End-of-life tyres & plastic to pyro-oil, carbon black & steel wire.
CPCB SOP-compliant pyrolysis plants for 2–20 TPD throughput. Continuous / semi-continuous reactor, multi-stage condenser train, NCG loop, wet scrubber + bag filter, online stack monitoring (CEMS).
Four standard tiers — sized to feedstock availability
Indicative ex-Manesar pricing for the standard reactor + condenser + APCS scope. Add CEMS hardware, civil work, fire safety, weighbridge and CPCB consent fees as applicable.
| Tier | Throughput | Reactor type | Best for | Indicative CapEx (2026) |
|---|---|---|---|---|
| K-Pyro 2 | 2 TPD | Batch / semi-continuous | Pilot / small EPR-driven plant | ~₹1.8 – 2.5 Cr |
| K-Pyro 5 | 5 TPD | Semi-continuous | Mid-size tyre processor / EPR aggregator | ~₹3.5 – 4.5 Cr |
| K-Pyro 10 | 10 TPD | Continuous | Industrial-grade pyrolysis plant | ~₹6 – 8 Cr |
| K-Pyro 20 | 20 TPD | Continuous (multi-reactor) | Large pyrolysis cluster / EPR producer responsibility | ~₹12 – 16 Cr |
Excludes: CEMS hardware (~₹35–60 L), civil + foundation, weighbridge, fire safety system, pyro-oil storage tank farm, transformer, CPCB CTE/CTO fees. Site DPR will refine the scope.
What's in the box
- Tyre / plastic shredder + wire pull-out unit
- Continuous or semi-continuous pyrolysis reactor with refractory lining
- Multi-stage condenser train (water-cooled)
- Pyro-oil storage tank — carbon-steel, vented, fire-rated
- Carbon black collection & pelletizer Optional
- Non-condensable gas (NCG) loop — burner reuse for reactor heat
- Wet scrubber + cyclone + bag filter (CPCB SOP-compliant)
- Steel wire baling unit + dispatch system
- Online stack monitoring (CEMS) — mandatory under CPCB SOP 2022
- Manifest forms 3, 4, 6 documentation pack for HOWM compliance
- Operator training (40 hours) + commissioning support
Tyre pyrolysis economics
Plastic pyrolysis shifts the yield mix — typically 60–75% pyro-oil, 15–20% char, 10–15% NCG. Steel wire stream is absent. Output viability depends on feedstock (PE/PP best, PVC excluded).
From DPR to commissioning — typically 28 to 36 weeks
The CPCB consent process is the longest pole — start CTE early. Below is a typical schedule for a 5 TPD K-Pyro plant.
DPR & site survey
Feedstock matrix · land study · electrical load · 2 weeks
CPCB CTE application
Consent-to-Establish dossier · 8–12 weeks (parallel)
Civil & foundation
RCC pad · drainage · fire pit · weighbridge · 8 weeks
Manufacturing
Reactor + condensers + APCS at Manesar · 14 weeks
Erection & piping
On-site assembly + utilities · 4 weeks
CEMS calibration
Online stack monitoring + 3-month trial run
CPCB CTO + handover
Consent-to-Operate · staff training · documentation
O&M support
1-yr warranty + AMC · spare parts ex-Manesar
CPCB SOP & CEMS — non-negotiable
CPCB's Standard Operating Procedure for Used Tyre Pyrolysis (revised 2022) mandates online stack monitoring (CEMS) for all pyrolysis plants. Budget for CEMS hardware + 3-month pre-commissioning trials. We supply CEMS-ready stack design and provide compliance dossier templates for HOWM Rules 2016 and state PCB CTE/CTO applications.
Common pyrolysis questions
What's the typical payback period?
For a 5 TPD K-Pyro on tyre feedstock, payback is typically 30–42 months at current pyro-oil rates (~₹35–45 / litre). Heavily dependent on feedstock cost (often free or paid by EPR aggregators), pyro-oil offtake price, and electricity tariff. Plastic pyrolysis has shorter payback (~24–30 months) when feedstock is free EPR-routed waste.
What feedstock can the reactor handle?
Tyres: car, truck, agri tyres (whole or shredded). End-of-life conveyor belts. Plastics: PE, PP, PS, mixed dirty plastic (post-segregation). Excluded: PVC (creates HCl in stack), PET (low oil yield), wet feedstock > 20% moisture, mixed PVC/multilayer films. Feedstock matrix is finalised at DPR stage.
What's the regulatory pathway?
(1) Apply for CPCB CTE (Consent-to-Establish) under HOWM Rules 2016 — typically 8–12 weeks. (2) Build the plant. (3) 3-month pre-commissioning trial run with CEMS data. (4) Apply for CTO (Consent-to-Operate) — typically 4–6 weeks after trials. (5) Annual surveillance + Form 3, 4, 6 manifest filing. KWTPL provides the design dossier and compliance templates; the buyer handles the CTE/CTO process via state PCB.
How do EPR obligations interact with pyrolysis?
Under the PWM 2016 (am. 2022) Plastic Waste Management Rules, brand owners and producers have EPR plastic-credit obligations. A pyrolysis plant registered under CPCB EPR portal can issue plastic credits to brand owners — adding a revenue stream beyond pyro-oil sales. We help structure the EPR registration and offtake agreements at DPR stage.
Manpower and operating cost?
5 TPD plant: 12–14 operators (3 shifts), 1 supervisor, 1 maintenance technician. Operating cost ~₹4,500–6,500 / tonne of feedstock processed (excludes feedstock cost, depreciation). Major variable: NCG recycle efficiency reduces fuel cost by 60–70% vs LPG-fired alternatives.
Lead time and AMC?
Manufacturing lead time 14 weeks ex-Manesar. Total project (DPR to CTO) typically 28–36 weeks. 1-year comprehensive warranty + AMC packages from year 2. Engineer on-site within 24-48 hr for any service call. Spare parts ex-Manesar with same-day dispatch.
Considering a pyrolysis project?
Send your feedstock spec, target throughput and site location — we'll respond with a tailored brief, indicative CapEx, regulatory pathway and project timeline within 1 working day.