World leaders in continuous type pyrolysis plants

Frequently Asked Questions (FAQ)

Questions:
1. What is the use and selling cost of carbon black?
2. What is the difference between your plant and other batch type pyrolysis plants commonly

available in market?
3. What is the catalyst?
4. Plant and machinery offered by you is fully automatic or semi-automatic?
5. What is the process for purchasing the pyrolysis plant from you? Do you arrange a visit the

existing plants supplied by you?

6. What is the land and building requirement?
7. If there is an environmental hazards in setting up the plant?
8. Can the gas generated during the process, be reused?
9. What is the market scenario of pyrolysis oil?
10. What are the recommended specifications of raw material?
11. This plant can be used for rubber if it is so, then cost of rubber shredder is included or not

how used tyres are cut into required size of pieces?

12. Can this plant be converted into batch type plant?
13. What happens if plant is stopped midway?
14. What are the government licenses/permissions required for setting the plant?
15. What are the safety features in the plant and machinery supplied by you?
16. What is the raw material input to finished product output ratio? Does the input-output ratio

change with the plant capacity?

17. What will be the life of plant? How is the maintenance schedule and after sales support?
18. Is it possible to upgrade the plant capacity by adding some equipment?
19. Which tyres are required Nylon or Radial?
20. What are the benefits available from government with respect to this project?
21. Raw Material Availability and area from were
22. Can we get NOC from Pollution Control Board?
23. Delivery time of the machinery
24. What is the production cost and selling cost of pyrolysis oil?

J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 1 of 8

World leaders in continuous type pyrolysis plants

25. Do we need to remove the steel wires from radial tyres before it can be used as a raw

material?
26. What is the fuel used for firing and if the Hydrocarbon gas can be used as fuel?

J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 2 of 8

World leaders in continuous type pyrolysis plants

ANSWERS
1. What is the use and selling cost of carbon black?
Most commonly sold as solid fuel in form of carbon bricks or pallets at the rate of Rs. 8 to 12/kg. Other
uses as powder are: Charcoal soil enrichment, Paint industry, ink industry, filler in plastic and rubber
parts manufacturing, for manufacturing high value products like activated charcoal etc. Selling cost Rs
4 to 5/k
2. What is the difference between your plant and other batch type pyrolysis plants commonly
available in market?
COMPARATIVE CHART
Batch type Vs Continuous type pyrolysis plant
Sr.
No.
1
2

4
5

6
7
8
9
10
11

12
13
14
15
16
17
18
19
20
21

Particulars

Batch type

Safety
History of accidents

unsafe
Accident prone plant,
hazardous for health of
workers
5 MT tyres + 22000 liters
hydrocarbon gas

Quantity of hydrocarbon in
reactor at a time for 5 TPD
plant
Cleanliness
Pollution Control:
RUNNING INDUSTRY
WITHOUT PREMISSION OF
POLLUTION CONTROL
BOARD IS ILLEGAL.
Energy efficiency
Leakages
Temperature control
Catalyst
Quality of fuel
Uses of fuel

Approx. selling price per liter

Production cost per liter of
pyrolysis oil
Maintenance
Working hours
Shredding of raw material
Machinery cost
Practical pay-back period
Expected life of plant and
machinery
Gas Storage
Raw material

Full of carbon particles

Solid and gaseous
emissions exceed limits.
Pollution Control Board does
not give permission to this
plant.
Less efficient
Often
No control
Not used
Inferior, like furnace oil
Mainly for burning in boilers
and furnaces

Continuous type by
Pyrocrat Systems
Safe
No accidents, completely
safe
250kg. plastic or tyre + 5500
liters gas
Clean
NIL,
Pollution control Board gives
permission to this plant.
The plant is eco- friendly.

Rs. 25/From tyres or rubber: Rs.

22/Occasional
12 hours
Not required
Less
Not proven
3 years

Energy efficient
Very rare
Controlled by control panel
Used
Superior, like diesel
In engines like electricity
generators, pumps, vehicles
etc.
Rs. 36/From plastic: Rs. 18/From tyres or rubber: Rs. 22/Less
24 hours
Required
Almost double
2 years
15 years

Not provided
Only tyres

Provided
Plastic and tyres

J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 3 of 8

World leaders in continuous type pyrolysis plants

3.

What is the catalyst?

The catalyst is environment friendly chemical used in process to increase the speed of reaction.
Current cost of catalyst is about Rs50/kg and is used in the plant 0.1 to 0.5% of the raw material feed
quantity. Technical details and name of catalyst is disclosed to client at the time of technology transfer.

4.

Plant and machinery offered by you is fully automatic or semi-automatic?

The machinery is semi-automatic, no manual handling of in process material or finished products. All
material transfer is done by machines including raw material feeding and charcoal removal.

5.

