CNX Vinyl · Steam and cooling plant · five-press fleet · proposed concept

Concept for the RFQs, not a construction drawing. Machine figures are Newbilt's published site requirements per press, extruder and hydraulic unit; boiler and chiller banks, tank sizes and pump duties are this repository's proposals and estimates until vendors quote. Click any piece of equipment.

Click any equipment

Each box explains what it does, the figures behind it with their source, and what the RFQ still has to settle. The buttons above switch between operating cases: which presses run, which modules are installed, and whether the plant covers the demand.

Design basis

Item	Figure	Source
Fleet	2 Duplex systems (4 HRP 12, 2 EX 50, 2 EX 35) + 1 Classic with built-in extruder; one central hydraulic and one air plant	pressing-line.mddoc
Steam per press	150 to 180 kg/h, min. 10 bar, 9.5 to 10.5 bar operating	Newbilt site requirements 3.2.3vendor
Press cooling water	up to 100 l/min, ~53 l/min used, in 20 to 25 °C at 10 bar, out ~60 °C, max. 2 bar (open)	site requirements 3.2.2vendor
Press cooling capacity	up to 125 kW per press, by cycle time	site requirements 3.2.2vendor
Extruder cooling	~4 l/min, 2 to 3 kW, in 20 to 25 °C, 5 to 10 bar	site requirements 3.3.3vendor
Hydraulic oil cooler	~8 l/min, up to 5 kW per aggregate (2.5 kW per press)	site requirements 3.4.2vendor
Cooling water quality	7 to 8 °dH, pH 7 to 9, ≤ 200 µm, ≤ 500 µS/cm, Cl ≤ 20 mg/l	site requirements 3.1.2vendor
Classic	counted as one HRP 12 + one extruder; Toolex Alpha cross-check 1.2 kg steam, 15 l water per cycle	fleet calculatorestimate
Five presses, full demand	steam 750 to 900 kg/h · cooling 652.5 kW · water 305 to 540 l/min	sum of the abovedoc
Chiller electrical input	~80 to 125 kW per 250 kW of cooling (air-cooled, hot season)	scale.mdestimate
Electric boiler alternative	~0.68 kWh per kg of steam at 98 %	fleet calculatorestimate
Annual steam heat	~1,170 MWh at 1.0 M records, ~1,750 MWh at the start fleet's full ~1.5 M	fleet calculator, biomass.mdestimate

Circulating water is not consumption: the loop recirculates. Boiler make-up is about 0.75 to 0.9 m³/h before condensate return, much less with it.

Equipment schedule (proposed)

Tag	Item	Duty	Phase	Status
WT-1	Duplex softener, dosing	~1.0 to 1.2 m³/h	launch	estimate
T-1	Feed tank / hotwell	~1.5 m³, 90 to 95 °C	launch	estimate
P-1	Feed pumps, duty/standby	~1 m³/h, ~13 bar	launch	estimate
B-1, B-2	Boiler modules, lead/lag	2 × 500 kg/h, 10.5 bar	B-1 launch, B-2 with Duplex 2	proposal
B-3	Third module for N+1	500 kg/h	option; position built at launch	RFQ option
B-4	Fourth position: pad, header branch, feeder	500 kg/h	growth, ~3 more presses	position only
ECON-1	Flue-gas economizer, fired boilers	feed in 90 to 95 °C, out by vendor	with a fired bank	1st measure
ACC-1	Steam accumulator	by cycle overlap	option	Newbilt option
HP-1	Heat-recovery heat pump	feed tank to 90 to 95 °C	if it pays	3rd measure
CH-1 to CH-3	Air-cooled chillers at 40 °C ambient	3 × 250 kW	one per press stage	proposal
CH-4	Fourth module for N+1	250 kW	option; pad built at launch	RFQ option
HX-1	Plate heat exchanger	~650 kW, ~2 K approach	launch: frame for 5, plates as presses arrive	estimate
TK-3, TK-2	Warm return / cold buffer tanks	~5 m³ each	launch	estimate
P-2, P-3, P-4	Transfer, VFD supply, primary pumps	up to ~540 l/min	launch, staged	estimate
TC-1	Dry cooler ahead of HX-1	~650 to 750 kW reject	option	RFQ option
GC	Galvanics cooling, separate	12 to 20 °C, 10 L/min per PDPU	phase 5	open

Phasing: backbone once, modules with the presses

Everything that is cheap to oversize now and costly to change in a running plant is built for the five-press fleet at launch; boilers, chillers and hydraulic pump sets come in identical modules as presses arrive. One controller sequences them lead and lag from the first module.

