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Ecocycle Intel

Tyres & rubber

Recovered carbon black plant

Pyrolysis char cleaned, milled and pelletised into a filler that replaces part of virgin carbon black.

Discuss this plantWhat the report covers

Most pyrolysis char in India is sold as a low-value fuel. A recovered carbon black (rCB) plant cleans it of steel and grit, mills it to a fine powder and wet-pelletises it, so rubber factories can handle it like ordinary carbon black. It earns the price gap to virgin black only through consistent quality and customer approvals, which is why the plant is built around its laboratory.

Feed
Char from continuous tyre pyrolysis plants, bought in or from an integrated pyrolysis line.
Capacity modelled
A standalone 40 TPD char-upgrading plant as the base, with pyrolysis-integrated and post-treatment variants.

Products and buyers

  • Pelletised recovered carbon black

    Mechanical rubber goods, footwear, non-critical tyre compounds

  • Fine powder

    Black masterbatch, inks, paints and coatings

Indian pyrolysis plants produced about 0.8 million tonnes of char in FY2024, but only around 0.05 million tonnes was upgraded to recovered carbon black. Source: Industry data compiled in the model-plant report

02Process

How the plant works.

INPyrolysis char
  1. 01Char receiving and drying
  2. 02Magnetic and grit removal
  3. 03Fine milling
  4. 04Classifying
  5. 05Wet pelletising
  6. 06Pellet drying
  7. 07Bagging and QC
  • OUTPelletised recovered carbon black
  • OUTFine powder
Fig. 01 · Recovered carbon black process flow · 7 stages

03Rules

What shapes the plant.

  • Carbon black manufacturing is Red category in Rajasthan's list; char milling has no named entry, so plan for Red until the board confirms in writing.
  • The CPCB pyrolysis SOP requires char to be co-processed or upgraded, which is the regulatory basis for the plant's feed.
  • Sold to each buyer's specification using carbon-black test methods; there is no Indian standard for rCB yet.

04Viability

What decides whether it pays.

  1. 01Customer qualification, which takes nine to twelve months and sets the price you can charge.
  2. 02Char consistency, which depends on the pyrolysis plants you buy from.
  3. 03Ash content and grit: what the product can and cannot be used in.
  4. 04Char supply within trucking distance, in competition with cement kilns.

05The report

What the recovered carbon black report covers.

A model-plant report exists for this plant type. A site-specific version replaces its assumptions with your feed, prices, quotes and location, and is written to be taken to a lender.

Request a site-specific report
  1. Executive summaryThe plant at a glance: capacity, products, project cost, returns and the decision it supports.
  2. Market and regulationFeed availability, buyers and prices, the rules that create or restrict demand.
  3. Site, capacity and productsLocation logic, plant size, product mix and specifications buyers will accept.
  4. Process and technologyThe route chosen and why, with a process flow and material balance.
  5. Machinery and utilitiesEquipment list with ratings and quantities, power, water, fuel and manpower.
  6. Environment and approvalsPollution-board category, emissions and effluent controls, licences and EPR registration.
  7. Capital and operating costBuilt bottom-up: land, civil, machinery, electricals, pollution control, pre-operative costs.
  8. Financials and sensitivityFive-year P&L, project financing, debt service, payback, and what moves the result.
  9. Risks and open questionsWhat must be confirmed with quotes, buyers and the regulator before money is committed.

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