diff --git a/README.md b/README.md index 0a1fd0d..1c88e65 100644 --- a/README.md +++ b/README.md @@ -164,6 +164,14 @@ The detail lives in dedicated documents: (for artists, labels and any other customer), and optionally launch a fan-funded campaign that the plant presses and ships to each fan once enough have pre-ordered, with refunds if not +- [Steam and cooling](docs/steam-cooling.html): the utility plant for the + five-press fleet as a clickable process diagram: water treatment, feed + tank and heat recovery, a bank of two 500 kg/h boilers, the steam header + and condensate return, and process cooling with three 250 kW chillers, + a plate heat exchanger, warm and cold tanks and a branch to every press, + extruder and the hydraulic oil cooler; operating cases from the launch + press to one module down, the design basis, an equipment schedule and + the open questions for the boiler and chiller RFQs - [Plant operation page](docs/plant-operation.html): a single static page animating the mature plant as a simulated SCADA overview at real cycle times: the Newbilt Duplex and two Classic presses, the Pheenix Alpha @@ -277,6 +285,7 @@ docs/ ├── roadmap.md Next steps in dependency order ├── scale.md Rough project sizing on one page ├── site-candidates.md Land options and the checks before choosing +├── steam-cooling.html Steam and cooling plant diagram, five-press fleet ├── sustainability.md Energy, water, materials commitments ├── traceability.md Process logging and per-order traceability └── worker-safety.md Training, clean rooms, PPE diff --git a/docs/biomass.md b/docs/biomass.md index bfb2803..b075311 100644 --- a/docs/biomass.md +++ b/docs/biomass.md @@ -10,16 +10,21 @@ and duty cycle. ## Demand: what the boiler would burn -The 400 kg/h boiler is roughly 300 kW thermal at full fire. With the heat -recovery architecture trimming the load and realistic duty cycles: +The five-press fleet draws 750 to 900 kg/h of steam at full demand, ~510 +to 610 kW thermal, from a proposed bank of two 500 kg/h boilers +([steam and cooling](steam-cooling.html)). Fuel follows records pressed, +not presses installed. With the heat recovery architecture trimming the +load and realistic duty cycles: -- Mature plant (semi-auto plus automated lines, two shifts, ~300 days/yr): - roughly **350 to 400 tonnes of air-dry wood per year** (at ~80% boiler - efficiency and ~4 kWh/kg air-dry wood) +- Mature plant (two shifts, ~300 days/yr, about 1.0 to 1.1 million + records): roughly **350 to 400 tonnes of air-dry wood per year** (at + ~80% boiler efficiency and ~4 kWh/kg air-dry wood); the start fleet at + its full ~1.5 million records needs up to **~550 t/yr** - Early operations (one press line, single shift): roughly a quarter of that, **~90 to 100 t/yr** - Bought as fresh wood chips (~45 % moisture, ~2.6 kWh/kg) the same heat - is **~540 to 620 t/yr**, which is what the fuel store and the monsoon + is **~540 to 620 t/yr**, up to ~840 t/yr at 1.5 million records, which + is what the fuel store and the monsoon stock have to be sized for (estimate) ## The 60 rai: own-grown fuelwood @@ -31,7 +36,8 @@ proven in Thailand (eucalyptus, acacia, leucaena, bamboo) yield roughly 8 to about **80 to 135 t/yr**: - Enough to cover **most or all of early operations** -- About **a quarter to a third of mature two-shift demand** +- About **a fifth to a third of mature two-shift demand** at ~1.0 million + records, a seventh to a quarter at the start fleet's full 1.5 million That makes the land a meaningful supplement and a strong brand story ("records pressed with steam from our own trees"), not a complete fuel @@ -139,10 +145,10 @@ storage are additional. - The 60 rai tilts the economics and the story