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Continuous Processing

Continuous Pyrolysis Technology

Transforming end-of-life tyres into industrial resources via a sealed, oxygen-free continuous pyrolysis loop. Explore the technical blueprint stage-by-step.

0 TPD
Processing Capacity
0 °C
Core Temperature
0 %
Zero Waste Process
Scroll to explore the process
How It Works

The Process at a Glance

01

Continuous Feed

Shredded tyre chips are automatically metered and fed into a sealed hopper system, ensuring uninterrupted input to the reactor.

02
450°C

Thermal Cracking

Inside the oxygen-free rotary kiln at 450°C, long-chain polymers decompose into hydrocarbon vapors, carbon char, and steel.

03
Oil Char Steel

Resource Recovery

Pyrolysis oil, carbon black, and steel wire are recovered with zero waste — every input tonne yields valuable outputs.

Our continuous rotary kiln operates 24/7 — no batch loading, no downtime. Each stage is engineered as a sealed, oxygen-free loop for maximum yield and safety.

Deep Dive ↓
Technical Steps

Process Sourcing to Output.

Scroll to explore each stage of our continuous pyrolysis technology.

Phase 01

Feedstock Sourcing

Scrap tyres are retrieved and loaded onto the primary continuous conveyor system. From here they are securely transported towards the processing center.

4.2 TPH
Feed Rate
100 TPD
Capacity
Phase 02

Tyre Shredding

Tyres are shredded into 50mm clean chips. Double magnetic separators pull out wire mesh bead wire before the chips enter the reactor hopper.

50mm
Chip Size
12%
Wire Recovery
Phase 03

Thermal Pyrolysis Reactor

In the sealed rotary kiln, feedstock is heated to 350-550°C. Hydrocarbon chains break down in an oxygen-free environment with uniform heat distribution.

450°C
Core Temp
0.0%
O₂ Level
2.5 RPM
Rotation
Phase 04

Fractional Condensation

Volatilized gases pass into a multi-stage condenser column. Condensable elements turn into heavy and light pyrolysis oil. Non-condensable syngas recycles back to fuel the kiln.

4
Stages
94%
Recovery
85°C
Outlet Temp
CARBON CHAR PYROLYSIS OIL
Phase 05

Output Product Recovery

Solid carbon char and pyrolysis oil are continuously collected into bulk storage tanks. The fully automated system requires zero manual handling.

9,800
Oil GCV kcal
7,200
Char GCV kcal
98%
Wire Purity
SYNGAS RECYCLE LOOP SHREDDER CARBON CHAR PYROLYSIS OIL
CONTINUOUS 350–550°C O₂ FREE ZERO WASTE 24/7 RUN
Tyre
Chips
Thermal
Distill
Output
25°C
Process Temp
01
Phase 01

Feedstock Sourcing

Scrap tyres are retrieved and loaded onto the primary continuous conveyor system. From here they are securely transported towards the processing center.

0
Feed Rate
0
Capacity
0
Wire Fraction
0
Continuous
02
Phase 02

Tyre Shredding

Tyres are shredded into 50mm clean chips. Double magnetic separators pull out wire mesh bead wire before the chips enter the reactor hopper.

0
Chip Size
0
Wire Recovery
0
Mag Separators
0
De-Bead Rate
03
Phase 03

Thermal Pyrolysis Reactor

In the sealed rotary kiln, the feedstock is heated to 350–550°C. Hydrocarbon chains break down in a safe, oxygen-free loop with uniform heat distribution.

0
Core Temp
0
Rotation
0
O₂ Level
0
Retention
04
Phase 04

Fractional Condensation

Volatilized gases pass into a multi-stage condenser column. Condensable elements turn into pyrolysis oil. Non-condensable syngas recycles back to fuel the kiln.

0
Stages
0
Recovery
0
Outlet Temp
0
Gas Scrubbed
05
Phase 05

Output Product Recovery

Solid carbon char and pyrolysis oil are continuously collected into bulk storage tanks. Fully automated with zero manual handling of recovered products.

0
Oil GCV kcal
0
Char GCV kcal
0
Wire Purity
0
Manual Steps
Feedstock
Shredding
Reactor
Condenser
Recovery
The Science

Molecular Decomposition

Witness the thermal breakdown of complex polymer chains into valuable hydrocarbons, gases, and recoverable materials.

