Heat Exchanger and Condenser — Pricing
Indicative price ranges for heat exchangers and condensers at three tyre pyrolysis plant capacity tiers — covering the condensation train that converts pyrolysis vapours into liquid Tyre-derived Pyrolysis Oil (TPO).
| Equipment | Low (3–6 TPD) | Mid (8–12 TPD) | High (15–20+ TPD) |
|---|---|---|---|
| Heat Exchanger | ₹6–10 lakh (1–2 stage) | ₹10–18 lakh (2–3 stage) | ₹15–30 lakh (multi-stage, high-grade) |
| Condenser | ₹8–15 lakh (2-stage, water-cooled) | ₹15–25 lakh (2–3 stage, knock-out drums) | ₹25–45 lakh (3–4 stage, SS tubes) |
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How to read this table
- Rows are the two equipment items; columns are the three capacity tiers (Low 3–6 TPD, Mid 8–12 TPD, High 15–20+ TPD).
- Price ranges are for equipment supply only; installation, piping, and cooling water system integration are separate costs.
- Multi-stage condensation at higher tiers improves oil recovery but adds more surface area to maintain — factor in increased maintenance cost when comparing single-stage vs multi-stage options.
About this table
The condensation train — the heat exchanger and condenser system — is the portion of a tyre pyrolysis plant that converts hot pyrolysis vapours from the reactor into liquid Tyre-derived Pyrolysis Oil (TPO). The quality and efficiency of this stage directly determines oil recovery percentage, oil quality, and the split between condensed oil and non-condensable gas sent to the burner. This table gives indicative prices for both items across capacity tiers.
The Heat Exchanger pre-cools the hot vapour stream leaving the reactor before it enters the condenser — reducing the thermal load on the condenser and improving overall condensation efficiency. At the low tier, a 1–2 stage heat exchanger configuration is typical; mid and high tiers progress to 2–3 stage and multi-stage configurations respectively. More stages mean better heat recovery — pre-heated cooling water from the heat exchanger can be used for reactor heating in a heat integration loop, reducing fuel consumption. The specification of heat exchanger tube material (carbon steel vs stainless steel vs copper-nickel) determines corrosion resistance to acidic condensate — lower-cost carbon steel is common at pilot scale but higher-grade materials extend service life in commercial operation.
The Condenser is the critical vessel where vapours actually convert to liquid. At the low tier, a 2-stage water-cooled condenser captures most of the condensable fraction. Mid-tier plants use 2–3 stage condensers with knock-out drums between stages — the knock-out drums separate entrained liquid droplets from the vapour stream between condenser stages, improving oil recovery. High-tier plants use 3–4 stage configurations with stainless steel tubes — the additional stages and better materials improve both oil recovery efficiency and oil quality, particularly for plants targeting distilled diesel-range product rather than raw TPO. A condensation system that recovers an additional 2–3% of oil yield from the vapour stream makes a meaningful difference to revenue over the plant's operating life.
Key insights
- Multi-stage condensation (2–3 stages at mid tier, 3–4 at high tier) improves oil recovery percentage meaningfully — even a 2% improvement in oil yield at 10 TPD represents significant additional revenue over the plant's operating life.
- Stainless steel condenser tubes at the high tier are a quality investment, not just a premium — pyrolysis vapour condensate is mildly corrosive, and carbon steel tubes require more frequent replacement in continuous operation.
- Heat exchanger heat recovery (using pre-heated cooling water to reduce reactor fuel consumption) is an operating cost lever — the investment in multi-stage heat exchangers pays back through reduced fuel cost at mid and high tier plants.
- Knock-out drums between condenser stages are a commercial-grade feature that significantly improves oil recovery from entrained liquid droplets — skipping them to reduce cost leaves recoverable oil in the gas stream.
Methodology & sources
Price ranges are indicative for Indian market procurement as of 2024–2025. Prices vary with tube material (carbon steel vs SS 304 vs SS 316), cooling water configuration, number of stages, and vendor. All prices exclude GST, installation, piping, and cooling water system. Condenser specifications should be validated against the pyrolysis vapour flow rate and composition expected from the specific reactor type chosen.
Related data tables
Pyrolysis Reactor — Pricing by Capacity
Indicative price ranges for tyre pyrolysis reactors at four capacity configurations — 3–6 TPD ABAP semi-continuous, 8–12 TPD semi-continuous and continuous options, and 15–20+ TPD fully continuous — for capital planning.
Storage Tanks and Cooling Tower — Pricing
Indicative price ranges for TPO (Tyre-derived Pyrolysis Oil) storage tanks and cooling towers at three tyre pyrolysis plant capacity tiers — essential equipment for oil product storage and process cooling water management.
TPO Refined Oil Fractions
A three-fraction breakdown of Tyre-derived Pyrolysis Oil (TPO) after distillation — light gasoline-range, diesel-range middle, and heavy oil — with boiling range, characteristics, and commercial applications for each.