Towards Sustainable Waste-to-Energy Solutions: Techno-Economic Insights from Scrap Tyre Pyrolysis in Nigeria

This study assessed the techno-economic performance and energy efficiency of scrap tyre valorization through pyrolysis in Nigeria, comparing two configurations: a pyrolysis plant integrated with power generation (Scenario 1) and a standalone pyrolysis plant (Scenario 2). Process simulations were carried out using Aspen Plus V12, and cost estimations were performed with the Aspen Process Economic Analyzer. For a feed capacity of 20 tons per hour, the pyrolysis process yielded steel wire (15.04%), char (35.57%), pyro-diesel (37.94%), gas (7.91%), and heavy oil (3.54%). Scenario 2 achieved a higher energy efficiency (94.44%) than Scenario 1 (51.23%). However, Scenario 1 demonstrated superior economic performance, with a Net Present Value (NPV) of USD 28.65 million and an Internal Rate of Return (IRR) of 34.48%, despite its higher capital investment of USD 27.63 million. Sensitivity analysis revealed that the selling price of pyro-diesel and the cost of scrap tyres were the most influential parameters affecting profitability. The findings provide useful insights for optimizing scrap tyre pyrolysis systems toward sustainable waste-to-energy applications in developing regions.