Cost of Pyrolysis Treatment for 1 Ton of Rubber-Based Solid Waste

Cost of Pyrolysis Treatment for 1 Ton of Rubber-Based Solid Waste

The total cost of pyrolyzing 1 ton of rubber-based solid waste is about 1,000-1,500 CNY/ton, which is significantly affected by raw material quality, production scale and process type. The cost of small-scale batch processes is at the upper end of the range, while that of medium and large-scale continuous processes can be reduced to 900-1,200 CNY/ton. The cost composition and key influencing factors are as follows:

I. Core Cost Composition (per ton of rubber-based solid waste)

Raw material procurement cost: 750-1,300 CNY, accounting for 60%-70% of the total cost and being the largest cost item. The recycling price of waste tires/rubber fluctuates significantly with regions and impurity content (proportion of steel wire and sediment).

Fuel and energy consumption cost: 80-200 CNY. External fuels such as coal, LNG and diesel are relied on in the initial stage, and self-produced combustible gas can be used as a substitute after stable production, reducing the cost by 30-50 CNY/ton.

Labor, water and electricity cost: 65-135 CNY, including 15-35 CNY/ton for water and electricity (mainly electricity) and 50-100 CNY/ton for labor. Batch processes require 3-4 workers per shift, while continuous processes can be streamlined to 2-3 workers per shift.

Equipment-related cost: 50-130 CNY, covering equipment depreciation of 30-80 CNY (calculated over a 5-10 year period, with higher unit depreciation for small-sca

le equipment) and replacement and maintenance of vulnerable parts of 20-50 CNY (sealing gaskets, heating pipes, reactor accessories, etc.).

Environmental operation and maintenance cost: 40-100 CNY, which is the cost of consumables, chemicals and equipment operation for exhaust gas purification and wastewater treatment. The cost is relatively higher in regions with strict environmental regulation.

Other miscellaneous costs: 20-40 CNY, including site management, taxes, material transportation and other incidental expenses.

II. Key Factors Affecting the Cost

Production scale and process: Continuous production lines have obvious economies of scale, with a fuel self-sufficiency rate of over 80%, which can amortize labor and depreciation costs. Batch equipment has a low initial investment but a higher unit treatment cost.

Raw material quality: Rubber-based solid waste with few impurities and unified specifications requires no additional sorting, which can reduce pretreatment losses and equipment wear, and directly lower raw material and operation costs.

Energy self-sufficiency rate: Full recovery and utilization of self-produced combustible gas from pyrolysis to replace external fuel is the most direct cost reduction method.

Regional environmental requirements: Regions with high environmental standards need additional investment in end-of-pipe treatment facilities, increasing the environmental operation and maintenance cost by 20%-30%.

III. Mainstream Cost Reduction and Optimization Directions

Establish raw material sorting standards, and prioritize the procurement of rubber-based solid waste with low sediment content and no mixing to reduce pretreatment costs.

Maximize the utilization of self-produced combustible gas to achieve self-sufficiency in heat supply for pyrolysis and completely replace external fuel.

For small and medium-scale projects, prioritize integrated equipment; for medium and large-scale projects, build continuous production lines to leverage economies of scale.

Apply for local environmental subsidies and tax incentives for comprehensive resource utilization. Subsidies in some regions can cover 10%-20% of the operating costs.