Continuous Pyrolysis Unit by LLC "Scientific and Production Enterprise EKO MASHPROM": Testing of the Physicochemical Properties of Synthetic Crude Oil

During commissioning work at the continuous pyrolysis unit located at 29A Peremohy St., Chornomorsk, Odesa Region, LLC "Scientific and Production Enterprise EKO MASHPROM" produced a sample of synthetic crude oil.

This sample was analyzed by the Testing Laboratory of Petrochemical Industry Products of the State Enterprise “State Fuel Company MASMA” (TL PNP SE "SFC MASMA"), which conducted a full range of tests to determine its physicochemical properties.

The synthetic crude oil, a pyrocondensate hydrocarbon mixture, was obtained through the pyrolysis of plastic waste. The feedstock included polypropylene (60%), high-density polyethylene (28%), and white and black polystyrene (12%). All materials were free from halogens such as fluorine and chlorine, significantly reducing the corrosion potential and environmental risks of the final product.

This type of pyrolysis fuel is often considered a higher-quality alternative to traditional fuels, such as M40 fuel oil or furnace fuel, offering improved performance characteristics, particularly higher heat output during combustion.

To assess the technical viability of the synthetic crude oil, a comprehensive analysis of its physicochemical parameters was conducted. The results were compared with conventional petroleum-based liquid fuels.

The comparative data of the physicochemical indicators are presented in the table.

Analysis of the test results shown in Table 1 confirms that the synthetic crude oil can be used as a liquid fuel alternative to low-sulfur, low-ash M-40 fuel oil, in accordance with DSTU 4058-2001 “Petroleum Fuel. Fuel Oil. Technical Specifications” and its amendments No. 1 and No. 2.

The product can be separated into two main distillate fractions—light and heavy—depending on the composition of the original feedstock:

Light fraction: boiling begins at 55–65 °C and ends at 210 °C; yield is 55–65% of the total volume.
Heavy fraction: boiling begins at 210 °C and ends at 285–320 °C; yield is 30–40%.

Both fractions passed corrosion testing via the copper strip test in accordance with DSTU EN ISO 2160:2012, confirming no corrosive impact on combustion equipment components.

Key indicators for the heavy fraction include:

Flash point (closed cup): 65 °C
Ignition temperature: 85 °C

These values indicate that the heavy fraction is safe and suitable for use as a liquid fuel in combustion systems, especially when the light fraction is separated for further petrochemical processing.

To determine the hydrocarbon composition of the light distillate fraction (boiling range: 60–210 °C), capillary gas chromatography was used according to ASTM D5134 (Standard Test Method for Detailed Analysis of Petroleum Naphthas through n-Nonane).

The detailed composition of the gasoline-range fraction of synthetic crude oil is as follows:

n-Pentane — 1.9%
Hexane — 6.1%
Benzene — 2.8%
Methylcyclopentane — 3.1%
Toluene — 8.9%
Naphthene — 2.4%
Ethylbenzene — 9.7%
p-Xylene — 1.4%
Styrene — 21.7%
o-Xylene — 0.5%
Alkylbenzene — 4.3%

The high content of aromatic hydrocarbons (arenes) in this fraction makes it a valuable feedstock for petrochemical applications. However, industrial use of this resource in Ukraine is currently limited by the absence of appropriate processing infrastructure.

If synthetic crude oil is used as fuel in thermal energy systems, it is crucial to ensure complete combustion to minimize the release of harmful substances, such as polycyclic aromatic hydrocarbons, carbon monoxide, soot, and other particulate matter.

Looking ahead, LLC "SPE EKO MASHPROM" plans to construct its first industrial facility for the production of pyrolysis fuel and the processing of plastic waste. The company is also developing advanced reactors capable of processing municipal solid waste, oil sludge, lignite, and other complex feedstocks.