further toward biomass, but only after the land-title check clears - The electric boiler remains the alternative: cleanest permitting, no fuel - logistics, but effectively grid-powered steam at a ~300 kW draw. On - PEA's time-of-use tariff that costs ~4.7M to 5.5M THB a year at mature - load against ~0.6M to 1.2M of fuel for biomass, and ~1.4M to 1.7M - against ~0.15M to 0.3M at early load, because the demand charge follows + logistics, but effectively grid-powered steam at a ~520 to 625 kW draw + for the five presses. On PEA's time-of-use tariff that costs ~5.2M to + 6.0M THB a year at mature load against ~0.6M to 1.2M of fuel for + biomass, and ~1.6M to 1.8M (one 500 kg/h module) against ~0.15M to 0.3M at early load, because the demand charge follows the boiler's full-power draw (estimates; see the [grid tariff](sustainability.md#grid-tariff-pea-and-what-it-decides)). The electric boiler is the more efficient machine; biomass is the far @@ -151,6 +157,6 @@ storage are additional. the coppice now (first harvest in 2 to 4 years), and add the biomass boiler at the automated-line expansion when demand and the fuel supply have both matured. At the tariff above that is a permitting and logistics - choice, not a cost one: every year on electric steam costs roughly 1.1M - to 4.9M THB more than biomass, so the switch should come as soon as the + choice, not a cost one: every year on electric steam costs roughly 1.4M + to 5.4M THB more than biomass, so the switch should come as soon as the permit and a fuel contract are in place diff --git a/docs/equipment/pressing-line.md b/docs/equipment/pressing-line.md index d1ba251..e966f24 100644 --- a/docs/equipment/pressing-line.md +++ b/docs/equipment/pressing-line.md @@ -78,14 +78,17 @@ automated candidate). What it means: two shifts, the range the [revenue model](../finance/revenue-model.md) uses: four semi-automatic presses at 60 to 80 records an hour (estimate) and the Classic at ~128 an hour (28 s cycle, vendor figure). -- **Utilities do not scale from the old figures.** At Newbilt's per-press - figures (steam 150 to 180 kg/h, cooling up to 125 kW per press), five - presses draw ~750 to 900 kg/h of steam and up to ~625 kW of cooling, - against the ~400 kg/h steam generator and ~250 kW cooling system that the - 2024 quote's exclusions describe for one Duplex. The boiler, chiller, - electrical connection and [utilities CSV](../finance/utilities-investment.csv) - are **not yet re-sized** for this fleet; that waits for the re-quote's - figures ([scale](../scale.md)). +- **Utilities, re-based for this fleet (October 2026).** At Newbilt's + per-machine figures (steam 150 to 180 kg/h, cooling up to 125 kW per + press) the five presses draw ~750 to 900 kg/h of steam and up to ~650 kW + of cooling with extruders and hydraulics, against the ~400 kg/h steam + generator and ~250 kW cooling system that the 2024 quote's exclusions + describe for one Duplex. The proposal is a bank of two 500 kg/h boilers + and three 250 kW chillers, one module per press stage; the layout, the + operating cases and the open RFQ questions are in + [steam and cooling](../steam-cooling.html), the electrical consequences in + [scale](../scale.md) and the costs in the + [utilities CSV](../finance/utilities-investment.csv). - **Investment**: the fleet change is carried in the added-scope table of [total investment](../finance/total-investment.md) until the next re-base. diff --git a/docs/facility-security.md b/docs/facility-security.md index a19714e..bfa2b7d 100644 --- a/docs/facility-security.md +++ b/docs/facility-security.md @@ -28,7 +28,8 @@ option per room. sensors logging in every zone, with alarms on excursions, tied into the plant monitoring