Stage	Steam	Cooling	Hydraulics, air
Launch (Single 2.1, one press)	hall for four modules; T-1, WT-1, P-1; mains with a valved, blanked branch per press position; B-1	compound with four pads; TK-2, TK-3 full size; HX-1 frame for ~650 kW, plates for one press; P-2 to P-4 on VFDs; CH-1	plant room full size; ring mains for the fleet, a capped tee per position; the Single 2.1 unit as the first pump set; one compressor
Duplex system 1	B-1 at 60 to 72 % load	CH-1 covers ~96 % of the peak: cold tank and cycle overlap, or CH-2 earlier	tap the ring main
Duplex system 2	B-2	CH-2	pump set on the manifold
Classic	B-1 and B-2	CH-3	pump set, if the Classic runs from the central plant
Options	B-3 (N+1), B-4 (growth), ACC-1, ECON-1	CH-4 (N+1), TC-1, pads for ~350 kW units	standby pump set

Rooms, four modules each (estimate)

Room	Size	Basis
Boiler hall	~18 × 9 m, 6 m high	four 3.5 m bays plus 4 m for T-1, WT-1, P-1 and the header; fired case (500 kg/h biomass body ~3.3 × 2.0 m); electric needs about half
Chiller compound	~12.5 × 10.8 m, open	four pads 4.0 × 2.6 m in two rows, screened; 250 kW at 40 °C is about a Carrier 30RB 080 to 090, 2.4 to 3.6 × 2.24 m
Pump and HX room	~8 × 5 m	HX-1, TK-2, P-2 to P-4, drives

Four boilers carry about eight presses with one in reserve. Four 250 kW chillers carry the five presses with CH-4 in reserve and leave no growth position, unless the pads take the larger frame (scale.md).

Open for the RFQs

Newbilt (re-quote)

Classic: steam, cooling, power, weight; can it run from the central hydraulic plant?
Central hydraulics: pressure at the presses over the ring-main lengths, filtration and isolation per branch, and whether the Single 2.1 unit can be the first central pump set.
Press return temperature over the cycle: 53 l/min at ~60 °C out of 20 to 25 °C is ~140 kW, more than the stated 125 kW peak. The real profile sizes HP-1, HX-1 and TC-1.
Is the accumulator needed with a modular boiler bank, and how big?
Condensate: the 2024 offer has one steam/water outlet valve and a steam trap per mould. How much cooling water reaches the trap per cycle, and can that condensate go back to boiler feed?

Boilers (Miura, Bangkok Industrial Boilers, STE)

2 × 500 kg/h against 3 × 500 kg/h and 1 × 1 t/h: price, footprint, lead/lag control, service from Chiang Mai.
Fuel: electric, biomass or LPG (sustainability.md, biomass.md); the electric bank draws ~520 to 625 kW.
Economizer on a fired bank: outlet feed and stack temperature, corrosion limit, pressure drop; rice husk ash is high in silica and abrasive, so fouling, cleaning, wear protection and a bypass.
Blowdown cooling to the effluent limit; boiler registration and licensed operator (facility-security.md).
Footprint per module with fuel feed, dust collector and fan, against the ~18 × 9 m hall laid out for four modules.

Chillers (Trane, Carrier, Daikin Applied, Hitachi)

3 × 250 kW against 3 × 350 kW (N+1), rated at 40 °C ambient; part-load efficiency.
Plate heat exchanger and tanks in scope; dry cooler TC-1 as a priced option.
Clearance drawing for four units in two rows of two; pads for the ~350 kW frame as a priced option (four would then carry about eight presses with one in reserve).

Site

Water analysis before either RFQ: it decides softener or RO and the loop treatment.
Grid: ~800 to 1,000 kVA without electric steam, 1,250 to 1,600 kVA with it (scale.md).

Legend

Saturated steam 10 bar

Condensate return

Treated feedwater

Raw / make-up water

Process cooling supply 20 to 25 °C

Process cooling return, open

Chiller loop, cold

Chiller loop, warm

Heat recovery feedwater loop

Blowdown, drains

Flue gas

°CTemperature, Newbilt figure

°CDesign target or estimate

TBDSet by the vendor or by measurement

Dashed boxes are options. Bow-ties are isolation or control valves (a stem marks a control valve), squares strainers, T a steam trap. Circles are instruments: PT pressure, TT temperature, FT flow, AT conductivity (off-spec condensate goes to the warm tank); every one is logged to the plant data platform (digital-factory.md). Flow times supply and return temperature on each branch gives that press's cooling load; steam flow against records pressed gives steam per record.