What is the process for purchasing the pyrolysis plant from you? Do you arrange a visit the
existing plants supplied by you?
Given below is the process for purchasing the pyrolysis plant from us:
Client contact through email
Send the Techno-commercial details, FAQs & New Customer Information Form for client
through email.
Client fills up the New Customer Information Form and emails it back to Pyrocrat.
Pyrocrat will intimate the suitable dates for primary discussion at Navi Mumbai office.
Client visits Pyrocrats Navi Mumbai office for technical discussion. During this meeting, the client
expresses his demands and pre-requisites before placing the order
Pyrocrat satisfies the clients demands to ensure that client has necessary confidence and
understanding of the plant and machinery
Client releases the purchase order for pyrolysis plant

6.

What is the land and building requirement?

7.

Plant
Capacity
(TPD)

Power
Requirement
(HP)

Built-up area
(Square Feet)

Roof
Height
(ft)

Utility section
land
(Sq ft)

25

1000

20

700

35

1500

25

1000

60

2500

25

1500

10

95

3000

25

2000

If there is an environmental hazards in setting up the plant?

The pyrolysis plant and machinery supplied by us follows the emission norms prescribed by Pollution
Control Board. You will get the permission from state Pollution Control Board to establish & operate the
plant.

J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 4 of 8

World leaders in continuous type pyrolysis plants

8.

Can the gas generated during the process, be reused?

Yes, hydrocarbon gas generated is used for heating reactors in plant.

9.

What is the market scenario of pyrolysis oil?

Currently pyrolysis oil manufactured from our plant is sold at Rs. 37 to 40/Lit.
Typical industrial applications of pyrolysis oil as a fuel:
Boilers
Furnaces
Hot Water Generators
Hot Air Generators
Thermic Fluid Heater
Electric Generators (mixed with 50% diesel)
Diesel Pumps (mixed with 50% diesel)

10. What are the recommended specifications of raw material?

No need for segregation, No need for cleaning, Tolerance: 5% of dust + 5% moisture, PVC +
Polycarbonate should be less than 5%

Waste Plastic
Electronic scrap
Mixed plastic (HDPE, LDPE, PE, PP, Nylon, Teflon, PS, ABS, FRP)
Multi Layered Plastic
Waste Tyres
Rubber
Plastic or rubber parts from vehicles
Waste oils etc.

Description

Example

Guideline

PET (Polyethylene
terephthalate)

Plastic Bottles for Soda and Water, Microwave Food

Trays, Some of Textiles

Less than 5% uniformly

mixed with rest of the
raw material.

Plastic Bags, Milk Jugs, Detergent Bottles, Cosmetic

Bottles, Watering cans, Corrosion protection
for steel pipelines, Folding chairs
Folding tables, Heat-resistant fireworks display mortars,
Hula hoops
Meter & Valve Boxes, Natural gas distribution pipe
systems, Plastic bags, Plastic lumber, Plastic
surgery applications (skeletal and facial reconstruction),
Portable basketball system bases

Recommended

PVC (Polyvinyl
chloride)

Shrink Wrap, Pipe, Siding, Blister Packs, Laminate

Flooring

Less than 5% uniformly

mixed with rest of the
raw material.

LDPE (Low Density

Polyethylene) ,
LLDPE (Linear Low
Density
Polyethylene)

Bags for Dry Cleaning and Produce, Stretch Wrap, Wire

Coverings

Recommended

HDPE (High-density
polyethylene), PE

(polyethylene)

PP (Polypropylene)
PS (Polystyrene)

Bottle Caps, Appliances, Automotive Parts, Computer

Parts
Cutlery, Cups, CD Cases, Packing Peanuts, Food

Recommended
Recommended

st

J103, 1 floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 5 of 8

World leaders in continuous type pyrolysis plants

Containers, Styrofoam
Agricultural Waste

Any Agricultural Waste

Road Waste

Any Road Waste

Tires/Rubber

Vehicle tyres, rubber parts of vehicle, bushes

etc

Note:

Not Recommended
Tolerance: 5% of dust +
5% moisture

Steel wires to be
removed before
processing.

It is recommended that the calorific value of raw material must be above 7000KCal/Kg.
Particle size: Less than 25mm, density more than 2MT/KL
Most of the plastic waste generated around the world is suitable for plants manufactured by
Pyrocrat Systems LLP

The cost of raw material shredder is not included in the offer. The reason is there are four different
types of raw materials which require different type of shredder. Tyres require a different shredded, film
type plastic requires dencifier, hard plastic requires hammer type shredder and soft plastic requires
cutter type shredder. This will be discussed in detail during meeting at Mumbai office.
11. Can this plant be converted into batch type plant?
No. We do not manufacture batch type plant.

12. What happens if plant is stopped midway?

Molten plastic/tyre inside the reactor solidifies. When electricity comes back, reactor is heated to melt
the inside plastic/tyre and then rest of the machinery is started. It is recommended that standby
generator of at least 10kW is available.