below. - **Energy design**: conditioning a whole factory in a tropical climate is - a major electrical load on top of the 250 kW process cooling, and it must + a major electrical load on top of the process cooling (up to ~650 kW for + the five presses), and it must be included in the solar PV and battery sizing from the start. Heat recovery from the press hall (steam, hydraulics, and hot PVC all reject heat) and from compressors should feed the design rather than fight it. diff --git a/docs/finance/total-investment.md b/docs/finance/total-investment.md index 2227fa0..8d11d44 100644 --- a/docs/finance/total-investment.md +++ b/docs/finance/total-investment.md @@ -23,7 +23,7 @@ July 2026; the underlying THB estimates are unchanged, because EUR/THB at | Stamper prep (Sibert VSP, VSF, VSC) | 60k – 170k | 1.9M – 5.7M | estimate kept until the re-base; Sibert has since confirmed USD 250k for the three (its time, spares, shipping and travel extra), the difference is in the table below | | Mastering and cutting room (Agnew or Sillitoe lathe system, cutter amps, console, room treatment) | 290k – 580k | 9.6M – 19.1M | estimate, bespoke market; the Sillitoe SDMS lists at USD 125k for lathe, head, amplifier and automation (ex tax, shipping), which makes the low end reachable; band kept until both quotes exist | | Metrology and QC stack (confocal, profiler, XRF, inline vision, audio station) | 350k – 810k | 11.5M – 26.7M | estimate, phaseable | -| Utilities, solar, HVAC, racking baseline | 730k – 1,270k | 24.0M – 41.6M | reviewed [utilities CSV](utilities-investment.csv), THB-native | +| Utilities, solar, HVAC, racking baseline | 730k – 1,270k | 24.0M – 41.6M | reviewed [utilities CSV](utilities-investment.csv), THB-native; sized for one Duplex, the five-press re-size is in the table below | | Building ~1,500 m² plus civil works | 650k – 1,100k | 21.4M – 36.2M | estimate at 12,000–20,000 THB/m² Thai industrial construction plus ~20% site works | | Land 6–8 rai, if purchased | 360k – 970k | 12.0M – 32.0M | estimate at 2–4M THB/rai industrial; leasing cuts this to near zero upfront | | Traceability and factory software | 60k – 170k | 1.9M – 5.7M | estimate | @@ -47,8 +47,9 @@ building, software and stamper prep lines, and the contingency on top). | Artist platform, public side (calculator, campaigns, payments) | 40k – 90k | 1.3M – 3.0M | estimate, [artist platform](../artist-platform.md) | | PVC material lab, day-one tier (incl. plaque press and sample conditioning) | 55k – 150k | 1.8M – 5.0M | estimate, [quality automation](../quality-automation.md); not costed in the metrology block above. The mature tier (torque rheometer, DSC, FTIR, ~120k – 240k) is deferred, with partner labs in between | | Stamper prep re-priced: USD 250k for VSP, VSF and VSC against the 60k – 170k block above | +190k (low case) / +80k (high case) | +6.3M / +2.6M | Sibert's budget confirmation, email of 5 October 2026 ([galvanics and stamper prep](../equipment/galvanics.md)); itemised quotation to follow. Its time, spare parts, shipping and travel are extra and fall into the freight/installation and spares blocks above | -| Press fleet changed (October 2026) to two Newbilt Duplex systems (two presses each, EX 50 main extruder and EX 35 colour extruder) plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k; the quote's second-extruder option becomes the EX 35), system 2 ~230k – 300k (two presses at the quoted ~115k per press and extruder set as the yardstick, plus hydraulic unit and EX 35, estimate; no EX 35 price on file), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, [pressing line](../equipment/pressing-line.md); the Newbilt re-quote replaces it. The utilities for five presses are not