The batch system mode makes them ideal for small to medium-sized production with minimal cost of investment and simple operation. The capacities range between 2 and fifteen tons daily. They can operate at high temperatures of between 300degC and 700degC, which improves efficiency of energy. This technology helps in the production of renewable energy and resource recuperation.
Batch Pyrolysis Plant
Batch Pyrolysis Plant can process 10–15 tons of waste (such as tires, plastics, and oil sludge) per day, and its annual profit is 10 times that of a small pyrolysis machine. It is suitable for small to medium-sized recycling plants, customers with stable and centralized raw material sources, as well as government environmental protection projects.
Features of Batch Pyrolysis Plant>>
Condensation systems that are efficient and efficient designed to maximize the efficiency of pyrolysis oil. Beyond liquids recovering solid byproducts, such as steel and carbon black (from tires) can be streamlined. The automated slag discharge process not just improves efficiency, but also improves the working atmosphere by reducing dust emissions.
The benefit of pyrolysis equipment for batch is their flexibility in processing various feedstocks. They can process a variety of organic materials, such as scrap tires (whole or shred) and various kinds of polymers (like PE, PS, PP), PS), rubber as well as biomass (such as rice husks, coconut shells bamboo, rice husks, coconut shells) , . The primary pyrolysis process is primarily is based on temperature profiles and times to ensure the optimal transformation of various feedstocks into important carbon black, oil, and gas.
About Batch Pyrolysis Plant Guide>>
What is Batch Pyrolysis Plant
A Batch Pyrolysis Plant is a waste-to-energy system that processes materials like tires, plastics, and sludge in batches to convert them into fuel oil, carbon black, and gas through pyrolysis.
Key Features & Benefits:
Pyrolysis is a decomposition process which involves heating organic materials at temperatures that are elevated, typically between 300 and 900 degrees Celsius, without oxygen, to avoid combustion. The process is used to break down complicated molecules in the feedstock into more simple, valuable products, including Syngas (a mixture of combustible gasses) as well as the pyrolysis oil (a liquid fuel) and charcoal (a solid carbonaceous substance).
Batch pyrolysis uses the same amount of raw material during every operational cycle. This is the whole process that involves loading a reactor, warming it up to the temperature required that allows the pyrolysis reaction to begin and cooling the reactor and then removing the products is completed for a single batch before the next will begin.
High Flexibility
Operators can easily adjust process parameters and switch between different types of feedstock with minimal operational disruption.Simple Operation
Compared to continuous systems, batch systems have a simpler structure and workflow, including steps like heating, loading, cooling, reacting, and unloading.High Return on Investment
The annual profit can be up to 10 times higher than that of a small pyrolysis machine—up to $450,000 per year.Feedstock Versatility
Capable of processing whole tires, bundled plastics, and other biomass materials without extensive preprocessing.
Core Components of Batch Pyrolysis Plant
Pyrolysis Reactor
The core of the system, it is designed to withstand temperatures of extreme heat (up to 800degC+) and provide an oxygen-free atmosphere. It is made of special steel alloys to withstand the harsh conditions of operation.
Pyrolysis Furnace System
Critical for increasing the temperature of reactors via indirect or direct heating techniques. Initial heating is fueled by fuels such as natural gas, diesel or LPG and the an option to switch to pyrolysis gas for greater energy efficiency.
Cooling System
Condenses volatile gases, vapors and gasses to liquid pyrolysis oil using condensers that are water-cooled. Essential for maximising oil yield and to ensure the quality of the product.
Feeding System
Loads raw materials (tires, plastics) into the reactor. Manual or automated (hydraulic auto-feeder) .
Oil Gas Separation & Collection System
Separates and collects condensed pyrolysis oil.
Carbon Black Discharge System
Removes solid residue (carbon black) after pyrolysis.
Emission Control
Environmental protection devices, including system for purifying exhaust gases desulfurization of water films and ceramic ring absorption as well as activated carbon absorption to satisfy the environmental standards.
What Types of Materials Can a Small-Scale Pyrolysis Machine Process?
