Higher asset utilization
Long campaigns reduce repeated heating and cooling, allowing more annual throughput from the installed reaction volume.
CONTINUOUS PYROLYSIS SYSTEMS
Steady state by design.
Built for sustained performance.
Continuous pyrolysis delivers high utilization, stable vapor load and stronger energy integration when feed preparation, oxygen exclusion, residence time, solids discharge, controls and maintenance are designed for long campaigns.
01FLOWoperating model
02UPTIMEeconomic driver
03SCALEcapacity pathway
01 / OPERATING LOGIC
A continuous reactor needs a continuous business.
Stable operation begins outside the reactor. The receiving network, preprocessing line, feed metering, vapor train, solids handling, utilities, maintenance organization and product market must all sustain the same operating campaign.
Stable campaigns come from coordinated feed supply, discharge, product qualification and downstream availability.
01Qualify & prepare→
02Meter & seal→
03Feed continuously→
04Convert→
05Separate & condense→
06Discharge & recycle
02 / PERFORMANCE & DESIGN
What it delivers. How to engineer it.
+Advantages
Stable vapor and product window
Steady feed and temperature can stabilize condensation load, product cuts, sampling and downstream quality control.
Stronger energy integration
A more constant process-gas and heat demand profile can improve burner control, heat recovery and utility sizing.
Automation and scale
Continuous metering and instrumentation support advanced control, reconciled mass balances and larger sustained production.
±Design priorities
Feed and discharge sealing
Solids or molten polymer must cross the pressure boundary without admitting oxygen or releasing hydrocarbons—a critical reliability and safety duty.
Sensitivity to feed preparation
Particle size, moisture, metals, PVC/PET, textiles and bulk density can disturb metering, heat transfer, residence time and product quality.
Online cleanability and isolation
Isolation, bypass, access, redundancy and cleaning systems keep the train productive and maintainable throughout long campaigns.
Higher system complexity
Controls, rotating equipment, seals, redundancy and skilled maintenance increase the capital and operating capability needed to earn high uptime.
Strong fit when
- ✓Qualified feedstock is available under dependable long-term supply.
- ✓The project needs sustained industrial throughput and stable quality.
- ✓Operators, maintenance systems and critical spares support long campaigns.
- ✓Product specifications and offtake can absorb regular production.
Best results require
- +Feed is qualified, consistently supplied and prepared to specification.
- +The design integrates management of plugs, seals and online isolation.
- +Products and downstream acceptance are qualified for regular production.
- +The financial model uses demonstrated availability targets.
03 / PRIORITIES
Pyrtherm engineering priorities
Feed specification and preparation
Define composition, size, moisture, density and contaminant limits that the metering and reactor system can tolerate.
Oxygen-tight material transfer
Engineer feeders, lock hoppers, extruders or valves together with purge, pressure control and safe solids discharge.
Heat transfer and residence time
Prove temperature uniformity and phase behavior at scale instead of extrapolating directly from laboratory kinetics.
Isolation and maintainability
Provide access, drains, bypasses, spares and cleaning logic to maintain availability while individual components are serviced.
Instrumentation and energy integration
Reconcile mass, stabilize pressure and vapor load, and match process-gas use with safe backup and disposal capacity.
THE DECISION TEST
Choose continuous for aligned supply, operations and market.
Continuous economics integrate the availability of every upstream and downstream system across the complete operating campaign.
See the batch 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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