re-sized yet ([scale](../scale.md)) | -| **Added so far** | **~420k – 610k** | **~13.8M – 20.2M** | about 8 to 10% on the full-vision subtotal | +| Press fleet changed (October 2026) to two Newbilt Duplex systems (two presses each, EX 50 main extruder and EX 35 colour extruder) plus one Newbilt Classic, replacing the two blocks above (930k – 1,290k): Duplex system 1 as the first block (350k – 370k; the quote's second-extruder option becomes the EX 35), system 2 ~230k – 300k (two presses at the quoted ~115k per press and extruder set as the yardstick, plus hydraulic unit and EX 35, estimate; no EX 35 price on file), the Classic ~290k – 460k (the AD12 band per press as a placeholder; no Newbilt price on file) | −60k (low case) / −160k (high case) | −2.0M / −5.3M | estimate, [pressing line](../equipment/pressing-line.md); the Newbilt re-quote replaces it. The utilities for five presses are re-sized in the row below | +| Utilities re-sized for the five-press fleet (October 2026): boiler bank 2 × 500 kg/h, chiller bank 3 × 250 kW with plate heat exchanger and tanks, larger softener and loop treatment ([steam and cooling](../steam-cooling.html)) | +185k (low case) / +294k (high case) | +6.1M / +9.7M | estimate, [utilities CSV](utilities-investment.csv) re-based from 24.0M – 41.6M to 30.1M – 51.3M THB | +| **Added so far** | **~605k – 905k** | **~19.9M – 29.9M** | about 12 to 15% on the full-vision subtotal | ## Phased entry diff --git a/docs/finance/utilities-investment.csv b/docs/finance/utilities-investment.csv index e24c48d..e19dc74 100644 --- a/docs/finance/utilities-investment.csv +++ b/docs/finance/utilities-investment.csv @@ -1,18 +1,18 @@ category,item,spec_summary,candidate_thai_suppliers,cost_low_thb,cost_high_thb,cost_basis,notes -steam,Electric/gas once-through boiler package,"~400-500 kg/h at 10 bar / 180 C incl. softener, feed tank, economizer, installed","Miura Thailand (Chachoengsao); Bangkok Industrial Boilers; STE Thailand",2500000,4000000,engineering estimate,"Miura-class modular once-through; BIB budget option ~2.0-3.5M; service is Bangkok-centric, confirm northern dispatch SLA" -steam,Biomass/wood-fired boiler package (option),"~0.5 t/h solid fuel (wood chips/pellets/rice husk) incl. fuel feed, grate, dust control, softener, installed",Getabec PCL (Thai fabrication and service),4000000,7000000,engineering estimate,"Sustainability path matching Deepgrooves NL precedent; Viessmann has no strong Thai channel; higher capex, lower fuel opex in the North; NOT included in baseline total" -steam,Steam balance of plant,"Traps, accumulator, condensate return",Forbes Marshall Thailand,0,0,included,"Largely included in boiler package rows; line kept for RFQ completeness" -compressed_air,Screw compressor skid (oil-injected),"~7.5 kW VSD screw + refrigerated dryer (3 C PDP) + coalescing filters + ~500 L receiver, installed","Atlas Copco Thailand; Kaeser Thailand (SM-T/Aircenter); Ingersoll Rand Thailand",350000,600000,engineering estimate,"14-30 m3/h demand is small (5-10 hp class); oil-injected + filter train meets 5 micron / 3 C spec" -compressed_air,True oil-free class-0 (option),Same duty in oil-free class-0,"Atlas Copco (ZR/ZT); Kaeser",1200000,1800000,engineering estimate,"Only if air contacts product stream; NOT included in baseline total" -cooling,Process chiller package 250 kW,"~71 RT air-cooled screw/scroll chiller + pumps + buffer tank + controls, installed, closed loop","Trane Thailand; Carrier Thailand; Daikin Applied Thailand; Hitachi Thailand",2500000,4000000,engineering estimate,"Newbilt spec: 220 l/min peak, 20-25 C supply; chiller is the safe choice for hot-season wet-bulb" -cooling,Cooling tower + HX loop (alternative),"FRP tower ~250-300 kW reject + plate HX + pumps + tanks + water treatment","Liang Chi Thailand (tower, large service org); Process Cooling Solutions; Tasaki (integrators)",1000000,2000000,engineering estimate,"Cheaper capex but wet-bulb-limited; hybrid tower + trim chiller is the efficiency-optimal design; NOT included in baseline total" -water,Boiler feedwater duplex softener,~0.5-0.8 m3/h feedwater duty,"Veolia Water Technologies Thailand; Hydrotek; local RO/softener integrators",80000,200000,market estimate,May suffice alone for a small fire-tube boiler -water,RO skid (option),0.5-1 m3/h low-TDS feed,"Veolia; Hydrotek; local integrators",200000,500000,market estimate,"Only if low-TDS feed needed; NOT included in baseline total" -water,Closed-loop cooling water treatment,"Side-stream filtration + dosing + conductivity blowdown control",Veolia; Hydrotek; local integrators,150000,400000,engineering estimate,Chemicals are ongoing opex on top +steam,Electric/gas once-through boiler bank,"2 x 500 kg/h modules at 10.5 bar / 180 C, lead/lag, shared feed tank, feed pumps, economizer, installed",Miura Thailand (Chachoengsao); Bangkok Industrial Boilers; STE Thailand,4500000,7000000,engineering estimate,"Five-press fleet 750-900 kg/h (steam-cooling.html); B-1 with the launch press, B-2 with Duplex 2; a third module for N+1 is an RFQ option; Miura-class modular once-through; service is Bangkok-centric, confirm northern dispatch SLA" +steam,Biomass/wood-fired boiler package (option),"~1 t/h solid fuel (wood chips/pellets/rice husk) incl. fuel feed, grate, dust control, softener, installed",Getabec PCL (Thai fabrication and service),6000000,10000000,engineering estimate,"Sized for the five-press fleet (was ~0.5 t/h for one Duplex); sustainability path matching Deepgrooves NL precedent; higher capex, lower fuel opex in the North; NOT included in baseline total" +steam,Steam balance of plant,"Traps, accumulator, condensate return",Forbes Marshall Thailand,0,0,included,Largely included in boiler package rows; line kept for RFQ completeness +compressed_air,Screw compressor skid (oil-injected),"~7.5 kW VSD screw + refrigerated dryer (3 C PDP) + coalescing filters + ~500 L receiver, installed",Atlas Copco Thailand; Kaeser Thailand (SM-T/Aircenter); Ingersoll Rand Thailand,350000,600000,engineering estimate,14-30 m3/h demand is small (5-10 hp class); oil-injected + filter train meets 5 micron / 3 C spec +compressed_air,True oil-free class-0 (option),Same duty in oil-free class-0,Atlas Copco (ZR/ZT); Kaeser,1200000,1800000,engineering estimate,Only if air contacts product stream; NOT included in baseline total +cooling,Process chiller bank 3 x 250 kW,"3 x ~71 RT air-cooled screw/scroll chillers rated at 40 C ambient + primary pumps + plate HX + warm and cold tanks + VFD supply pumps + controls, installed",Trane Thailand; Carrier Thailand; Daikin Applied Thailand; Hitachi Thailand,6500000,10500000,engineering estimate,"Five-press fleet up to ~650 kW and 305-540 l/min (Newbilt site requirements, 20-25 C supply); one module per press stage; 3 x 350 kW for N+1 as the alternative (steam-cooling.html)" +cooling,Cooling tower + HX loop (alternative),Dry cooler or FRP tower ~650-750 kW reject + plate HX + pumps + tanks + water treatment,"Liang Chi Thailand (tower, large service org); Process Cooling Solutions; Tasaki (integrators)",2000000,3500000,engineering estimate,Cheaper capex but wet-bulb-limited; hybrid tower + trim chiller is the efficiency-optimal design; NOT included in baseline total +water,Boiler feedwater duplex softener,~1.0-1.2 m3/h feedwater duty (five-press boiler bank),Veolia Water Technologies Thailand; Hydrotek; local RO/softener integrators,120000,300000,market estimate,May