A private pyrolysis R&D facility in the west of Ireland was developed to enable commercial-scale experimentation with advanced thermal conversion technologies. Designed to support continuous processing at throughputs of up to one tonne per hour, the facility provides a controlled environment for testing diverse feedstocks, optimising reactor parameters, and developing new downstream processes.

At the centre of the system is an indirect-fired rotary kiln, selected for its ability to deliver stable, oxygen-free thermal treatment across a wide temperature range. Around this core, the project integrates a tailored suite of material handling, ventilation, gas treatment, and safety systems to create a flexible platform for both research and pilot-scale production.

Transforming a standard industrial building into a high-temperature process environment required detailed spatial modelling, equipment placement strategies, ventilation design, and the establishment of safe operational pathways. Iterative development was essential to balance thermal efficiency, maintenance access, environmental performance, and day-to-day research needs.

The facility also includes an on-site laboratory for feedstock assessment, material testing, and analysis of pyrolysis outputs. This integration of pilot-scale processing with analytical capability allows controlled experimentation and iterative refinement of thermal conversion approaches without leaving the building.

As a dedicated testbed for continuous pyrolysis, the facility demonstrates how industrial-scale systems can be adapted for innovation. It provides researchers and engineers with a versatile environment for developing new low-carbon materials, refining thermal processes, and exploring future pathways for sustainable production.