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Tyres & rubber

Tyre pyrolysis oil plant

Shredded tyres heated without oxygen into industrial fuel oil, char and steel, in a continuous plant.

Discuss this plantWhat the report covers

Pyrolysis breaks tyre rubber down at 400–500 °C in a sealed reactor, condensing the vapour into tyre pyrolysis oil, a heating fuel that competes with furnace oil in boilers, thermic-fluid heaters and kilns. The char left behind is the raw material for recovered carbon black. India's batch plants are being phased out, so a new plant is built continuous, to CPCB's standard operating procedure.

Feed
Wire-free tyre chips, 15–30 mm, from an in-house shredding line or a crumb plant; domestic tyres only.
Capacity modelled
15, 30, 60 and 120 tonnes of tyres per day; the reference plant is a single 60 TPD continuous line.

Products and buyers

  • Tyre pyrolysis oil

    Industrial heating fuel; cement kilns

  • Char

    Fuel for cement kilns, or upgraded to recovered carbon black

  • Steel wire

    Melting scrap

  • Pyrolysis gas

    Burnt in the plant's own heaters

India processed about 2.7 million tonnes of waste tyres by pyrolysis in FY2024, about three-quarters of all tyres recycled, almost all in batch plants that the rules now phase out. Source: CPCB and industry data compiled in the model-plant report

02Process

How the plant works.

INWire-free tyre chips
  1. 01Shredding and wire removal
  2. 02Airlock feed under nitrogen
  3. 03Continuous reactor
  4. 04Condensation
  5. 05Oil separation and storage
  6. 06Gas scrubbing and burners
  7. 07Char discharge
  • OUTTyre pyrolysis oil
  • OUTChar
  • OUTSteel wire
Fig. 01 · Tyre pyrolysis oil process flow · 7 stages

03Rules

What shapes the plant.

  • Only continuous plants for new units in Rajasthan, built to CPCB's January 2024 SOP: nitrogen-purged feed, closed oil and char handling, a 30 m stack and flare, zero liquid discharge.
  • Imported tyres may not be used for pyrolysis.
  • The oil may be sold only as an industrial fuel to buyers whose consent allows it; brick kilns and NCR industries are excluded, and the tank farm needs a PESO licence.

04Viability

What decides whether it pays.

  1. 01The oil price, which tracks furnace oil at a discount and moves with crude.
  2. 02Whether the char is sold as fuel or upgraded to carbon black.
  3. 03Securing tyre supply early: capacity in the market exceeds the tyres available.
  4. 04Siting: a designated industrial area outside the excluded districts.

05The report

What the tyre pyrolysis oil 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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