Feed and campaign flexibility
Different qualified feed campaigns can be separated, sampled and adjusted without disturbing a permanently flowing train.
BATCH PYROLYSIS SYSTEMS
Flexible by design.
Disciplined by the cycle.
Batch pyrolysis offers an effective pathway for variable feed, moderate throughput, campaign operation and staged investment when loading, heat-up, conversion, cooling and turnaround are engineered as one production cycle.
01CYCLEoperating model
02FLEXfeed and campaigns
03MODULARcapacity pathway
01 / OPERATING LOGIC
Every minute of the cycle counts.
Daily production is calculated from a repeatable full cycle that includes preparation, inerting, heating, conversion, cooling, unloading, inspection and a safe return to service.
Multiple vessels can be staggered to smooth vapor production when scheduling, shared utilities and maintenance are engineered together.
01Prepare & load→
02Seal & inert→
03Heat→
04Convert & condense→
05Cool→
06Unload & inspect
02 / PERFORMANCE & DESIGN
What it delivers. How to engineer it.
+Advantages
Scalable entry capacity
A single vessel or modular train can create an efficient first capital step as the supply chain and product market expand.
Access between cycles
Internal inspection, residue removal and targeted cleaning can be planned between batches instead of requiring a full continuous-train outage.
Staged capacity
Additional reactors can be added and staggered when feedstock, utilities, operators and offtake grow with the project.
±Design priorities
Complete-cycle utilization
Heating, cooling, loading and unloading are incorporated into the tonnes-per-day production basis and operating schedule.
Thermal fatigue
Repeated temperature and pressure cycles load shells, welds, refractory, seals and rotating interfaces differently from steady operation.
Variable vapor load
Gas and vapor flow change across the cycle, forcing condensers, knockouts, burners and controls to perform over a wide turndown range.
Operating discipline
Opening, inerting, startup and shutdown are coordinated through interlocks, gas testing, trained operators and repeatable procedures.
Strong fit when
- ✓Feedstock volume is variable, regional or still being contracted.
- ✓The project needs staged capital or commercial-scale validation.
- ✓Product campaigns or periodic cleanout are valuable.
- ✓Several reactors can share utilities and operate on a staggered schedule.
Best results require
- +The offtake schedule matches campaign-based production.
- +Daily throughput is calculated from complete-cycle performance.
- +Labor, cleaning space and turnaround systems support the operating plan.
- +The energy system accommodates cyclic process-gas production.
03 / PRIORITIES
Pyrtherm engineering priorities
Cycle mass and energy balance
Measure every phase, including reaction time, to define capacity, fuel demand and production opportunities.
Metallurgy and fatigue review
Specify shell, weld, refractory, seals and supports for the real thermal cycle and expected equipment life.
Condensation across turndown
Control wax, aerosols, pressure and product cuts from the beginning to the end of vapor generation.
Staggered production architecture
Coordinate reactors, cooling, gas use, operators and maintenance to maintain balanced production across the train.
Transient safeguards
Design inerting, cause-and-effect, relief, gas monitoring and procedures around every startup and shutdown.
THE DECISION TEST
Choose batch for flexibility and scalable capacity.
The relevant comparison is installed cost per reliable annual tonne, including cycle efficiency, labor, utilities, cleaning, replacement life and product qualification.
See the continuous pathway04 / TECHNICAL BASIS
Technical basis
Selected reactor and pilot-plant research used to frame this comparison. Actual performance depends on feedstock, reactor configuration, operating window and the complete balance of plant.
01Waste Tire Pyrolysis: Comparison between Fixed Bed and Moving Bed Reactors↗02Continuous Rotating Cone Pilot Plant for Polyethylene and Polypropylene↗03Product Yields in Continuous HDPE Pyrolysis in a Conical Spouted Bed↗04Liquid-Fed Waste Plastic Pyrolysis Pilot Plant: Reactor Volume and Product Yields↗
SELECT THE OPERATING MODEL FROM THE PROJECT BASIS
Batch or continuous is a system decision.
Pyrtherm compares both pathways against real feedstock supply, throughput, product quality, utilities, maintenance capability, CAPEX, OPEX and market commitments before equipment is selected.
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