suffice alone for a small fire-tube boiler +water,RO skid (option),0.5-1 m3/h low-TDS feed,Veolia; Hydrotek; local integrators,200000,500000,market estimate,Only if low-TDS feed needed; NOT included in baseline total +water,Closed-loop cooling water treatment,Side-stream filtration + dosing + conductivity blowdown control,Veolia; Hydrotek; local integrators,200000,500000,engineering estimate,"Sized for the five-press loop with its open return tank (Newbilt press outlets are open, max. 2 bar); chemicals are ongoing opex on top" water,Galvanics ZLD evaporator (future),"Small MVR or low-temp vacuum evaporator for plating rinse, installed","Core unit imported (WTEYA, Greenlan, Fred); Thai integration via Veolia or Hydrotek",3000000,8000000,market estimate,"For the future galvanics line, zero-discharge requirement; NOT included in baseline total" -storage,Pallet racking and shelving,"100-200 pallet positions selective/heavy-duty (beams sized 1000-1500 kg/pallet, records are dense) + archive and finished-goods shelving, installed","Jenbunjerd; local fabricators (Sahawatthanakit, UPR, SD Shelf); SSI Schaefer (premium)",800000,1500000,published list prices + engineering estimate,"SSI Schaefer premium tier ~1.5-3M for same scope; ~1000-2000 THB per pallet position at local tier" +storage,Pallet racking and shelving,"100-200 pallet positions selective/heavy-duty (beams sized 1000-1500 kg/pallet, records are dense) + archive and finished-goods shelving, installed","Jenbunjerd; local fabricators (Sahawatthanakit, UPR, SD Shelf); SSI Schaefer (premium)",800000,1500000,published list prices + engineering estimate,SSI Schaefer premium tier ~1.5-3M for same scope; ~1000-2000 THB per pallet position at local tier hvac,Whole-factory HVAC,"~1500 m2 at 20-26 C, 35-60% RH, ePM1/F7-F9 filtration sized for burning-season PM2.5, ducting and controls","Daikin Thailand; Trane; Mitsubishi Electric; Carrier; filtration: Camfil Thailand, AAF",7500000,15000000,engineering estimate at 5000-10000 THB/m2,"RH low end of 35% is aggressive for tropics and drives desiccant cost; if 45-60% RH acceptable, cost drops materially" -hvac,Clean-room-grade zone adder,"Cutting room + galvanics clean room, ~2 x 60 m2, ISO 7/8 with HEPA terminals, positive pressure, airlocks","Same HVAC vendors + clean-room contractors; Camfil HEPA",1200000,3400000,engineering estimate at 10000-28000 THB/m2 adder,Applied only to the two tight zones -solar,PV rooftop EPC (illustrative 300 kWp),"Turnkey C&I rooftop EPC incl. Deye hybrid inverters, at 25000-35000 THB/kWp","Solar Nicolo (Deye tier-1 distributor); Banpu NEXT; SCG Cleanergy; Sermsang; local Chiang Mai installers",7500000,10500000,market rate per kWp; size illustrative,"Final kWp open until site selection; PEA TOU 3.2.2 plus Ft (Sep-Dec 2026): self-consumed PV worth ~3.7 THB/kWh, ~4.5-7 yr payback (sustainability.md, grid tariff)" -solar,Battery stack 271 kWh (Gobel),"GP-SRA-HV314 HV LiFePO4 rack, 15 x 18 kWh packs, direct from Shenzhen, 50-60 day lead",Gobel Power (no Thai distributor; integration by solar EPC),1400000,2030000,vendor listed price USD 39900-58000 at ~35 THB/USD,"Confirm Deye BMS protocol compatibility and that the EPC warrants a mixed-vendor DC bus; certs (UN38.3/IEC 62619/CE) to be requested" -total,BASELINE TOTAL,"Electric steam + oil-injected air + chiller + softener + loop treatment + local racking + HVAC + clean zones + 300 kWp solar + 271 kWh BESS",,23980000,41630000,sum of baseline rows,"~630k-1100k EUR at 38 THB/EUR; excludes options rows (biomass premium, oil-free, tower alternative, RO, ZLD evaporator, SSI premium tier); all figures budgetary +/- 30%, get RFQs before BOI/finance filings" +hvac,Clean-room-grade zone adder,"Cutting