Decomposition Progress
PYROLYSIS ZONE — 450°C S POLYISOPRENE + CARBON BLACK + STEEL Pyrolysis Oil C₅–C₂₀ Hydrocarbons Syngas CH₄ + H₂ + CO Carbon Black Recovered Carbon Steel Wire Fe — Recyclable
Pyrolysis Oil
Pyrolysis Oil (TDO)
Yield: ~45% by mass
Composition: C₅–C₂₀
Calorific Value: 42 MJ/kg
Use: Industrial fuel oil
Syngas
Synthetic Gas
Yield: ~8% by mass
Composition: CH₄, H₂, CO
Calorific Value: 18 MJ/m³
Use: Recycled as process fuel
Carbon Black
Recovered Carbon Black
Yield: ~35% by mass
Grade: N550–N660 equiv.
Surface Area: 40–80 m²/g
Use: Rubber, pigments, ink
Steel Wire
Steel Wire Recovery
Yield: ~12% by mass
Material: High-carbon steel
Purity: 98%+ after cleaning
Use: Steel recycling mills
Material Flow

Mass & Energy Balance

Complete mass accountability from 100 TPD waste tyres to four valuable output streams.

100 TPD Waste Tyres INPUT ♻ Recycled Pyrolysis Oil 45% — 45 TPD Carbon Black 35% — 35 TPD Steel Wire 12% — 12 TPD Syngas 8% — 8 TPD 45% 35% 12% 8%
Technical Specifications

Engineering Excellence

Precision-engineered systems delivering consistent, high-quality output with industry-leading safety standards.

Core System
Reactor Specifications
0°C 150° 300° 450° 600° 0 °C Operating Max: 600°C
Reactor Type Rotary Kiln
Diameter 2.8 m
Length 12 m
Material SS310S
Atmosphere Inert (N₂)
Pressure -5 to +2 kPa
Thermal Profile
Temperature Stages
Preheating
150–200°C
Devolatilization
250–350°C
Primary Cracking
350–450°C
Peak Reaction
450–500°C
Cooling
80–120°C
Compliance
Safety Certifications
ISO 9001:2015
Quality Management
CPCB Norms
Pollution Control Board
BIS Standards
Bureau of Indian Standards
Emissions
Emission Standards
Particulate Matter (PM) < 50 mg/Nm³
Limit: 150 mg/Nm³
SOx < 100 mg/Nm³
Limit: 250 mg/Nm³
NOx < 80 mg/Nm³
Limit: 300 mg/Nm³
CO < 60 mg/Nm³
Limit: 300 mg/Nm³
Performance
Key Metrics
0
TPD
Feed Rate
Capacity
0
Minutes
Retention
Time
0
%
Output
Quality Index
0
%
Plant
Uptime

What This Means For Your Operations

The precision engineering above translates directly to your bottom line. High calorific value (9,800+ kcal/kg) means lower fuel consumption per batch of asphalt or cement. Continuous 24/7 processing guarantees identical viscosity in every drop, meaning zero burner nozzle clogging and uninterrupted dispatch even during peak construction season.

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Technical Comparison

Continuous vs. Batch.

Parameter Continuous Batch
Operating Mode
24/7 continuous feeding
Load, heat, cool, repeat
Thermal Efficiency
High (syngas recycled)
Low (energy wasted cooling)
Environmental Control
Hermetically sealed
Gas/dust leaks
Output Consistency
Highly uniform
Variable batch-to-batch
Safety Controls
Continuous pressure check
Airlocks absent
Operating Mode
Continuous
24/7 continuous feeding
Batch
Load, heat, cool, repeat
Thermal Efficiency
Continuous
High (syngas recycled)
Batch
Low (energy wasted cooling)
Environmental Control
Continuous
Hermetically sealed
Batch
Gas/dust leaks
Output Consistency
Continuous
Highly uniform
Batch
Variable batch-to-batch
Safety Controls
Continuous
Continuous pressure check
Batch
Airlocks absent

Ready to Partner
With Us?

Contact our commercial desk to book offtake contracts, feedstock sourcing allocations, or request specifications sheets.

Contact Commercial Desk