Plant Area Requirements by Reactor Type
Minimum plot area requirements for tyre pyrolysis plants by reactor type — ABAP Batch reactors (3,000–4,000 m² base plus increments per additional reactor) and Continuous process plants (7,000 m² minimum for 60+ TPD scale).
| Plant Type | Reactor Size | Min. Area (1 reactor) | Per Additional Reactor | Max Area |
|---|---|---|---|---|
| ABAP Batch | 10–12 tonne | 3,000 m² | +750 m² | 6,000 m² |
| ABAP Batch | 20 tonne | 4,000 m² | +1,000 m² | 6,000 m² |
| Continuous | Any (> 60 TPD) | 7,000 m² | — | — |
Beyond definitions
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How to read this table
- Each row is one reactor type configuration; columns show reactor size, minimum area for the first reactor, area increment per additional reactor, and maximum area under the incremental formula.
- Min. Area and Per Additional Reactor figures are regulatory minimums — actual plant area will typically be 20–50% larger to accommodate feedstock storage, product storage, and vehicle movement comfortably.
- Maximum Area (6,000 m²) applies only to the ABAP Batch formula — Continuous process plants do not have an equivalent cap as they are specified as a fixed minimum.
About this table
Tyre pyrolysis plants in India must meet CPCB and SPCB minimum plot area requirements that vary by reactor type and capacity. This table gives the specific minimum area requirements for the two reactor types authorised under current Indian regulations: the ABAP (Alternative to Batch and Pyrolysis) Batch reactor, and continuous-process pyrolysis systems.
The ABAP Batch reactor (which replaced the old batch pyrolysis systems banned under CPCB's 2019 notification) comes in two main size classes. A 10–12 tonne reactor requires a minimum plot of 3,000 m² for the first reactor, with each additional reactor adding 750 m² to the minimum requirement up to a maximum of 6,000 m² regardless of reactor count beyond that point. A single 20-tonne reactor requires 4,000 m², with each additional 20-tonne reactor adding 1,000 m² up to the same 6,000 m² cap. The 6,000 m² maximum reflects the SPCB's view that beyond that plot area, the site can be managed within the available footprint regardless of additional reactors, as long as road access, green belt, and fire safety requirements are all met within the plot.
The Continuous process pyrolysis plant (for capacities above approximately 60 TPD) has a minimum area requirement of 7,000 m² — higher than the ABAP Batch maximum, reflecting the continuous plant's larger equipment footprint (feed conveying systems, longer condensation trains, larger storage infrastructure) and higher output volumes that require more storage and dispatch area. The continuous plant's minimum area is a fixed floor — it does not scale with additional processing capacity in the same way the ABAP Batch formula does, because the continuous process is designed as an integrated system rather than a scalable reactor array.
Key insights
- The 6,000 m² maximum for ABAP Batch plants means that beyond a certain reactor count, additional reactors can be added without proportionally increasing minimum plot area — this is a density efficiency benefit for operators scaling up within ABAP configuration.
- Continuous process plants require 7,000 m² minimum — more than the ABAP Batch maximum — reflecting the larger integrated equipment footprint and storage requirements of continuous operation.
- Regulatory minimum area and practical operating area are different — a plant designed at exactly the minimum area will have no buffer for feedstock surge, expanded storage, or equipment maintenance access.
- ABAP Batch area requirements are additive per reactor — operators planning 4 or more 10-tonne reactors will hit the 6,000 m² cap and should design the site assuming that maximum regardless of the final reactor count.
Methodology & sources
Plant area requirements reflect CPCB and SPCB guidelines for tyre pyrolysis plant authorisation as of 2024 under the ABAP framework established post-2019 batch pyrolysis ban. Requirements may vary by state SPCB interpretation and are subject to revision. Verify current requirements with the SPCB in the state where the plant will be located before finalising site dimensions.
Related data tables
Pyrolysis Plant — Zone Area Allocation
A four-zone area allocation guide for a tyre pyrolysis plant layout — showing recommended percentage allocation of total plot area across processing, storage, administration, and movement/safety zones with key sub-areas.
Site Selection — Zonal Requirements
Seven mandatory site selection parameters for a tyre pyrolysis plant in India — industrial zone classification, habitation and water body setback distances, eco-sensitive zone buffers, road access requirements, green belt minimum, and fire access route.