Pyrolysis fuel oil (PFO) and heavy fuel oil (HFO) are two of the most widely used low-grade industrial fuels across global energy, marine, and manufacturing sectors. While they are often grouped together due to similar end uses, the differences in origin, properties, and handling requirements are significant.
This article provides a practical overview of each fuel type, where they are commonly used, and what infrastructure is required to store and transport them safely. As demand for both fuels increases, especially in emerging energy and waste recovery markets, understanding how to manage them effectively is becoming increasingly important.
What is pyrolysis fuel oil
Pyrolysis fuel oil is a dark, viscous liquid derived from the thermal decomposition of plastic, rubber, or biomass in the absence of oxygen. It is a byproduct of the pyrolysis process, where waste materials are converted into usable fuels, typically in waste-to-energy or recycling operations.
The composition of pyrolysis fuel oil varies widely depending on feedstock and processing conditions. It generally contains long-chain hydrocarbons, aromatics, and oxygenated compounds. These properties affect combustion behaviour, energy content, and storage stability.
PFO is used in applications such as cement kilns, industrial boilers, furnaces, and as a blending component in some marine fuels. Its growing role in the circular economy makes it an attractive alternative for industries seeking to reduce waste or diversify fuel sources.
Due to its composition and variability, storing and transporting PFO requires careful consideration of temperature, material compatibility, and contamination risk.
What is heavy fuel oil
Heavy fuel oil is a residual product from crude oil refining. It is one of the densest, most viscous fuels in widespread commercial use and is often burned in marine engines, large industrial heating systems, and backup generators.
HFO contains long-chain hydrocarbons and higher concentrations of sulphur and impurities. It requires heating to reduce viscosity before it can be pumped or combusted, and typically has lower combustion efficiency than distillate fuels.
In marine environments, HFO is still used widely despite regulatory changes such as the IMO 2020 sulphur cap. Compliance now often involves scrubbers or fuel blending, but HFO remains a staple in power and shipping sectors due to its low cost and high availability.
Handling heavy fuel oil presents unique challenges in logistics, including the need for insulated or heated tanks, special discharge systems, and regular cleaning to prevent sludge formation.
Handling considerations for PFO and HFO
Although PFO and HFO have different origins, they share similar handling requirements. Both must be kept at elevated temperatures to maintain flow properties and avoid settling or phase separation. Unheated tanks or uncontrolled transfers can result in product degradation, operational delays, or equipment fouling.
Storage of pyrolysis fuel oil and heavy fuel oils requires thermal insulation, heating capabilities, and materials that resist chemical breakdown. Tanks must also accommodate venting, bunding, and safe access for maintenance.
For overland and containerised transport, using tank containers designed for viscous or alternative fuels is essential. TEC’s solutions provide intermodal compatibility, integrated heating systems, and bunded design to reduce spillage risk and environmental exposure.
These storage and handling systems ensure compliance with regional and international standards, whether for industrial plants, transport depots, or portside fuel terminals.
Why storage infrastructure matters
As interest in pyrolysis oil increases and HFO continues to serve critical energy functions, storage infrastructure is playing a larger role in fuel viability. Poorly managed storage not only creates operational risk, but also reduces the value of these fuels through contamination or loss.
TEC provides engineered storage solutions for low-grade fuels, including bunded, insulated, and portable tank systems suitable for global use. Containerised formats are particularly effective for decentralised operations, remote sites, and phased infrastructure projects.
For a breakdown of how containerised systems compare to permanent installations, see our modular vs fixed bitumen storage blog. For system specifications and layout options, explore the Bitutainer Storage Facility product page.
Final thoughts on fuel selection and handling
Selecting the right fuel is only part of the operational picture. Ensuring that it is stored and transported safely, efficiently, and in line with compliance expectations is just as important.
Both PFO and HFO are viable energy sources with specific handling requirements. With the right infrastructure in place, they can be used reliably across multiple industries without increased risk.
TEC supports clients with tank systems built to handle heavy, viscous, and emerging fuels. From waste-to-fuel projects to long-distance distribution, we offer solutions that protect product integrity and support safe delivery at every stage.
Explore our engineered tanks for pyrolysis and heavy fuel oil storage!