room + galvanics clean room, ~2 x 60 m2, ISO 7/8 with HEPA terminals, positive pressure, airlocks",Same HVAC vendors + clean-room contractors; Camfil HEPA,1200000,3400000,engineering estimate at 10000-28000 THB/m2 adder,Applied only to the two tight zones +solar,PV rooftop EPC (illustrative 300 kWp),"Turnkey C&I rooftop EPC incl. Deye hybrid inverters, at 25000-35000 THB/kWp",Solar Nicolo (Deye tier-1 distributor); Banpu NEXT; SCG Cleanergy; Sermsang; local Chiang Mai installers,7500000,10500000,market rate per kWp; size illustrative,"Final kWp open until site selection; PEA TOU 3.2.2 plus Ft (Sep-Dec 2026): self-consumed PV worth ~3.7 THB/kWh, ~4.5-7 yr payback (sustainability.md, grid tariff)" +solar,Battery stack 271 kWh (Gobel),"GP-SRA-HV314 HV LiFePO4 rack, 15 x 18 kWh packs, direct from Shenzhen, 50-60 day lead",Gobel Power (no Thai distributor; integration by solar EPC),1400000,2030000,vendor listed price USD 39900-58000 at ~35 THB/USD,Confirm Deye BMS protocol compatibility and that the EPC warrants a mixed-vendor DC bus; certs (UN38.3/IEC 62619/CE) to be requested +total,BASELINE TOTAL,Electric steam bank + oil-injected air + chiller bank + softener + loop treatment + local racking + HVAC + clean zones + 300 kWp solar + 271 kWh BESS,,30070000,51330000,sum of baseline rows,"Five-press fleet (October 2026; was 23.98M-41.63M THB for one Duplex); ~790k-1350k EUR at 38 THB/EUR; excludes options rows (biomass premium, oil-free, tower alternative, RO, ZLD evaporator, SSI premium tier); all figures budgetary +/- 30%, get RFQs before BOI/finance filings" diff --git a/docs/fleet-calculator.html b/docs/fleet-calculator.html index 8a85c3b..ddefb96 100644 --- a/docs/fleet-calculator.html +++ b/docs/fleet-calculator.html @@ -473,7 +473,7 @@ grp("Stamper making", [ grp("Energy", [ ["kwhPrice", "Electricity, blended", 3.81, "THB/kWh", "doc", "scale.md: PEA TOU 3.2.2 at two shifts, before the demand charge (Ft September to December 2026)"], ["demandPrice", "Demand charge", 132.93, "THB/kW a month", "doc", "PEA 3.2.2 (scale.md)"], - ["restKW", "Rest of the plant while running", 120, "kW", "est", "Estimate: HVAC, lighting, galvanics, finishing, offices; puts the start fleet in scale.md's 4.3 to 6.4M THB a year before PV"], + ["restKW", "Rest of the plant while running", 120, "kW", "est", "Estimate: HVAC, lighting, galvanics, finishing, offices; puts the start fleet in scale.md's 4.5 to 6.8M THB a year before PV"], ["pvKWp", "Roof PV", 247, "kWp", "doc", "scale.md"], ["pvYield", "PV yield, all self-consumed", 1400, "kWh/kWp", "doc", "scale.md: 1,400 to 1,500 kWh/kWp a year in northern Thailand"], ["heatPrice", "Steam heat from biomass", 0.7, "THB/kWh", "doc", "biomass.md: 0.5 to 0.9 at 1.35 to 2 THB/kg delivered"], @@ -506,8 +506,8 @@ grp("Workwear: Engelbert Strauss for all staff", [ ["wwDuty", "Thai import duty on workwear", 14, "%", "doc", "HS 6203 work trousers 13.8 % (customs-compliance.ai, March 2026); BOI does not cover clothing; import VAT reclaimable"], ]); grp("Planned plant, for the checks", [ - ["boiler", "Steam boiler", 400, "kg/h", "doc", "scale.md: sized for one Duplex system"], - ["chiller", "Chiller", 250, "kW", "doc", "scale.md: sized for one Duplex system"], + ["boiler", "Steam boiler bank", 1000, "kg/h", "doc", "steam-cooling.html and scale.md: 2 × 500 kg/h modules (proposal, estimate)"], + ["chiller", "Chiller bank", 750, "kW", "doc", "steam-cooling.html and scale.md: 3 × 250 kW air-cooled modules (proposal, estimate)"], ["hall", "Payap press hall", 870, "m²", "doc", "site-candidates.md, Payap scenario model"], ]); const A0 = Object.fromEntries(AS.map(r => [r[1], r[3]])); diff --git a/docs/plant-operation.html b/docs/plant-operation.html