Waste tires
Fuel Oil: 35%–45%
Carbon Black: 30%–35%
Steel Wire: 10%–15%
Non-condensable Gas: 5%–10%
Waste Plastics
Fuel Oil: 45%–75%
Carbon Black (if applicable): 10%–15%
Non-condensable Gas: 10%–20%
Oil Sludge / Oil Residue:
Fuel Oil: 20%–40%
Solid Residue (slag): 60%–80%
Non-condensable Gas: Trace
Rubber Products
Fuel Oil: 35%–45%
Carbon Black: 30%–35%
Steel Wire (if applicable): 10%–15%
Gas: 5%–10%
Agricultural waste
Biochar: 25%–35%
Wood Vinegar: 10%–15%
Wood Tar: 5%–10%
Combustible Gas: 30%–50%
1.Material Preparation and Loading
The feedstock, which includes waste tires or plastics is made, which may require sorting or a small reduction in size. The prepared material is placed into the pyrolysis unit via a large furnace door or a dedicated loading port.
2.Heating and Pyrolysis Reaction
This reactor gets heated with an external source of fuel till the temperature is within the pyrolysis range. It is typically between 300 and 900degC dependent on the feedstock used and the desired product. When the temperature rises organic matter undergoes thermal degradation.
Temperature Ranges
Temperature at low temperature 300 to 500 degrees Celsius (favors the production of char)
- Medium Temperature: 500-700 degC (balanced products)
*Temperature at high: 700 to 900 degrees Celsius (maximizes the production of gas)
Reaction Products
- Volatile components – Oil gas
- Remains of Solid – Char/carbon Blac
- The steel wires (from tires) remain in tact
1.Oil Gas Cooling and Collection
The gas that is produced by Pyrolysis is directed by a manifold as well as a series of condensers that are water-cooled. When the gas cools the condensable portion liquefies and transforms into pyrolysis oil. It is then stored within oil storage tanks. (Energy Efficiency: Gases that are not condensable (syngas) can be reused to power the reactor, thus reducing dependence on fossil fuels from the outside, and increasing overall efficiency.)
2.Reactor Cooling and Slag Discharge
Following pyrolysis it is necessary to have the reactor at a temperature that is safe (typically less than 100-40 degrees Celsius) prior to solid residues being able to be eliminated. The process of cooling can be speeded up through convection vents or cooling devices. (Safety Note A proper cooling system is essential to ensure the safety of handling steel and char wires that are discharged via an enormous door or a dedicated system of slagging.)
- Emission Treatment：The residual flue gases resulting result from heating processes or uncondensed syngas go via an exhaust purification process prior to being discharged into the air in order to comply with environmental regulations. (Environmental Compliance: The most recent systems incorporate water spraying ceramic ring absorption, as well as activated carbon absorption to make sure emissions are in compliance with regulatory requirements.)
What is the cost and benefit of Batch Pyrolysis Plant
A Batch Pyrolysis Plant with a daily output of 5-10 tons requires a capital investment of approximately $350000, but can generate a net profit of $450,000 per year and achieve a return on investment within 12 months.
Batch Pyrolysis Plant: Detailed Cost & Revenue Breakdown
*(10 tons/day capacity example)*
1. Cost Structure
| Component | Cost Details | Notes |
|---|---|---|
| Equipment | $100,000 – $300,000 | Includes basic emission control (cyclone + scrubber) |
| Installation | $15,000 – $30,000 | Requires concrete foundation, 380V power, gas pipeline |
| Facility Upgrade | $10,000 – $50,000 | Explosion-proof workshop/steel shelter (region-dependent) |
| Daily Operating Costs | ||
| – Electricity | $80 – $120/day (15kW motor × 10h) | $0.1 – $0.15/kWh rate |
| – Fuel (Gas/Diesel) | $50 – $100/day (High consumption during heating phase) | Depends on feedstock moisture |
| – Labor | $60 – $120/day (3-5 operators) | Developing country wages |
| – Maintenance | $20 – $50/day (Seals, activated carbon, etc.) | High wear-and-tear |
2. Revenue Streams
*(Tire pyrolysis example, 10 tons/day processing)*
| Output | Yield | Market Price | Daily Output | Daily Revenue |
|---|---|---|---|---|
| Pyrolysis Oil | 45% | $0.6 – $1.0/kg | 4.5 tons | $2,700 – $4,500 |
| Carbon Black | 30% | $0.15 – $0.3/kg | 3 tons | $450 – $900 |
| Steel Wire | 15% | $0.1 – $0.2/kg | 1.5 tons | $150 – $300 |
| Total | $3,300 – $5,700/day |
3. Payback Period
Daily Net Profit:
$4,500 (mid-range revenue) - $350 (operating costs) = $4,150Total Investment:
$200,000 (equipment) + $30,000 (installation) + $30,000 (facility) = $260,000Break-even Point:
$260,000 ÷ $4,150 ≈ 63 days*(Theoretical, actual 8-12 months with downtime)*
4. Regional Variations
