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Waste treatment and utilization
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IPEC – a Leader in Production of Waste Processing (Pyrolysis) Equipment

IPEC was founded in 2004 and specializes in handling organic waste. The scope of its activities lies in treatment of organic wastes of different types with recovery of liquid fuel, biochar and gas. In 2012 the company joined the Safe Technologies Industrial Group. In 2012, the company joined Safe Technologies Industrial Group. IPEC specialists have developed and established production of pyrolysis plants of TDP type at the production facilities of the ST-Arsenal Metal Processing Plant.

The equipment is designed for processing of any organic waste oil sludge, rubber, plastic, polyethylene, etc.

ST-Arsenal is a production site equipped with the most up-to-date equipment, it has own machine shop and an extensive fleet of specialized equipment that allows IPEC specialists to implement turnkey projects from the manufacture of plants to the full range of logistics and construction-installation works in the shortest possible terms.

It is worth noting that, IPEC conducts tests at the production site on the existing TDP plant upon the customer’s request. We are always ready to arrange pilot launches on the selected raw materials, so each customer can be sure of the positive result of processing. This approach, combined with many years of experience, guarantees high quality and reliability of the equipment manufactured.

The pyrolysis technology offered by IPEC is a unique development in the Russian market. The Thermal Decomposition Plant (TDP) is designed for treatment and pyrolysis of organic waste:

  • oil sludge, drill cuttings on a hydrocarbon and salt basis
  • waste drilling fluids
  • oiled soils
  • oil emulsions
  • used oils
  • solid fractions in MSW (polyethylene, plastic)
  • used tires and rubber waste
  • motherboard and computer PCBs

Pyrolysis results in valuable raw materials: boiler fuel, pyrolysis gas, heat, and carbon black, which can be used in the production of fuel briquettes, or certified commercial subsoil (depending on raw materials).

The use of pyrolysis plants produced by IPEC is relevant in various areas of industry. Thus, the TDP plant is indispensable for operation at remote fields for oil sludge processing, due to the difficulties in disposal of waste in geographically remote areas and high fines charged by environmental supervision authorities.

Enterprises that regularly generate waste such as waste oil, worn tires and general rubber goods can significantly reduce waste management costs and profit from the sale or use of useful components resulting from recycling.

TDP pyrolysis plant: history and facts

2013 – active introduction and popularization of pyrolysis technology in the domestic market is observed after IPEC merged into ST IG. A long-term partnership with the leaders of the oil and gas industry was initiated. Thus, deliveries were made to NOVATEK PJSC (waste recycling of Termokarstovoye oil and gas condensate field, Yamalo-Nenets Autonomous District), Gazprom Neft PJSC (waste recycling of Vyngapurovskoye oil and gas deposit, Yamalo-Nenets Autonomous District).

2014 – development of the exclusive technology based on the TDP-2 series to implement a continuous cycle of processing of any drilling and oil sludge, regardless of its composition. The pyrolysis process continuity contributes to an increase in the operation efficiency of the entire Complex, eliminates the need for additional start-up and shutdown operations, and reduces the plant downtime.

2015 – creation of a low-capacity continuous pyrolysis plant TDP-2-200 (capacity up to 200 kg/h). Its design features enable feeding dry and liquid raw materials at the same time. Technological equipment of TDP-2-200 is mounted in a standard 40 ft. container and is delivered in the maximum prefabricated composition. The low power consumption (up to 10 kW/h) is also important. All of the above advantages explain the great popularity of this model in the market right up to date.

2016 – equipping Thermal Decomposition Plants with Capstone microturbines enabled to enter a new direction of IPEC – autonomous power management due to energy generation as a result of organic waste recycling. Thus, waste becomes a secondary resource. The operation of the TDP-based facility and the Capstone microturbine in remote and hard-to-reach regions of the country, shift camps with undeveloped infrastructure, etc. is especially relevant. Such a version also reduces the peak load on the entire power network of the facility and ensures the uninterrupted operation of the Complex in full in emergencies.

2017 – the release of the upgraded high-performance TDP-2-2000 plant. The furnace capacity for processing oily waste reaches 2 tons per hour. Externally, the pyrolysis plant has not changed and remained small. A new auger system contributes to a more efficient distribution of raw materials. Due to high capacity, the plant can process tens of tons of waste per day directly at their generation site. Currently, this TDP model is in great demand in the fields, and IPEC regularly receives requests from grateful customers about the possibility of developing a new model with increased capacity.

Thermal Decomposition Plant: the present and the future

In recent years, IPEC has been actively winning the market for the utilization of oil waste (oil sludge, spent drilling muds, acid tars, etc.). Continuous pyrolysis plants of TDP series are used by service companies as the main points for utilization of oil production wastes directly at the field. For example, since 2016, the specialists BT-Promotkhody LLC have been providing services for processing of drilling waste at the Kuyumbinskoye oil and gas condensate field, developed by Slavneft-Krasnoyarskneftegaz LLC, on the basis of the Complex where high-performance continuous pyrolysis plants TDP-2 are the main functional equipment.

Commissioning of the Complex for drilling waste processing at the production sites cuts down expenses on waste management and landfilling, excludes the negative impact on the surrounding ecosystem, and facilitates switching to pitless drilling recommended by the Government of the Russian Federation.