13. What are the government licenses/permissions required for setting the plant?

NOC from Local Municipal Corporation (7days)

DIC (District Industries Centre) registration (7days)
NOC from PCB (Pollution Control Board) (10Days)

Note: these are the Licenses/permissions required in India. In case plant is proposed outside India, this
list may vary.
14. What are the safety features in the plant and machinery supplied by you?
We have ensured 3 to 4 layers of safety in plant by use of equipment like: nitrogen generator,
airlock feeding system, airlock carbon removal system, automatic pressure release valves, and
automatic temperature control valves, use of flameproof motors wherever applicable expansion
joints etc.
There is no major safety precaution to be taken while operating the plant. Smoking or naked flame
should not be allowed inside the plant etc.

J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 6 of 8

World leaders in continuous type pyrolysis plants

15. What is the raw material input to finished product output ratio? Does the input-output ratio
change with the plant capacity?

Input Material

Input Quantity

Waste mixed plastic scrap

10,000kgs

- 6,500 to 9,000 lit of Pyrolysis Oil

- 500 to 1,000 Kg of Hydrocarbon Gas
- 500 to 700 Kg of carbon Black

Nylon Scrap Tyres

10,000kgs

- 4,500 to 5,000 lit of Pyrolysis Oil

- 1,000 to 1,200 Kg of Hydrocarbon Gas
- 3,000 to 3,500 Kg of carbon Black

10,000kgs

Radial Scrap Tyres

Output quantity

4,000 to 4,500 lit of Pyrolysis Oil

800 to 1,000 Kg of Hydrocarbon Gas
2,750 to 3,250 Kg of carbon Black
800 to 1,000 kgs of Mild steel wire scrap

16. What will be the life of plant? How is the maintenance schedule and after sales support?
Reactor life is 15 years. Some parts of the plant and machinery may be required to be changed due to
normal wear and tear. Annual maintenance cost is less than 5% of the machinery cost. Given below
are the type of maintenance and specifications of our support by Pyrocrat:
Preventive Maintenance: to be carried out by client at his own cost. Pyrocrat will train and offer
guidance time to time
Maintenance due to manufacturing defect: Pyrocrat will carry out the necessary maintenance free
of cost
Operational Maintenance: In case of any maintenance resulting from the improper
operation/handling of equipment, the cost for the same will be incurred by the client. Pyrocrat will
offer necessary support and guidance.

17. Is it possible to upgrade the plant capacity by adding some equipment?

No, you cannot expand the capacity from 5TPD to 10 TPD. 10TPD separate Machinery will be
installed.

18. Which tyres are required Nylon or Radial?

Both can be used. Steel wires need to be removed from radial tyres.

19. What are the benefits available from government with respect to this project?
Will be discussed during meeting at our head office, Mumbai

20. Raw Material Availability and area from were.

Waste plastic and tyres are generated in very huge quantities across India and abroad. In India the
waste plastic and tyre scrap market is an unorganized sector. Being an unorganized sector, waste
plastic and scrap market is in hands of number of small and medium size scrap dealers located in
outskirts of all the major cities and industrial areas. Most of these scrap dealers do not have websites
and their contacts are not listed in business directories like yellow pages or just dial. This make it
difficult to locate these scrap dealers. If you are looking for the source of raw material, you are
J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 7 of 8

World leaders in continuous type pyrolysis plants

requested to visit the outskirts of city where scrap dealers might be located and enquire the raw
material availability and rate yourself. Current rates at which plastic scrap is purchased by our clients
varies from Rs 5 to 12/kg. Tyres are available at Rs 7 to 11/kg. Once you are able to locate these
scrap dealers in your area, you will suddenly realize that plastic and tyre raw material is available
abundantly which is suitable to our pyrolysis plant.

21. Can we get NOC from Pollution Control Board?

Yes, Pyrocrat will give the necessary information and documents for getting permission from Pollution
Control Board. In case the plant is proposed outside India, this point can be discussed during meeting
at Pyrocrats office.

22. Delivery time of the machinery

Capacity

Months

1TPD

2TPD

3TPD

3.5

5TPD

4 to 5

10TPD

4 to 6

23. What is the production cost and selling cost of pyrolysis oil?

In Indian scenario pyrolysis oil production cost is:

Rs. 14 to 18 lit with plastic as raw material
Rs. 18 to 22 lit with tyre as raw material
24. Do we need to remove the steel wires from radial tyres before it can be used as a raw

material?
Yes.
25. What is the fuel used for firing and if the Hydrocarbon gas can be used as fuel?

The fuel used for firing can be pyrolysis oil/industrial diesel or hydrocarbon gas. The
hydrocarbon gas is generated on the pyrolysis plant. During startup of the plant, liquid fuel is
used for approximate 2 hours. After 2 hours, the plant runs only on hydrocarbon gas.

J103, 1st floor, Tower 7, CBD Belapur Railway Station Commercial Complex, Sector 11, C.B.D. Belapur,
Navi Mumbai, Maharashtra State, India. PIN: 400 614 | Phone and Fax: 022 2759 9010
Email: info@pyrolysisplant.com | Visit us: www.pyrolysisplant.com
Page 8 of 8