| Country | Equipment Cost | Oil Price | Payback Period | Policy Support |
|---|---|---|---|---|
| China | $150,000 | $0.8/kg | 10 months | Local subsidies (up to 30%) |
| India | $120,000 | $0.6/kg | 14 months | GST exemption |
| Germany | $500,000 | $1.2/kg | 5 years | BAT compliance (+$200k for RTO) |
| Nigeria | $100,000 | $1.0/kg | 7 months | Import duty exemption |
5. Critical Factors
Feedstock Quality: PVC/chlorine-containing plastics require dechlorination (+$50k)
Emission Compliance: EU mandates RTO systems (+$150k)
Labor Efficiency: Automated models reduce 3 staff positions ($50k+/year savings)
Recommendation:
Ideal for: Processors handling >5 tons/day, mixed/complex waste (e.g., hazardous materials)
Not for: Small-scale operators (consider modular mini plants)
Specific Parameters>>
| System | Main Furnace System | PUHB-7 | Quantity | Specification Model | Characteristics | Remarks |
|---|---|---|---|---|---|---|
| Main Furnace | Pyrolysis Main Furnace | Unit | 1 | 2600*7700 | 16mm | Q345R |
| Circular Door | Set | 1 | 1500 | 16mm | Q345R | |
| Insulation Shell | Set | 2 | Matching main furnace | Assembly | ||
| Main Furnace Base | Set | 1 | Matching main furnace | Assembly | ||
| Furnace Door Bolts | Set | 19 | Matching main furnace | Precision Part | ||
| Furnace Chamber | Set | 1 | Matching main furnace | Assembly | ||
| Support Roller | Piece | 4 | Matching main furnace | Rod Bearing | Standard Part | |
| Transmission | Custom Gear Ring | Piece | 1 | Matching main furnace | Standard Part | |
| Variable Speed Motor | Unit | 1 | Matching system | 7.5kw | Standard Part | |
| Pulleys (Large/Small) | Set | 1 | Matching reducer | Standard Part | ||
| Reducer | Unit | 1 | 500 | 7.5KW | Cast Steel Housing | |
| Sealing System | Gas Outlet | Piece | 1 | 6425 | Standard Part | |
| Graphite Ring | Piece | 10 | φ425 | Standard Part | ||
| Sealing Body | Piece | 1 | φ425 | Assembly | ||
| Bellows Compensator | Piece | 1 | φ425 | 316 Stainless Steel | ||
| Asbestos Packing | Box | 1 | φ425 | Standard Part | ||
| Separation System | Gas Bag | Unit | 1 | φ900x1800 | 6mm | Standard Part |
| Residue Oil Tank | Unit | 1 | Matching gas bag | Assembly | ||
| Condensation System | Tubular Condenser (with Water Tank) | Set | 1 | Matching main furnace | Assembly | |
| Settling Tank | Unit | 1 | φ600x1000 | Standard Part | ||
| Oil Collection Tank | Unit | 1 | 5T | Standard Part | ||
| Oil Pump | Unit | 1 | Matching system | 2.2KW | Explosion-proof | |
| Slag Discharge | Central Slag Discharge Door | Unit | 1 | φ530 | Sealed Discharge | Assembly |
| Slag Discharger | Set | 1 | φ530 | Sealed Discharge | Assembly | |
| Non-Condensable Gas Recycling | Water Seal Tank | Unit | 1 | φ900x1500 | Standard Part | |
| Flame Arrester | Piece | 1 | DN50 | Standard Part | ||
| Waste Gas Burner | Set | 4 | Matching combustion chamber | Standard Part | ||
| Burner Brick | Piece | 8 | Matching burner | Standard Part | ||
| Hose | Set | 4 | Matching burner | Standard Part | ||
| Desulfurization & Dust Removal | Desulfurization Tower | Set | 1 | Matching system | Assembly | |
| Dust Removal Water Pump | Unit | 1 | Matching system | 3.0KW | Stainless Steel Impeller | |
| Induced Draft Fan (with Motor) | Unit | 1 | Y5-47-5C | 5.5KW | Assembly | |
| Fan Damper | Piece | 1 | Matching fan | Standard Part | ||
| Safety System | Explosion-proof System | Set | 1 | Matching system | Standard Part | |
| Instrumentation | System Instruments | Group | 1 | Matching system | Assembly | |
| Control Cabinet | Electrical Control Cabinet | Set | 1 | Matching system | With Speed Controller | Assembly |
| Piping | Pipes & Fittings | Group | 1 | Matching system | Assembly | |
| 3-Stage Heavy Duty Feeder | Pressure Cylinder | Set | 1 | Assembly | ||
| Pusher | Set | 1 | Assembly | |||
| Motor | Piece | 1 | Assembly | |||
| Feeder Frame | Piece | 1 | Assembly | |||
| Feeder Roller | Piece | 1 | Assembly | |||
| Feeder Casters | Piece | 4 | Assembly | |||
| Feeder Adjuster | Piece | 4 | Assembly |
Equipment work Video>>
Our batch pyrolysis plant is ideal for companies and government-backed projects that have a stable supply of waste materials such as plastic, rubber, tires, oil sludge, and biomass. With a daily processing capacity of 5–10 tons, this system offers an efficient and cost-effective solution for converting waste into valuable fuel and carbon materials. Designed for larger-scale operations in both industrial and municipal settings, our plant delivers reliable performance with easy operation and maintenance. Backed by global client trust and professional after-sales service, we’re ready to customize the right pyrolysis solution for your long-term waste management strategy.