TDP pyrolysis plants have proven themselves in Russia and the CIS countries. Our Customers are the leading oil companies of the Russian Federation (Gazprom Neft PJSC, NOVATEK PJSC, LLC LUKOIL-Komi, RN-Uvatneftegaz LLC, etc.), industrial and service companies ETK KazSlanec LLP, BT-PROMOTKHODY LLC, Apatit JSC, etc.), as well as municipalities and the private sector (State Enterprise of the Kaliningrad Region Unified Waste Management System, etc.). Many years of experience and prestigious IPEC references, as well as the fact that no similar equipment is produced in the European market, contribute to the growing demand for the company’s products in the international market.

In 2016, an international certificate was issued for the entire range of TDP-2 continuous pyrolysis plants for compliance with the European Directive ‘On the Safety of Machines and Equipment’ (2006/42/EC). Compliance with international standards allowed starting deliveries to the European market. Currently, TDP-2-2000 projects are implemented for the Estonian company Aktsiaselts VKG Oil (Viru Keemia Grupp).

2018 was marked by a full-fledged entry into the international market. According to the agreements concluded earlier, after European certification for manufactured equipment, contracts, IPEC began supplying equipment outside of Russia. Contractual obligations were fulfilled for large industrial enterprises in Estonia, Switzerland and Israel.

The development of processing technologies for other types of raw materials (waste) goes along with the development of new markets. For the first time, the processing of shredded waste from automobile production (ASR) and electronic scrap (in particular, printed circuit boards containing precious metals) was tested and introduced. In parallel, the process equipment modernization was launched in order to increase productivity and energy efficiency. TDP-2 plant equipped with additional reactors, each of which fulfills its purpose, were tested and implemented. Similar complexes successfully operate at oil production facilities of Oil and Gas Company SLAVNEFT. Pilot runs of the TDP-2-200M in combination with a power plant based on the Capstone C65 microturbine were completed, which gave impetus to a new direction – autonomous generation of electricity from processed products.

2019 – the range of waste processed at TDP-2 plants was replenished with sludge of sewage treatment plants. This type of waste required a rethinking of the processing technology. The reactor was split up into zones (drying zone – pyrolysis zone). IPEC obtained a patent for equipment and technologies in the territories of the countries of the Eurasian Union, where continuous pyrolysis is recognized as innovative. The leaders of the oil industry (ROSNEFT, Gazprom Neft) equip the fields under development with TDP-2 complexes that supports the switch to the advanced technologies of pitless drilling recommended by the Government of the Russian Federation.The IPEC Thermal Decomposition Plant (TDP) is an efficient and cost-effective way of waste processing. The plant dimensions and the fastening points fully correspond to the dimensions of the 40 ft. container to deliver the plant by ordinary cargo transport. The plant operates on fuel formed as a result of processing. In addition, the destruction process releases heat for production space heating. All this makes the Thermal Decomposition Plant one of the best technologies of recycling organic waste of industrial enterprises and oil fields.

2020 – the model range of TDP-2 continuous operating plants was supplemented with a fundamentally new model: a rotating pyrolysis reactor for plastics waste recycling. This system makes it possible to achieve a much better distribution of the reaction mass over the reactor space and a more uniform and stable thermal decomposition process. We also introduced a new unit –

2021 – work continues on the innovative model of TDP-2 with a rotating reactor for plastic recycling. This design will increase the residence time of raw materials in the reactor, which will lead to a deeper processing of raw materials. The unit was successfully launched at Gazprom Neft’s facility to dispose of drilling waste from the Messoyakha fields. Harsh climatic conditions dictated changes in the design of the unit and its operating modes. A contract was signed with one of the leaders in the oil production market for the delivery of a highly productive continuous pyrolysis plant TDP-2. The modernization included an increase in unit capacity, changes in the design of augers and reactor, in which another working zone was added, a different type of heat exchangers specially designed for this process were used for media cooling.

2022 – the project for JSC “East Siberian Oil and Gas Company” (PJSC “Rosneft Oil Company”) for the delivery of modernized TDP-2-3000 is being implemented. The continuous pyrolysis furnace was upgraded to meet the customer’s objectives and was equipped with 4 high-capacity reactors. Prior to shipment to the site, the Thermal Decomposition Plant passed the control tests at IPEC production site.

The IPEC Thermal Decomposition Plant (TDP) is an efficient and cost-effective way of waste processing. The plant dimensions and the fastening points fully correspond to the dimensions of the 40 ft. container to deliver the plant by ordinary cargo transport. The plant operates on fuel formed as a result of processing. In addition, the destruction process releases heat for production space heating. All this makes the Thermal Decomposition Plant one of the best technologies of recycling organic waste of industrial enterprises and oil fields.

Safe Technologies Industrial Group provides strict quality control over the works. The management structure and production departments are certified according to the ISO:9001 international quality management system. Technical equipment of the production site of the Industrial Group is constantly being upgraded. A complete package of permits has been received for the entire TDP product range, including a positive conclusion of the state environmental examination, international certificates of compliance with Directive 2006/42/EC (TUV NORD). The quality and reliability of IPEC products are recognized internationally.

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