Current Batch
B2024-003
RUNNING
Reactor Temperature
452°C
NORMAL
Oil Production Rate
295 kg/h
NORMAL
System Pressure
0.15 bar
NORMAL
Reactor Temperature
System Pressure
Gas Flow Rate
Oil Production
Process Parameters
Batch Operations
Current Batch: B2024-003
Start Time: 08:30 AM
Running Time: 2h 15m
Product Quality Status
Pyrolytic Oil
Density: 0.89 g/cm³
Viscosity: 4.2 cSt
Flash Point: 68°C
ASTM COMPLIANT
Carbon Black
BET Surface: 42 m²/g
Ash Content: 8.5%
Volatile Matter: 2.1%
N550 GRADE
Technical Data & Hardware Specifications
Complete sensor and safety system hardware specifications for tire pyrolysis plant monitoring
Temperature Sensors
Primary Reactor Sensors (3 zones)
Sensor Type:Type K Thermocouple
Temperature Range:0°C to 1000°C
Accuracy:±1°C or 0.25% of reading
Response Time:<1 second
Protection:Inconel 600 sheath
Connection:M12 connector, IP67
Output Signal:4-20mA transmitter
Condenser & Gas Cooling
Sensor Type:RTD Pt100
Temperature Range:-50°C to 200°C
Accuracy:±0.3°C
Housing:316SS, sanitary fitting
Certification:ATEX Zone 1, SIL 2
Pressure Measurement Systems
Reactor Pressure Monitoring
Sensor Type:Capacitive pressure transmitter
Pressure Range:-1 to +2 bar absolute
Accuracy:±0.01 bar (0.1% FS)
Material:316L SS wetted parts
Protection:IP67, NEMA 4X
Output:4-20mA + HART protocol
Safety Rating:SIL 2/3, ATEX certified
Vacuum System Monitoring
Sensor Type:Absolute pressure transmitter
Vacuum Range:0 to -1 bar absolute
Resolution:0.001 bar
Temperature Compensation:-40°C to +85°C
Flow Measurement Systems
Gas Flow Monitoring
Sensor Type:Ultrasonic flow meter
Flow Range:0 to 2000 m³/h
Accuracy:±1% of reading
Pipe Size:DN100 to DN300
Operating Temp:-40°C to +200°C
Communication:Modbus RTU/TCP, 4-20mA
Liquid Flow (Oil Production)
Sensor Type:Coriolis mass flow meter
Flow Range:0 to 500 kg/h
Accuracy:±0.1% of rate
Density Range:0.5 to 1.5 g/cm³
Viscosity:Up to 1000 cP
Weight & Load Cell Systems
Feedstock Weighing System
Load Cell Type:Compression load cells (4x)
Capacity:10 tons per cell (40t total)
Accuracy:±0.1% of full scale
Material:Stainless steel, IP68
Temperature Range:-30°C to +70°C
Output:2mV/V strain gauge
Certification:OIML R60, C3
Product Storage Monitoring
Tank Level Type:Radar level transmitter
Range:0 to 20 meters
Accuracy:±3mm
Frequency:26GHz FMCW radar
Process Connection:2" ANSI flange
Gas Analysis Equipment
Multi-Gas Analyzer
Technology:FTIR + Electrochemical
Measured Gases:O2, CO, CO2, SO2, NOx, CH4
O2 Range:0-25% ±0.1%
CO Range:0-1000 ppm ±2ppm
Response Time:<30 seconds T90
Sampling System:Heated, filtered probe
Calibration:Auto daily + manual
LEL Safety Monitor
Sensor Type:Catalytic bead
Range:0-100% LEL
Accuracy:±3% LEL
Response Time:<10 seconds T90
Alarm Levels:20% LEL warning, 40% LEL alarm
Safety Rating:SIL 2, ATEX Zone 1
Safety & Emergency Systems
Emergency Shutdown System (ESD)
Safety Level:SIL 3 certified system
Response Time:<2 seconds from trigger
Shutdown Triggers:High temp, pressure, gas leak
Manual Stations:3x locations, mushroom buttons
Valve Actuation:Fail-safe pneumatic valves
Backup Power:30-minute UPS system
Fire & Gas Detection
Flame Detectors:UV/IR triple spectrum (4x)
Detection Range:30m radius, 120° cone
Gas Detectors:Fixed point (8x locations)
Response Time:Flame: <3 sec, Gas: <10 sec
Communication:Addressable loop + 4-20mA
Environmental Monitoring
Stack Emissions:Continuous opacity monitor
Particulate:Isokinetic sampling system
Noise Monitoring:Class 1 sound level meter
Data Logging:Continuous with 5-year storage
Compliance:EPA Method 5, 9, 22 certified
Control System Integration
PLC System Requirements
Controller:Allen-Bradley ControlLogix or Siemens S7-1500
I/O Capacity:128+ analog, 256+ digital points
Communication:Ethernet/IP, Modbus TCP/RTU
Safety Module:Integrated SIL 3 safety PLC
Programming:Ladder logic + function blocks
Network Infrastructure
Industrial Switch:Managed L3, 24-port PoE+
Fiber Backbone:Single-mode, redundant ring
Wireless:Industrial WiFi 6, mesh topology
Security:VPN, firewall, NAC
Protocols:OPC-UA, MQTT, EtherNet/IP
Documentation & Commercial Value
Complete technical documentation, system capabilities, and commercial value proposition for the Pyrolysis Plant Monitoring System
Comprehensive Documentation
README.md
Complete project overview and user guide
Project Overview✅ Complete
- Live system URLs and access information
- User guide for all roles (operators, managers, safety)
- Performance metrics and capabilities