About Batch Pyrolysis Plant FAQ>>
Batch vs Continuous Pyrolysis Systems
| Feature | Batch Pyrolysis System | Continuous Pyrolysis System |
| Operation Mode | Cyclical, discrete batches | Uninterrupted, steady-state |
| Processing Capacity | Lower, typically up to 12-15 T/D | Higher, 10-100+ T/D |
| Initial Investment | Lower | Higher |
| Flexibility | High, can handle varied feedstocks | Lower, requires uniform feedstock |
| Complexity | Simpler design, easier operation | More complex, higher automation |
What kinds of feedstocks can be processed by a Batch Pyrolysis Machine?
Batch pyrolysis machines can be versatile in their ability to handle various different waste materials. Common feedstocks include tires, different kinds of rubber, plastics and even medical waste as well as domestic waste.
How Does a Batch Pyrolysis Plant Work?
The feedstock is first prepared that could include tires plastics, biomass, or even waste tires is then pumped into the pyrolysis unit. The reactor is then sealed to create a oxygen-free space, the heating the process increases the temperature typically between 200 and 900 degrees Celsius, the syngas and oil are then pumped out of the reactor into a condensing system where the oil vapors are then cooled before being liquefied to form the pyrolysis oil. The non-condensable syngas is recirculated to be used in the heating system to power the reactor, which makes the process more efficient in energy use , . When the pyrolysis reaction has been complete and the gasses have been gathered and the reactor is left to cool. After cooling to a temperature that is safe, usually less than 40-80degC, the remains, which is mostly carbon black (and steel wires in the case of tires that were processed) is released from the reactor . The entire process from feeding to discharge is a single batch cycle.
What are the capabilities of a the Batch Pyrolysis Plant?
Process capacity usually measured in terms of tons daily (T/D) as well as tons of batch but sometimes by kilograms/hour (kg/h) when it comes to smaller equipment. Based on the data gathered the typical capacities for batch pyrolysis machines vary between 100 kilograms per day, up to 20-25 tons per day.
How long is expected life span of the batch Pyrolysis Plant?
The life expectancy of a batch pyrolysis device greatly depends on the standard of its design as well as the material used for vital components like the reactor, its operating conditions, as well as the amount of maintenance it is given. Reactors constructed of boiler steel that is standard (e.g Q345R) are typically cited with an average lifespan of 2 to 3 years. However, reactors built from premium stainless steel (e.g. the 304, 303 or 310S) may have a longer lifespan, usually with a range of 5 to 8 years.
How are Emissions and Pollutants Controlled?
To remove the flue gas that is generated by burning fuels to make the reactor heat Desulfurization systems, such as de-dust towers and water film dust collectors, as well as Pulse dust collectors can be utilized to eliminate sulfur oxides and particulate matter prior to it is released to the air. Syngas that is not condensable in pyrolysis that may include H2S and other hazardous components the air purification device is employed.
What are the products that result from Batch Pyrolysis Process?
The most important by-products are pyrolysis oils, carbon black as well as syngas (non-condensable gas). In the process of recycling tires steel wire is an important by-product. The Pyrolysis oil constitutes the principal liquid by-product, which is made from the oil vapor that is produced by the process of thermal decomposition.
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