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.
| Parameter | Batch | ABAP (Semi-Continuous) | Continuous |
|---|---|---|---|
| Operation Mode | Manual | Semi-automatic | Fully automatic |
| Processing Time | 8–12 hrs/batch | 6–10 hrs/batch | 20+ hrs/day continuous |
| Efficiency | Lower (idle time) | Better (less idle) | High throughput, minimal downtime |
| Manpower | High | Moderate | Low |
| Fuel Consumption | Higher per tonne | Moderate | Lower per tonne |
| Maintenance | Moderate | Moderate | Higher (complex system) |
| Capital Expenses | Low initial, high operational | Moderate | High initial, lower long-term |
| Suitability | Small-scale (BANNED) | Mid-scale operations | Large-scale commercial |
Beyond definitions
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How to read this table
- Rows are operational parameters; columns compare the three plant types side by side.
- Batch column is shown as BANNED — this column provides context only; no new batch plant can be commissioned in India.
- ABAP is the regulatory baseline for new mid-scale plants; Continuous is the choice for large-scale (15–20+ TPD) operations seeking lower operating cost per tonne.
About this table
Tyre pyrolysis plants exist in three process configurations — batch, ABAP semi-continuous, and fully continuous — each with fundamentally different operational economics, capital requirements, and regulatory status in India. This table compares all three across eight parameters, with the critical note that batch pyrolysis is now banned under CPCB regulations and included here only for comparative understanding.
The original Batch process loaded tyres into a sealed reactor, ran a 8–12 hour heating cycle, then cooled and discharged char and opened the reactor for the next load. The process was entirely manual, used high labour, produced inconsistent output (the beginning and end of each batch produced different oil quality than the middle), and generated the highest fuel consumption per tonne of throughput because of repeated heating and cooling cycles. The CPCB banned batch pyrolysis in 2019 because of uncontrolled emissions during loading and unloading, and the inability of batch systems to maintain the pollution control standards required under tyre pyrolysis regulations. It is listed here only to provide context for operators encountering legacy equipment or considering second-hand plant purchases — any batch equipment requires conversion to ABAP configuration before SPCB consent can be obtained.
The ABAP (Alternative to Batch and Pyrolysis) semi-continuous process is the current regulatory-compliant standard for mid-scale operations in India. ABAP reduces idle time between batches through automated feeding and controlled loading sequences, improving throughput to 6–10 hours per batch cycle while maintaining pollution control. Manpower requirements are moderate — operators manage the automated feeding and monitor process conditions rather than performing manual loading. Continuous process plants operate 20+ hours per day without batch cycles, using auger or rotary kilns to move feedstock through a continuous thermal zone. The result is consistently higher throughput, lower fuel per tonne (no repeated heating/cooling), and lower manpower relative to output. Capital cost is significantly higher, and maintenance is more complex — continuous systems have more moving mechanical components than batch or semi-continuous systems.
Key insights
- Batch pyrolysis is banned in India — any operator considering second-hand equipment must confirm it is ABAP-compliant, not a legacy batch system, before proceeding with SPCB consent application.
- ABAP semi-continuous is the appropriate entry point for mid-scale (8–12 TPD) operations — it meets regulatory requirements and offers better economics than batch at a lower capital cost than continuous.
- Continuous process plants have lower fuel consumption and lower manpower per tonne but higher maintenance complexity — the economics favour continuous at 15+ TPD scale where the lower per-tonne operating cost justifies higher capital.
- Processing time differences (6–10 hrs/batch for ABAP vs 20+ hrs/day continuous) translate directly into daily throughput — a 10-tonne ABAP reactor running 2 batches per day processes 20 tonnes; a continuous reactor can process 20+ tonnes continuously.
Methodology & sources
Comparative parameters described are based on standard tyre pyrolysis industry characterisation as of 2024. CPCB batch pyrolysis ban refers to the 2019 CPCB notification mandating ABAP or continuous systems for tyre pyrolysis. Specific operational parameters (processing time, fuel consumption per tonne) vary by reactor manufacturer and design — confirm with equipment vendor for plant-specific data.
Related data tables
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.
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Pyrolysis Reactor — Pricing by Capacity
Indicative price ranges for tyre pyrolysis reactors at four capacity configurations — 3–6 TPD ABAP semi-continuous, 8–12 TPD semi-continuous and continuous options, and 15–20+ TPD fully continuous — for capital planning.