Ghana 50 Million USD Plastics-to-Oil Facility
A single-site industrial plastic-to-oil plant powered by 5 continuous pyrolysis lines — designed to process 125 TPD of mixed waste plastics into marketable diesel-range fuel and carbon black, generating $8M–$13M in annual revenue at steady state.
What This Project Is Built to Do
This project delivers a fully integrated, industrial-scale plastic-to-oil conversion facility on a single site in Ghana. The plant is engineered around 5 continuous pyrolysis lines, each capable of converting mixed waste plastics — primarily PE, PP, and PS — into pyrolysis oil and carbon black through a thermochemical cracking process.
Core Site Components
- 5 continuous plastic pyrolysis lines
- Feedstock receiving, sorting, and pre-processing
- Reactor, condenser, and syngas reuse area
- Carbon black discharge and storage
- Pyrolysis oil tank farm
- Control room, workshop, and warehouse
- Full utility systems and environmental controls
Plan Coverage
This document provides a deep dive into every major cost and operational element, including:
- Equipment specification and procurement
- Shipping, logistics, and customs clearance
- Installation, commissioning, and operator training
- On-site civil works and infrastructure
- Power connection and backup systems
- Maintenance reserve and spare parts
- Operating capital for the first 6–9 months
Plant Concept & Site Layout
The facility is designed as a purpose-built industrial site with a logical, modular layout. Each of the 5 pyrolysis lines operates independently but shares centralized pre-processing, utility, and storage infrastructure — maximizing operational efficiency while reducing redundant capital expenditure.
Feedstock Zone
Dedicated receiving and sorting area with covered storage, shredding/sizing equipment, and magnetic separation to prepare feedstock for pyrolysis reactors.
Reaction & Recovery Zone
Five continuous reactors with condensation systems, syngas recovery loops, and carbon black discharge — all interconnected through a centralized PLC control architecture.
Storage & Dispatch Zone
Pyrolysis oil tank farm, carbon black silo and bagging area, and product loading/unloading pads — designed for efficient product offtake logistics.
Utilities & Safety Zone
Cooling water systems, transformers, generator backup, compressed air, fire protection, gas detection, drainage, and spill containment — all engineered to local regulatory standards.
Land Requirement: 5–7.5 Acres
Each plastic-to-oil line requires approximately 2,500–3,000 m² of direct operational footprint. For a 5-line site, the total land requirement expands significantly once roads, utility corridors, buffer zones, and storage areas are factored in.
Pyrolysis Lines
Each line footprint: 2,500–3,000 m²
Direct m² Footprint
Core line area: 12,500–15,000 m²
Total Site m²
Including roads, buffers, and utilities
Max Acres Required
Realistic design basis: 5–7.5 acres
Beyond the direct line footprint, the full site must accommodate: feedstock receiving yard, internal access roads, utility yard and transformer bays, oil tank farm, control/admin buildings, workshop facilities, fire-water system infrastructure, and green buffer/safety setbacks along the perimeter.
Core Process Line Architecture
Each of the 5 pyrolysis lines is built around a standardized, fully integrated process train. This modular approach ensures consistency in operations, simplifies maintenance, and enables efficient operator training across the entire plant.
Feeding System
Hopper, controlled feed mechanism, and screw feeder — integrated with the upstream shredder/pre-processing line for consistent throughput into the reactor.
Continuous Pyrolysis Reactor
Insulated steel reactor engineered for steady-state continuous operation, with controlled movement of feedstock through the thermal cracking zone.
Condensation System
Multi-stage condensers with gas/oil separation and a dedicated cooling loop to recover pyrolysis oil at target yield and quality.
Syngas Recovery & Burner
Gas cleaning, gas buffer storage, and syngas reuse as process fuel — eliminating reliance on external energy for reactor heating and reducing net operating cost.
Carbon Black Discharge
Continuous discharge with controlled cooling, plus downstream handling and storage systems — enabling consistent carbon black product quality for sale.
