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.