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.
| Capacity | Type | Price Range |
|---|---|---|
| 3–6 TPD (Low) | Semi-continuous (ABAP), auto feeder, manual char discharge | ₹45–70 lakh |
| 8–12 TPD (Mid) — Semi | Semi-continuous (ABAP) | ₹55–90 lakh |
| 8–12 TPD (Mid) — Continuous | Continuous | ₹90 lakh–1.4 crore |
| 15–20+ TPD (High) | Fully continuous, refractory lining, full automation | ₹1.3–2+ crore |
Beyond definitions
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How to read this table
- Rows are capacity configurations; columns show reactor type description and indicative price range.
- The 8–12 TPD tier has two rows — one for ABAP semi-continuous and one for fully continuous — because both options exist at this scale and have meaningfully different costs.
- Price ranges are for the reactor unit only; peripheral equipment (gas line, char discharge, safety systems) is separate.
About this table
The reactor is the largest and most defining capital investment in a tyre pyrolysis plant. Its capacity, design type (ABAP semi-continuous vs fully continuous), and specification determine plant throughput, operating cost, and regulatory compliance status. This table gives indicative price ranges across capacity tiers and reactor types for Indian market procurement.
At the 3–6 TPD low capacity tier, an ABAP semi-continuous reactor with automated feeder and manual char discharge is the entry-level specification. This reactor type processes tyres in discrete batches but with automated feeding to reduce manual handling — meeting CPCB's ABAP mandate while remaining accessible in cost. The 8–12 TPD mid capacity tier offers a choice between ABAP semi-continuous and continuous reactors — a significant design decision. The ABAP semi-continuous at mid tier is an upgrade from the low-tier version with higher throughput automation; the continuous reactor at the same capacity tier costs substantially more but eliminates the batch cycle and produces more consistent output quality. Both are legal under CPCB regulations; the choice depends on the operator's capital availability and appetite for operational complexity.
At the 15–20+ TPD high capacity tier, a fully continuous reactor with refractory lining and full automation is the standard specification. Refractory lining (heat-resistant ceramic material inside the reactor shell) extends reactor life and reduces thermal cycling damage — an important feature at high-throughput plants where the reactor runs 20+ hours per day. Full automation at this tier means PLC-controlled feeding, temperature management, and char discharge without operator intervention at the reactor itself — reducing manpower and improving consistency. The reactor's price at this tier represents the single largest equipment line item in the plant capital budget.
Key insights
- The step from ABAP semi-continuous (mid tier) to fully continuous reactor at the same 8–12 TPD capacity nearly doubles the reactor price — the decision between the two must be based on operational economics, not just capital cost.
- Refractory lining at the high tier is a mandatory life-extension feature for 20+ hours per day continuous operation — skipping it to reduce cost shortens reactor life significantly at that utilisation level.
- Full automation at 15–20+ TPD reduces manpower requirement at the reactor stage but increases maintenance complexity — operators need technicians with automation system experience, not just mechanical trades.
- The reactor is typically 40–55% of total pyrolysis plant equipment cost — proportioning overall CAPEX estimates from reactor price is a useful quick-check method during early feasibility planning.
Methodology & sources
Price ranges are indicative for Indian market ABAP-compliant reactor procurement as of 2024–2025. Prices vary significantly with reactor wall material (carbon steel vs alloy steel vs refractory-lined), automation level, and vendor (domestic vs imported). All prices exclude GST, installation, commissioning, and safety system integration. ABAP compliance must be confirmed with the SPCB — do not purchase a reactor before confirming it meets current ABAP specification requirements with your state SPCB.
Related data tables
Batch vs ABAP vs Continuous — Full Comparison
A comprehensive eight-parameter comparison of the three tyre pyrolysis plant types — batch (now banned), ABAP semi-continuous, and continuous — covering operation mode, throughput efficiency, manpower, fuel, maintenance, capital cost, and regulatory suitability.
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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).
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