PLC Control System
Full PLC/HMI suite with real-time alarms, process monitoring, and automatic shutdown logic — ensuring safe, stable, and data-driven plant operation.
Shared Plant Equipment & Systems
Centralized shared infrastructure serves all 5 lines simultaneously, avoiding duplication while ensuring redundancy in critical systems. These systems are sized for full 5-line capacity from day one.
Pre-Processing Equipment
- 2–3 industrial shredders (primary sizing)
- Magnetic separator for ferrous removal
- Belt conveyors and hoppers between zones
- Carbon black silo and bagging area
- Tank farm for pyrolysis oil storage
Power & Utilities
- Startup burner / auxiliary furnace
- Diesel generator backup
- Transformers and switchgear
- Compressed air system
- Cooling tower and water circulation package
Environmental & Safety Systems
- Wastewater / oily water separator
- Fire hydrants and extinguishing system
- Emergency gas flare for non-condensable relief
- Nitrogen / inerting package where required
- Gas detection and continuous monitoring
- Bund walls, spill containment, and drainage
- Perimeter lighting, CCTV, and security gate
Nameplate vs. Practical Operating Capacity
The plant carries a nameplate capacity of 125 TPD across all 5 lines (25 TPD per line). However, responsible financial planning requires modeling realistic utilization — accounting for feedstock variability, maintenance downtime, Ghana's seasonal conditions, and the learning curve during Year 1 ramp-up. All annual calculations use 330 operating days per year.
Year 1 — Ramp-Up
60% utilization
75 TPD average throughput
24,750 tons processed/year
Year 2 — Stabilized
75% utilization
94 TPD average throughput
31,020 tons processed/year
Year 3 — Mature
85% utilization
106 TPD average throughput
34,980 tons processed/year
Feedstock Plan: Targeting Pyrolysis-Suitable Plastics Only
This plan does not assume that all collected waste plastic is usable. Only feedstock fractions that are technically and economically suitable for pyrolysis are counted in the processing model. This conservative approach protects yield assumptions and prevents reactor contamination and downtime.
Primary Target Feedstock
- PE — Polyethylene (HDPE, LDPE, LLDPE)
- PP — Polypropylene
- PS — Polystyrene
Excluded / Minimized
- PVC — chlorine contamination risk
- PET — poor oil yield profile
- High-moisture or high-inert fractions
- Soil, stones, metals, and glass
Feedstock Supply Sources
- Municipal collection partners and transfer stations
- Landfill recovery contractors
- Informal aggregators and waste pickers
- Industrial and commercial plastic waste streams
- Market and packaging waste suppliers
- Emergency spot purchases for buffer coverage
Annual Feedstock Requirement
At 75–106 TPD operating average, the plant requires 24,750–34,980 tons/year of clean, processable feedstock. A 2–4 week buffer inventory will be maintained on-site to ensure uninterrupted operation.
Revenue Products: Pyrolysis Oil & Carbon Black
The plant operates with two external revenue streams in Phase 1. Syngas is treated as an internal energy offset rather than a sold product — a conservative but appropriate planning assumption that reduces exposure to fluctuating gas pricing and offtake complexity.
Pyrolysis Oil — 70% Yield
Primary revenue product. A diesel-range fuel oil suitable for industrial burner applications and blending. Sold at $350–$500/ton depending on grade and market conditions.
Carbon Black — 15% Yield
Secondary product from solid char residue. Recovered continuously from the reactor discharge system. Sold at $80–$180/ton for use in rubber, coatings, and construction applications.
Syngas — 15% (Internal Use)
Non-condensable gases recovered and reused as process fuel to heat the reactors — reducing external energy spend. Not counted as a revenue line in financial projections.
At steady-state Year 3 production (106 TPD × 330 days), the plant will generate approximately 24,486 tons/year of pyrolysis oil and 5,247 tons/year of carbon black — representing the basis for the high-case revenue projection of $13.2M.