- Installation and setup instructions
TECHNICAL_SPECIFICATIONS.md
Engineering specifications and hardware requirements
Engineering✅ Complete
- Industry research foundation (2025 studies)
- ASTM quality standards integration
- Sensor specifications and safety systems
- Environmental compliance requirements
API_DOCUMENTATION.md
Complete REST API reference and integration guide
API Reference✅ Complete
- 25+ REST endpoints with examples
- Authentication and security protocols
- Real-time data formats and structures
- Error codes and troubleshooting
SYSTEM_ARCHITECTURE.md
Database schema and system design documentation
Architecture✅ Complete
- 15+ database tables with relationships
- Edge computing architecture design
- Security framework and user management
- Performance optimization strategies
RESEARCH_FINDINGS.md
Industry standards foundation and process research
Research✅ Complete
- 2025 industry research analysis
- Process optimization studies (12% improvement)
- ASTM quality testing standards
- Environmental monitoring requirements
PROJECT_SUMMARY.md
Executive overview and commercialization guide
Business✅ Complete
- Complete project deliverables summary
- Commercial value proposition
- Target market analysis
- Revenue stream opportunities
Complete System Capabilities
Industry Research & Standards
Deep analysis from 2025 research (Nature.com, E3S Web Conferences)
ASTM standards integration (D1765, D6556, D4052, D445, D93)
12% yield improvement based on SCADA optimization studies
Environmental compliance and safety specifications
Software Architecture
Hono.js on Cloudflare Workers (edge computing)
Comprehensive D1 database schema (15+ tables)
Real-time dashboard with digital gauges
JWT authentication with role-based access
Real-time Monitoring
18 sensor types: Temperature, pressure, flow, weight, gas analysis
Multi-color gauges with industrial-grade visualization
Live charts: Temperature trends and production rates
Multi-level alarm system with acknowledgment workflow
Business Intelligence
Production reports: Yield analysis and efficiency metrics
Financial reports: Revenue, costs, profitability tracking
Maintenance reports: Equipment reliability and scheduling
Quality reports: ASTM compliance and test results
Key System Specifications
| Feature | Specification | Performance |
|---|---|---|
| Sensor Types | 18 industrial categories | Comprehensive |
| Response Time | <1 second updates | Real-time |
| Concurrent Users | 50+ simultaneous | Enterprise |
| Data Volume | 1M+ readings/day | High Volume |
| Process Range | 1-20 tons/hour | Scalable |
| Quality Standards | ASTM D1765, D6556, D4052, D445, D93 | Compliant |
| Safety Systems | Emergency shutdown, gas detection | SIL 2/3 |
| Deployment | Global edge computing | Worldwide |
Commercial Value Proposition
Target Market
Pyrolysis Plant Manufacturers
Complete monitoring solution for new installations
Industrial Operators
Retrofit existing facilities with modern monitoring
Government Facilities
Municipal waste processing operations
Environmental Companies
Compliance optimization and monitoring services
Economic Benefits
12%
Yield Improvement
Based on SCADA research
95%
Uptime Target
Predictive maintenance
100%
Compliance
Automated reporting
2-3yr
ROI Timeline
Typical payback period
Revenue Streams
Software Licensing
License fees to plant manufacturers
High VolumeSaaS Subscriptions
Monthly/annual subscriptions for operators
RecurringProfessional Services
Installation, training, and consulting
PremiumSupport Contracts
Maintenance and technical support
StableInnovation Highlights
Edge Computing
Ultra-low latency via Cloudflare Workers global network
Industry-Specific
Purpose-built for tire pyrolysis operations
Real-time Intelligence
Live process optimization and predictive analytics
Global Scalability
Multi-plant deployment capability
Standards Compliance
ASTM quality integration and regulatory compliance
Complete Solution
End-to-end monitoring and control platform
Ready for Commercialization
Production-Ready Industrial Solution
This comprehensive pyrolysis plant monitoring system is immediately ready for market deployment with complete documentation, proven technology stack, and demonstrated commercial value.
✅ Turnkey Software Package✅ Professional Documentation✅ Industry Compliance✅ Scalable Architecture✅ Live Demonstration System
18+
Sensor Types
15+
Database Tables
25+
API Endpoints
1M+
Daily Readings
Active Alarms
10:45