Build a Profitable
Pyrolysis Plant

Pyrolysis plant costs range from $200,000 for a small 5 TPD batch unit to over $5 million for a large-scale 50+ TPD continuous plant. The total investment depends on capacity, feedstock type, automation level, and whether oil purification/distillation is included. APChemi provides detailed cost breakdowns and ROI projections for each project.

Pyrolysis is a thermochemical decomposition process that breaks down organic materials (plastics, tires, biomass) at elevated temperatures (400-700°C) in the absence of oxygen. The process converts waste into valuable products: pyrolysis oil, carbon black, steel (from tires), and combustible gas. It is a key technology in chemical recycling and the circular economy.

Batch pyrolysis processes one load at a time with start-stop cycles, suitable for smaller operations (5-15 TPD). Continuous pyrolysis feeds material and extracts products non-stop, achieving higher throughput (20-100+ TPD), better energy efficiency, and more consistent product quality. APChemi specializes in continuous systems for commercial-scale operations.

Pyrolysis oil has multiple applications: as industrial fuel (replacing heavy fuel oil), as feedstock for steam crackers to produce new plastics (circular economy), as a blending component for marine fuels, and after further refining, for diesel and naphtha production. ISCC Plus certified pyrolysis oil commands premium prices in the circular plastics market.

Pyrolysis plants can process various organic waste: end-of-life tires, mixed plastic waste (PE, PP, PS), biomass and agricultural waste, waste windmill blades, rubber waste, and used oil. Each feedstock type requires specific reactor design and operating parameters for optimal yield. APChemi has experience with all major feedstock categories.

A complete pyrolysis plant project takes 12-24 months from feasibility study to commissioning. This includes 2-3 months for feasibility and design, 6-12 months for manufacturing and procurement, 3-6 months for installation and commissioning, and 1-2 months for performance testing. APChemi's project management approach ensures on-time delivery.

Key criteria: proven commercial-scale references (not just lab/pilot), relevant patents and technology IP, ISCC Plus or similar certifications, project management experience, after-sales support capability, and financial stability. Red flags include lack of operational reference sites, unrealistic yield claims, and no process guarantees. APChemi has 49+ delivered projects as references.

Required permits typically include: environmental impact assessment, air emissions permit, waste processing license, building permits, fire safety clearance, and operational permits. Requirements vary by country and region. APChemi's project management consultancy includes full regulatory guidance and permit application support for your specific location.