Three-Case Revenue Projections: Years 1–3
Revenue is modeled across three pricing cases for both products. The base case represents the most likely planning scenario. Low and high cases bound the realistic range given Ghana market conditions and global commodity pricing for pyrolysis oil and recovered carbon black.
Base case assumes pyrolysis oil at $425/ton and carbon black at $130/ton — both conservative relative to current West African market benchmarks. Year-over-year revenue growth is driven primarily by increasing utilization rates, not pricing assumptions.
Annual Operating Cost Structure
Operating costs are structured around 24/7 continuous plant operation with a staffing headcount of 90–100 personnel. The OPEX model grows year-over-year in proportion to increased throughput — feedstock, logistics, and maintenance costs scale with volume, while fixed overhead (insurance, administration) remains relatively stable.
Year 1 Total OPEX
$4.89M
Year 2 Total OPEX
$5.77M
Year 3 Total OPEX
$6.43M
Workforce: ~90–100 Personnel for 24/7 Operation
Continuous operation across three rotating shifts requires a structured workforce spanning operations, maintenance, HSE, logistics, and administration. The staffing plan is designed for full operational coverage from commissioning through steady-state production.
Operations Team
- Plant Manager: 1
- Operations Supervisors: 4
- Control Room Operators: 10
- Field Operators: 24
- Pre-Processing Crew: 18
Technical Team
- Maintenance Mechanics: 8
- Electrical / Instrument Techs: 6
- Lab / Quality Staff: 3
Support Functions
- HSE Staff: 3
- Warehouse / Logistics: included in 20+ support staff
- Administration: included in 20+ support staff
- Security Personnel: included in 20+ support staff
Labor Cost Trajectory
Year 1: $1.10M — baseline staffing
Year 2: $1.20M — incremental additions
Year 3: $1.30M — full steady-state team
Feedstock acquisition cost is budgeted at a weighted average of ~$50/ton in Year 1, inclusive of aggregator payments, collection transport, sorting incentives, and contamination losses.
EBITDA-Style Operating View: Low / Base / High Cases
The operating profit model presents a clear range of outcomes across three pricing scenarios. Even in the low case, the plant generates positive EBITDA from Year 1 — confirming the project's fundamental commercial viability. The base case delivers a compelling return trajectory, while the high case supports a payback period of approximately 6–7.5 years on total capital deployed.
CAPEX Allocation: Seven Budget Categories
The $50M capital budget is structured across seven distinct expenditure categories — from core process equipment through to operating capital for the initial ramp period. Each category is sized to reflect real-world costs for an industrial facility in Ghana, including Ghana-specific logistics, civil construction, and regulatory compliance requirements.
Equipment Package
5 continuous pyrolysis lines (reactors, condensers, burners, gas recovery, discharge systems, PLC packages) plus all shared plant equipment: shredders, conveyors, separators, carbon black handling, tank transfer pumps, flare, cooling towers, and water circulation systems.
Shipping & Logistics
Ocean freight and origin handling, destination customs and terminal clearance, inland heavy haul and escorted transport, and full marine/inland cargo insurance for all equipment packages.
Installation, Commissioning & Training
Specialist installation crews, cranes and rigging, electrical/controls integration, pre-commissioning and hot commissioning, Factory Acceptance Testing (FAT), classroom and hands-on operator training, full documentation, and post-commissioning support.
On-Site Infrastructure & Civil Works
Site prep, earthworks, reactor foundations, condenser/pump plinths, tank farm slabs, MCC/substation slab, process shed, control room, workshop, warehouse, welfare block, internal roads, drainage, bund walls, spill containment, feedstock yard, carbon black shed, oil loading area, and perimeter security.
Power Generation & Electrical
Transformers and switchgear, MCC/VFD/PLC room fit-out, cabling, cable trays and earthing, backup diesel generator sets, UPS and critical controls backup for uninterruptible operation.
Permitting, Legal & Compliance
Environmental approvals (Ghana EPA), fire authority approvals, local authority permits, legal documentation, land documentation, and specialist compliance consulting throughout the permitting process.
