ABAP vs Batch Components — What Changes
A six-component comparison of the prohibited batch pyrolysis configuration against the mandated ABAP (semi-continuous) design, showing exactly what hardware and operating procedures must change to meet India's regulatory requirements.
| Parameter | Batch | ABAP (Semi-Continuous) |
|---|---|---|
| Reactor Design | Open-top reactor; chamber opened to atmosphere after each cycle | Fully sealed reactor with sealed discharge outlets; chamber never opens |
| Heating Control | Manual burner adjustment; temperature drift common | PLC-controlled automated fuel management; consistent temperature within tight tolerance |
| Feeder Mechanism | Manual loading by workers; reactor chamber open during feed | Automatic feeder (mechanical or hydraulic pusher / screw conveyor) through sealed entry valve |
| Condensation | Single-stage condensation; TPO recovery limited (around 35 percent of feedstock mass) | Multi-stage condensation; TPO recovery improves to 40 to 45 percent of feedstock mass |
| Gas Cleaning | Basic gas scrubber; limited emissions capture; cannot meet State Pollution Control Board standards | Automated gas scrubber and filtration with safety interlocks; meets State Pollution Control Board Consent to Operate |
| Discharge | Manual opening of reactor chamber; workers physically enter to remove char and steel | Sealed automated discharge via screw conveyors or hydraulic mechanisms; workers do not enter the reactor |
Beyond definitions
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How to read this table
- Each row is one plant component; left column shows the batch configuration, right column shows the ABAP (semi-continuous) replacement
- Row colours are for visual grouping only — they do not indicate severity or cost tier
- ABAP stands for Approved Batch-cum-Alternate Process, the regulatory term used by CPCB and SPCBs for the semi-continuous configuration
About this table
India's pollution control regulators have effectively phased out open-top batch pyrolysis reactors for waste tyres, mandating the shift to ABAP — the semi-continuous configuration that keeps the reactor chamber sealed throughout the process cycle. The difference between the two is not incremental; almost every major plant component needs to change, and this table documents each one side by side so that a founder upgrading an existing batch plant or evaluating a new installation knows exactly where the engineering and cost delta sits.
The most fundamental change is the reactor itself. A batch reactor opens to atmosphere after each processing cycle to load fresh tyres and discharge char and steel wire — this is the source of the uncontrolled emissions that regulators have prohibited. The ABAP reactor uses sealed discharge outlets and an automatic feeder (mechanical pusher, hydraulic ram, or screw conveyor) that introduces material through a sealed entry valve without ever opening the chamber. Heating control shifts from manual burner adjustment — prone to temperature drift — to a Programmable Logic Controller (PLC) that manages fuel supply and maintains reactor temperature within a tight tolerance.
Condensation and gas cleaning improve materially. Single-stage condensation in a batch plant recovers around 35 percent of feedstock mass as Tyre Pyrolysis Oil (TPO); multi-stage condensation in an ABAP plant pushes this to 40 to 45 percent. The gas scrubber in a batch plant is typically basic and cannot meet State Pollution Control Board Consent to Operate standards; an ABAP plant uses automated scrubbing and filtration with safety interlocks that are a prerequisite for the Consent to Operate application. The discharge step changes from workers physically entering the reactor chamber to fully sealed screw conveyor or hydraulic discharge — a significant occupational safety improvement as well as a regulatory one.
Use this table alongside the Batch vs ABAP vs Continuous full comparison and the Tyre Pyrolysis Implementation Timeline to map each hardware change to the procurement and civil work phase. Vendors who supply ABAP-compliant reactors will provide a bill of materials that maps to these six component categories.
Key insights
- Every major plant component must change when upgrading from batch to ABAP — this is a near-complete re-engineering, not a minor retrofit
- Multi-stage condensation in ABAP plants improves Tyre Pyrolysis Oil recovery from around 35 percent to 40 to 45 percent of feedstock mass, directly improving revenue per tonne processed
- PLC-controlled heating eliminates the temperature drift common in batch plants, which also reduces off-spec char and oil fractions
- Sealed discharge removes the need for workers to enter the reactor chamber, reducing both occupational risk and regulatory exposure
- The ABAP gas cleaning system is a prerequisite for State Pollution Control Board Consent to Operate — a batch scrubber cannot meet this standard
Methodology & sources
Configuration descriptions reflect CPCB guidelines and industry-standard ABAP equipment specifications as of 2024–25. TPO recovery percentages are typical operating ranges; actual yields depend on feedstock tyre type, reactor temperature profile, and condensation train design. Verify component specifications with your reactor vendor before procurement.
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.
Pyrolysis Influencing Factors and Their Effects
A process control reference table showing how six pyrolysis variables (temperature, time, pressure, particle size, heating rate, feedstock) should be set to maximise each of six target outputs — oil, gas, char, limonene, BTX aromatics, and high-quality char.
Tyre Pyrolysis Implementation Timeline
A seven-phase roadmap from initial market research through to Consent to Operate, showing typical durations, which phases can run in parallel, and the output artifact that closes each phase — total end-to-end timeline is 12 to 18 months.