Two sets batch type pyrolysis plant installed in India in October of 2019, India is very mature market for pyrolysis industry, but now the government is also looking to replace the batch type plant to be more environmental continuous machines, we believe in the future, Indian market will be active again.
Comparison of Waste Tyres Batch and Continuous Pyrolysis Plant
Waste tire pyrolysis equipment can be divided into batch pyrolysis plant and continuous pyrolysis plant according to the operation mode. There are significant differences between the two in terms of working principle, processing efficiency and applicable scenarios. The following comparative analysis from multiple dimensions will help customers understand the characteristics needs of pyrolysis plants:
| Type | Working Principle |
| Batch pyrolysis plant | Batch processing: Batch pyrolysis equipment can process 6-15T/D of waste tires at a time. Pyrolysis reactor can process the entire tire. |
| Cyclic operation: Each batch of materials needs to go through the process of "feeding → heating pyrolysis → cooling → discharging", and a single cycle takes a long time (usually 10-24 hours). | |
| The reactor is in a closed state during the pyrolysis process. The double-layer reactor uses external heating (such as gas or electric heating) to decompose the tire in an oxygen-free or oxygen-deficient environment. | |
| Continuous pyrolysis plant | Continuous processing: Crushed tire rubber particles (usually 5-8mm) are continuously fed into the reactor through a screw conveyor and other devices. |
| Dynamic operation: The material moves continuously in the pyrolysis reactor, and the pyrolysis temperature and residence time can be precisely controlled to achieve 24-hour continuous production. | |
| Heating method: indirect heating, high system integration, automatic control of material flow and heat distribution. |
| Type | Batch pyrolysis equipment | Continuous pyrolysis equipment |
| Energy efficiency | Each batch needs to be reheated, resulting in large heat losses. Shutdowns between batches result in heat waste. | The temperature is stable during continuous operation, and the heat utilization rate is higher. |
| Equipment investment | Simple structure, low initial investment, usually 1-5 million US dollars. High labor costs (batch operation and monitoring required). Low maintenance frequency, but shutdowns for material changes affect efficiency. | The system is complex (including modules such as continuous feeding, temperature control, and exhaust gas treatment). The initial investment is high, usually more than 5-20 million US dollars. High degree of automation and low labor cost. |
| Product stability | Temperature and residence time fluctuate greatly between batches. Product (pyrolysis oil, carbon black, steel wire) quality consistency is poor. | The process parameters are precisely controlled, the product components are stable, and the recovery rate of pyrolysis oil is high (usually 5%-10% higher than that of intermittent type). |
| Flexibility | Suitable for processing small batches and multiple varieties of materials (mixed waste tires, waste containing impurities). Process parameters (temperature, residence time) can be flexibly adjusted. | Suitable for processing single varieties and large-scale materials. Adjusting parameters requires shutdown or slow transition, and the flexibility is low. |
| Environmental performance | Simple exhaust gas treatment system. | Fully enclosed continuous operation, exhaust gas (such as H₂S, benzene) is collected and treated more thoroughly, in line with strict environmental protection standards (such as the EU BAT directive). |
