Gas Scrubber and Ball Mill — Pricing
Indicative price ranges for gas scrubbers and ball mills at three tyre pyrolysis plant capacity tiers — the gas scrubber cleans non-condensable gas before it enters the burner, and the ball mill grinds pyrolysis char into carbon black powder for sale.
| Equipment | Low (≤8 TPD) | Mid (8–22 TPD) | High (≥22 TPD) |
|---|---|---|---|
| Gas Scrubber | ₹6–12 lakh (single tower, PP-FRP) | ₹12–20 lakh (larger tower, venturi) | ₹18–35 lakh (2-cell system) |
| Ball Mill | ₹6–12 lakh | ₹12–20 lakh | ₹18–35 lakh |
Beyond definitions
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How to read this table
- Rows are the two equipment items; columns are the three capacity tiers (Low up to 8 TPD, Mid 8–22 TPD, High 22+ TPD).
- Gas scrubber sizing is based on NCG volume (m³/hr), not plant TPD directly — confirm the NCG flow rate from your reactor supplier before specifying scrubber size.
- Ball mill capacity must match char production volume — specify ball mill throughput (tonnes of char per hour) not just ball mill size (diameter).
About this table
The gas scrubber and ball mill address the two problematic by-products of tyre pyrolysis: the non-condensable gas stream (which contains acidic compounds that must be cleaned before use as reactor fuel) and the solid char (which must be ground fine enough to be sold as carbon black product). This table gives indicative prices for both items across plant capacity tiers.
The Gas Scrubber cleans the non-condensable pyrolysis gas (NCG) — the fraction that does not condense in the condenser train — by removing hydrogen sulfide (H2S), ammonia, particulates, and other acidic compounds before the gas is routed to the reactor burner or flare. Without scrubbing, burning unscrubbed NCG emits sulfur dioxide and other pollutants that exceed CPCB stack emission standards, resulting in consent violations. At the low tier, a single-tower PP-FRP (polypropylene/fibre-reinforced plastic) scrubber with alkaline wash is standard. Mid-tier plants use larger towers with venturi scrubbers for higher gas volumes. High-tier plants use two-cell systems that provide redundancy — one cell can be cleaned or maintained while the other continues operation. The gas scrubber is a CPCB compliance item, not an optional add-on; a tyre pyrolysis plant without a functioning gas scrubber cannot meet the emission standards in its CTO conditions.
The Ball Mill grinds pyrolysis char (solid residue from the reactor) into fine carbon black powder suitable for sale to rubber compounders, plastic manufacturers, or paint producers. Unground char is low-value; ground char that meets particle size and ash content specifications can sell at a premium as recovered carbon black (rCB). Ball mill size is matched to the char output from the reactor — at a typical 20–25% char yield by weight, a 10 TPD plant produces 2–2.5 tonnes of char per day, and the ball mill must process that volume to avoid char accumulation. The ball mill is also one of the highest-noise-generating items in the plant — noise control enclosures are often required to meet ambient noise limits.
Key insights
- The gas scrubber is a CPCB compliance requirement — a pyrolysis plant without a compliant gas scrubber cannot meet CTO stack emission conditions and will face consent notices.
- Ball mill investment is what converts low-value char into saleable carbon black — the return on ball mill investment depends entirely on whether carbon black buyers are available in the plant's market area.
- Noise control enclosures around the ball mill are often required to meet ambient noise limits — this is a civil works cost that should be factored into the ball mill procurement budget.
- Two-cell gas scrubber systems at high tier provide operational redundancy — one cell can be maintained while the other continues cleaning NCG, preventing shutdown of the gas recovery loop.
Methodology & sources
Price ranges are indicative for Indian market procurement as of 2024–2025. Gas scrubber prices vary with tower material (PP vs FRP vs SS), scrubbing liquid system (alkaline wash vs water wash vs two-stage), and vendor. Ball mill prices vary with grinding capacity (tonnes per hour), media material, and automation level. All prices exclude GST, installation, ductwork (gas scrubber), and noise enclosure civil works (ball mill). CPCB emission standards for gas scrubbers should be confirmed with the SPCB for the specific plant location.
Related data tables
Heat Exchanger and Condenser — Pricing
Indicative price ranges for heat exchangers and condensers at three tyre pyrolysis plant capacity tiers — covering the condensation train that converts pyrolysis vapours into liquid Tyre-derived Pyrolysis Oil (TPO).
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.
Recovered Carbon Black (rCB) — Application Areas
Five industry application areas for recovered carbon black (rCB) from tyre pyrolysis — covering rubber compounding, plastic pigmentation, paint tinting, construction additives, and activated carbon adsorbents — with the specific role rCB plays in each.