Pyrolysis Facilities

Pyrolysis Facilities

Advanced Thermal Conversion Solutions for Waste & Biomass

Overview

Pyrolysis Facilities are advanced thermal processing systems designed to convert​​ carbon-rich wastes​​ into​​ valuable energy products​​ under​​ oxygen-free conditions. Mechasol provides​​ engineered pyrolysis solutions​​ for waste tires, plastics, biomass, municipal solid waste (MSW), sludge, and industrial residues, enabling the recovery of​​ pyrolysis oil, syngas, and solid char.

Unlike conventional incineration, pyrolysis operates without combustion, ensuring​​ lower emissions, higher product quality, and superior energy recovery.

Pyrolysis Process Fundamentals

Pyrolysis is the​​ thermal decomposition of organic materials in the absence of oxygen, typically operating between​​ 350°C and 800°C, depending on feedstock and desired product distribution.

Based on the provided documents:

• 450–500°C​​ → liquid (pyrolysis oil) dominant

• >700°C​​ → syngas dominant

• <450°C​​ → char dominant

The process is​​ endothermic, requiring controlled external heat input and precise temperature management.

Feedstock Types & Preparation

Mechasol Pyrolysis Facilities are engineered for a wide feedstock range:

Typical Feedstocks

• Waste tires (whole, shredded, de-wired)

• Non-recyclable plastics

• Biomass (wood waste, agricultural residues)

• Municipal solid waste (after inert separation)

• Sludge and high-organic industrial residues

Pre-Treatment Systems

• Weighing & feeding control

• Steel wire extraction (for tires)

• Shredding and particle size reduction

• Drying systems (critical for high-moisture feeds)

Feedstock preparation is​​ crucial for reaction stability and product quality.

Pyrolysis Reactor Technologies

Mechasol designs and integrates different reactor types depending on application:

Rotary Kiln Reactors

• Ideal for heterogeneous and difficult wastes

• Long residence time and excellent mixing

• Widely used for tire and MSW pyrolysis

Screw / Auger Reactors

• Compact and continuous operation

• Precise temperature and residence time control

Fluidized Bed Reactors

• High heat transfer rates

• Preferred for fine and homogeneous biomass

Reactors are designed for​​ batch or continuous operation, depending on capacity and economics.

Product Streams & Utilization

Pyrolysis Oil

• High calorific value (≈ 41–43 MJ/kg)

• Used as:

  • Industrial furnace fuel

  • Boiler and power plant fuel

  • Refinery and petrochemical feedstock (after upgrading)

Syngas

• NCV:​​ 10–20 MJ/Nm³

• Utilized for:

  • Reactor self-heating

  • Power generation (gas engines / turbines)

  • CHP systems

Solid Char

• Carbon black-rich material

• Applications:

  • Activated carbon production

  • Soil amendment (biochar)

  • Solid fuel

Condensation, Separation & Upgrading Systems

Mechasol pyrolysis facilities include:

• Multi-stage condensers

• Gas-oil separation vessels

• Scrubbers and gas cleaning units

• Fractional distillation columns

• Reboilers and heat exchangers

These systems ensure​​ stable product quality and downstream usability.

Energy Integration & Heat Recovery

To maximize efficiency, Mechasol integrates:

• Waste heat recovery boilers

• Hot oil or hot water circuits

• Syngas-fired heaters

• Steam generation for auxiliary use

This significantly reduces external fuel demand and improves​​ overall plant energy efficiency.

Environmental Control & Safety

Emission Control Systems

• Gas scrubbers (alkaline / chemical)

• Particulate filters

• Condensable VOC removal

• Controlled vent and flare systems

Safety Features

• Inert gas (nitrogen) blanketing

• Pressure relief systems

• Emergency shutdown logic

• Advanced automation & PLC/DCS control

Facilities are designed to meet​​ EU, international, and local environmental regulations.

Slow vs Fast Pyrolysis Capability

Mechasol supports both:

• Slow Pyrolysis​​ → char-focused

• Fast Pyrolysis​​ → bio-oil focused (≈60% yield)

Fast pyrolysis systems feature:

• Rapid heating rates

• Vapor residence time < 1 second

• Immediate quenching of vapors

Modular & EPC Delivery Model

Mechasol Pyrolysis Facilities are delivered as:

• Skid-mounted modular units

• Containerized process blocks

• Full EPC turnkey plants

Scope includes engineering, procurement, fabrication, installation, commissioning, and operator training.

Typical Applications

• Waste tire recycling plants

• Plastic-to-fuel facilities

• Biomass energy projects

• Municipal waste valorization

• Industrial waste minimization

Mechasol Value Proposition

• Strong thermal & process engineering expertise

• Feedstock-flexible and scalable designs

• High energy recovery and product quality

• Modular, future-proof plant architecture

• Full EPC and lifecycle support

Summary

Mechasol Pyrolysis Facilities transform waste liabilities into​​ valuable energy and material resources. By combining advanced reactor design, efficient heat recovery, and robust environmental control, Mechasol delivers​​ sustainable, profitable, and regulation-compliant pyrolysis solutions​​ for modern industrial applications.