An integrated vacuum catalytic pyrolysis platform converts hydrocarbon waste into ULSD-grade multi-grade fuels at 15-120 Torr using a single vacuum pump as the sole driving force. The platform features selectable multi-mode vertical reactor isolation (dual-airlock, knife gate valve, or hybrid) scalable from pilot (7.5 m, five stages) to commercial (14 m, four stages) configurations, configurable horizontal reactor thermal management (multi-component achieving unexpectedly low thermal gradient under vacuum, dual-mode, or triple-mode), multi-layer nanocomposite catalyst with FIR emissive layer (including HEO option with self-regenerating noble metal nanoparticles), inline capillary-condensation desulfurization overcoming six Teaching Away references, physics-constrained neural network control with non-trainable hard-constraint layers optionally augmented by vision-based vapor monitoring, cyclone-type separators for continuous particulate and droplet removal without consumable media, and dual-medium staged condensation with boiling-range-classified product collection for direct multi-grade fuel segregation. Thirty claims differentiated over 31+ prior art references with 19 supporting examples.