What is it?
Continuous pyrolysis is a process where organic materials, like waste tires, plastic, or rubber, are heated in an oxygen-free environment, leading to the decomposition of the material and the production of fuel oil, carbon black, and other valuable byproducts. Unlike batch pyrolysis, continuous pyrolysis operates continuously without interruption, allowing for continuous feeding, slagging, and oil production, resulting in higher efficiency and automation.
Purpose:
- Eliminate hazardous or bulky waste (biomass, plastics, rubber, sludge, etc.) through thermal decomposition.
- Recover useful resources like fuel-grade pyrolysis oil, combustible syngas, and carbon-rich char.
- Reduce landfill dependency , environmental pollution, and carbon footprint.
- Support decentralized waste management, especially in regions lacking access to conventional disposal infrastructure.
The purpose of the Continuous Pyrolysis Plant is to:
How it Works?
Feeding System :
Waste materials are fed continuously into the pyrolysis chamber using a screw or belt conveyor, ensuring uniform feed and uninterrupted operation.
Pyrolysis Chamber :
The chamber operates under controlled oxygen-free conditions at high temperatures (typically 400°C–850°C). The unique infrared heating modules ensure uniform thermal distribution with low energy input.
Thermal Decomposition :
Organic materials break down into vapors, gases, and char. The vapors are condensed into pyrolysis oil, while non-condensable syngas is redirected to fuel the heater, making the process selfsustaining.
Char Collection :
Solid carbon residues (biochar or recovered metal/carbon) are collected via a discharge screw.
Gas Cleaning & Emission Control :
Advanced filtration and scrubber units treat gases to meet CPCB norms, ensuring safe, odorless, and environmentally compliant air emissions.
Core Benefit:
- 100% Continuous Operation – No batch time, no idle stages.
- Zero Waste Discharge – All outputs are either valuable products or safely treated.
- Low OPEX – Proprietary infrared pyrolysis reduces fuel and utility costs.
- Eco-Friendly – No burning, no fly ash, no harmful emissions.
- High Resource Recovery – Up to 90% material conversion efficiency
- Modular & Scalable – Easily deployable in urban, semi-urban, or remote setups.
Salient Features:
- Radiating Pyrolysis Heating – Fast, uniform, and cost-effective thermal treatment.
- Modular Design 0.2 TPD to 20 TPD customizable capacities.
- Fully Automated PLC Control – Intelligent monitoring and real-time alerts.
- Low Footprint – Compact design suitable for limited-space installations.
- Corrosion-Resistant Contact Materials – SS 304/316 or Inconel for long service life.
- Multi-Feed Compatibility – Handles plastic, biomass, rubber, sludge, e-waste, etc.
- Emission Norm Compliant – Designed to meet India’s CPCB and global standards
- Remote Monitoring (Optional) – IoT-enabled dashboards for smart tracking.
Industries Benefited:
- Chemical & Pharmaceutical Manufacturing
- Oil Refineries and Petrochemicals
- Plastic & Rubber Waste Processors
- FMCG & Packaging Units
- Biomedical & Hazardous Waste Disposal
- Municipal Solid Waste Processing
- Agro-based Industries & Food Processing
- Battery, Tyre, and E-Waste Handlers
- Laboratories & R&D Centres.
