Range
Capital Expenditure Allocation
8.2 Equipment Package
Main process equipment: 2 continuous pyrolysis lines, condensers, burners, gas recovery, discharge systems, PLC/control packages.
Shared plant equipment: shredders, conveyors, separator, carbon black handling, tank transfer pumps, flare, cooling towers, water circulation package. Includes full supporting process train and shared pre-processing/utilities around the line.
8.3 Shipping & Logistics
Includes: ocean freight, origin handling, destination customs/clearance, inland heavy transport, cargo insurance. Covers ocean freight and origin handling; destination clearance and terminal handling; inland heavy haul and escorted transport; marine/inland insurance.
8.4 Installation, Commissioning & Training
Full breakdown of: FAT, mechanical installation, electrical/instrumentation, piping/utilities, pre-commissioning, hot commissioning, training, handover, post-commissioning support. Includes specialist install crews; cranes, rigging, assembly; electrical and controls integration; commissioning and testing; classroom + hands-on training; documentation and handover support.
8.5 On-Site Infrastructure & Civil Works
Site prep and earthworks (survey, clearing, grading, compaction, fencing); foundations and structural pads (reactor pads, condenser and pump plinths, tank farm slab, MCC/substation slab); buildings and enclosures (process shed, control room, workshop, warehouse, welfare block, simple lab room); roads and circulation; drainage, piping corridors, spill containment; feedstock and output storage areas; buffer / landscaping / security (greenbelt, gate, perimeter lighting, CCTV conduits).
8.6 Power Generation & Electrical Connection
For transformers, switchgear, cabling, control systems, and potential generator sets. Includes: transformer and switchgear; MCC/VFD/PLC room fitout; cabling, trays, earthing; backup diesel generator; UPS and critical controls backup.
8.7 Permitting, Legal & Compliance
Includes: environmental approvals, fire authority approvals, local permits, legal documentation, land documentation, compliance consulting.
8.8 Initial Spare Parts / Maintenance Reserve
Maintenance section covers bearings, belts, pumps, valves, motors, sensors, PLC cards, wear parts, tools, and emergency spares. Our reserve will be built before startup, not after the first breakdown.
8.9 Operating Capital
Includes feedstock procurement, consumables, utilities, labor, maintenance materials, environmental compliance, insurance, transportation, and working capital buffer as part of initial operating capital. For the first 6–9 months.
OPEX — Annual Operating Cost
9.1 OPEX Summary by Steady-State Year
9.2 Feedstock Cost
Approximate weighted feedstock acquisition cost of $50/ton in Year 1 rising toward $50–$55/ton as throughput expands. Cost includes: payments to aggregators, sorting incentives, collection transport, loading/unloading, contamination losses.
9.3 Labor
24/7 operation requires shifts. Total headcount about 40–50 people: plant manager (1), operations supervisors (2), control room operators (5), field operators (12), pre-processing crew (9), maintenance mechanics (4), electrical/instrument techs (3), HSE staff (3), lab/quality staff (3), warehouse/logistics/admin/security (10+).
9.4 Utilities
Includes: startup diesel, power for shredders, conveyors, pumps, fans, control systems, water and cooling, compressed air, backup power fuel. Syngas reuse lowers net energy cost, but the plant will not budget assuming zero external energy spend.
9.5 Maintenance
Includes: preventive spares, consumables, breakdown reserve, electrical and instrumentation spares, workshop tooling.
9.6 Logistics
Includes: feedstock trucking, internal loader/forklift operations, product dispatch, vehicle fuel and maintenance.
Revenue
A. Volume Build
B. Selling Price
Pyrolysis Oil / Plastic-Derived Diesel
Low case: $350/ton
Base case: $425/ton
High case: $500/ton
Carbon Black
Low case: $80/ton
Base case: $130/ton
High case: $180/ton
C. Revenue Breakdown by Year
EBITDA-Style Operating View
Low / Base / High cases across all three years:
Full Project Timeline (In Days)
Total Duration: 420–480 days (14–16 months)
Phase 1 — Development & Approval
Day 0 → Day 60 (60 days)
Objective: Lock land, approvals, and supply chain.
- Feasibility studies
- Legal + permits
- Environmental studies (ESIA)
- Engineering design
- Project management
Deliverables: Feasibility report, ESIA (draft → near final), land secured, initial approvals in progress, supply MOUs.
Phase 2 — Site & Infrastructure Build
Day 45 → Day 180 (135 days)
Objective: Build full plant foundation (scaled for 2 lines, expandable).
- Land prep + grading
- Foundations (2 lines)
- Buildings (control, storage, workshop)
- Roads + drainage
- Tank farm
Deliverables: Fully prepared industrial site, civil works complete, ready for equipment installation.
Phase 3 — Equipment Procurement & Delivery
Day 60 → Day 240 (180 days)
Objective: Acquire and deliver all processing equipment.
- 2 × plastic-to-diesel units
- Shredders + conveyors
- Utility systems
Deliverables: Equipment fabricated, FAT completed, delivered to Dakar site.
Phase 4 — Installation & Commissioning
Day 180 → Day 360 (180 days)
Objective: Turn equipment into a working plant.
- Mechanical installation
- Electrical + PLC setup
- Piping + utilities
- Cold testing → hot commissioning
Deliverables: Fully installed plant, commissioning report, safety systems operational, staff trained. 👉 First oil produced.
Phase 5 — Operations & Ramp-Up
Day 360 → Day 420+ (60 days initial ramp)
Objective: Stabilize operations and reach target throughput.
- Feedstock procurement
- Labor + operations
- Maintenance + optimization
Deliverables: Stable 24/7 operation, monthly production reports, environmental compliance reports. Ramp from 30% → 60% → 85% utilization.
TPD Processed (Steady State)
~10K–14K tons/year plastic converted
Annual Revenue Potential
Final output at steady state
Dakar, Senegal Waste-to-Energy Plan (Plastic → Diesel)