Spare Parts & Operating Capital
Pre-built maintenance reserve (bearings, belts, pumps, valves, motors, sensors, PLC cards, wear parts, tools, and emergency spares) plus 6–9 months of operating capital covering feedstock procurement, utilities, labor, consumables, and environmental compliance.
Full Project Timeline: 540 Days (18 Months)
The project is structured across five overlapping phases, from initial land-locking and permitting through to full steady-state operations. Phases 2 and 3 run in parallel — site construction and equipment manufacturing proceed simultaneously — compressing the total schedule to 18 months from project kick-off to first oil.
Phase 1
Days 0–90
Development & Approval
Feasibility, permitting, ESIA, land, supply agreements
Phase 2
Days 60–270
Site & Infrastructure Build
Earthworks, foundations, buildings, roads, tank farm
Phase 3
Days 90–300
Equipment Procurement
Manufacturing, FAT, shipping, logistics to Ghana
Phase 4
Days 270–480
Installation & Commissioning
Mechanical install, electrical, PLC, cold/hot testing, training
Phase 5
Days 480–540+
Operations & Scale-Up
Ramp 30% → 60% → 85% utilization, full production
Phase-by-Phase Deliverables
Each project phase has defined objectives, key activities, and measurable deliverables. The following breakdown provides engineering leads and investors with a clear view of what is being accomplished — and what is being de-risked — at each stage of the 18-month development and construction schedule.
Phase 1 — Development & Approval (Days 0–90)
Objective: Lock land, approvals, and supply chain.
- Site selected (5–7 acres), government engagement initiated (Ghana EPA, local authority)
- Feasibility studies, ESIA (draft to final), engineering design completed
- Feedstock supply agreements signed; offtake discussions commenced
- Land secured; government approvals progressed
Phase 2 — Site & Infrastructure Build (Days 60–270)
Objective: Build the full plant backbone, future-proofed for all 5 lines.
- Earthworks, grading, compaction, fencing; reactor foundations for all 5 machines
- Control room, workshop, warehouse, and feedstock yard constructed
- Internal roads, drainage, and oil storage tanks installed
- Deliverable: Fully prepared, expansion-ready industrial site
Phase 3 — Equipment Procurement & Delivery (Days 90–300)
Objective: Acquire all core processing equipment and deliver to Ghana.
- 5 × plastic-to-oil units ordered, manufactured, and Factory Acceptance Tested (FAT)
- Shredders, conveyors, and ancillary equipment procured
- Shipping and logistics coordination from origin to Ghana port
- Deliverable: All machines on-site, FAT-certified, ready for installation
Phase 4 — Installation & Commissioning (Days 270–480)
Objective: Turn equipment into a working, commissioned plant.
- Mechanical installation, electrical and PLC integration, piping and utilities connected
- Cold testing progressed to hot commissioning and full load testing
- Safety systems operational; operators trained on-site
- Deliverable: First oil produced; plant ready for ramp-up
Phase 5 — Operations & Scale-Up (Days 480–540+)
Objective: Stabilize operations and reach nameplate utilization.
- Utilization ramp: 30% → 60% → 85% over initial 60-day period
- Feedstock quality optimization and long-term buyer relationships locked
- Monthly production and environmental compliance reports issued
- Steady state: 100–150 TPD processed, $8M–$13M annual revenue potential
Investment Summary: Ghana Plastics-to-Oil Facility
At steady-state Year 3 operations, this facility will process up to 34,980 tons of waste plastic per year, produce approximately 24,500 tons of pyrolysis oil and 5,200 tons of carbon black, and generate between $9.0M and $13.2M in annual revenue — with EBITDA margins ranging from 23% (low case) to 51% (high case) at Year 3 throughput levels.
TPD Nameplate
Installed processing capacity across 5 lines
Total Project Budget
Full CAPEX including civil, equipment, logistics, and operating capital
Max Annual Revenue
Year 3 high-case projection
Project Timeline
From kick-off to first oil production