index 0e51f19..72bf168 100644 --- a/docs/plant-operation.html +++ b/docs/plant-operation.html @@ -949,13 +949,13 @@ const DETAILS={ finish:{t:'7b · Finishing',w:'Inner sleeve and, once assembled, the shrink wrapper. The labels are already on: they were pressed in.',c:['Inner sleeve scuff check per lot','Shrink wrap sampled'],f:['2 to 3 days per order (production timeline)']}, pack:{t:'8 · Packaging and assembly',w:'The runout matrix code is scanned against the jacket barcode, so the wrong record in the right jacket is caught every time.',c:['Matrix code vs jacket barcode on every unit','Barcode verification'],f:['Packaging and finished goods ~300 to 500 m²']}, ship:{t:'9 · Fulfillment',w:'Bulk pallets, or per-parcel dropship for the label; carrier tracking joins the traceability record. Test pressings leave here for the artists.',c:['Consignment vs bill of materials','Tracking per shipment or per end customer'],f:['Quoted lead time 7 to 9 weeks mature, 2 to 3 weeks for a repress']}, - boiler:{t:'Steam boiler',w:'Saturated steam at 10 bar / 180 °C heats the moulds; each press draws ~1.3 kg per cycle. Four presses need 600 to 720 kg/h at Newbilt\'s 150 to 180 kg/h per press, so the boiler is shown at 800 kg/h. That is an estimate: scale.md sizes the boiler at 400 kg/h, which covers the Duplex alone. Below 9.5 bar the presses hold in STEAM (Steam dip button).',c:['Pressure held between 9.5 and 10.5 bar at the press','Feedwater treatment, condensate return'],f:['Fuel decision open: biomass, LPG or electric','Detached boiler hall with a 14 m flue','scale.md\'s 400 kg/h is the Duplex figure; to be re-based for the four-press fleet']}, - chiller:{t:'Process cooling',w:'Cooling water sets the vinyl after the steam phase. The four presses here can need up to 125 kW each, so the chiller is shown at 500 kW (estimate; scale.md\'s 250 kW is the Duplex figure). If the supply water runs warm, the Classics stretch their cooling and their cycle. The galvanics plating units take a small branch at 12 to 20 °C.',c:['Supply 20 to 25 °C, closed loop','Up to 100 l/min per press, ~53 l/min average (site requirements)'],f:['~80 to 125 kW electrical per 250 kW of cooling','PDPU coil: 10 L/min at 12 to 20 °C (2024 flyer)']}, + boiler:{t:'Steam boiler',w:'Saturated steam at 10 bar / 180 °C heats the moulds; each press draws ~1.3 kg per cycle. Four presses need 600 to 720 kg/h at Newbilt\'s 150 to 180 kg/h per press, so the boiler is shown at 800 kg/h. That is an estimate for this four-press page; the five-press plan (scale.md, steam-cooling.html) is a bank of two 500 kg/h modules. Below 9.5 bar the presses hold in STEAM (Steam dip button).',c:['Pressure held between 9.5 and 10.5 bar at the press','Feedwater treatment, condensate return'],f:['Fuel decision open: biomass, LPG or electric','Detached boiler hall with a 14 m flue','Five-press plan: 750 to 900 kg/h on a 2 × 500 kg/h boiler bank (steam-cooling.html)']}, + chiller:{t:'Process cooling',w:'Cooling water sets the vinyl after the steam phase. The four presses here can need up to 125 kW each, so the chiller is shown at 500 kW (estimate for this four-press page; the five-press plan is a 3 × 250 kW chiller bank, steam-cooling.html). If the supply water runs warm, the Classics stretch their cooling and their cycle. The galvanics plating units take a small branch at 12 to 20 °C.',c:['Supply 20 to 25 °C, closed loop','Up to 100 l/min per press, ~53 l/min average (site requirements)'],f:['~80 to 125 kW electrical per 250 kW of cooling','PDPU coil: 10 L/min at 12 to 20 °C (2024 flyer)']}, comp:{t:'Compressed air',w:'Dry, filtered air for the press and extruder actuators, the Sibert machines and the silvering unit.',c:['Dew point max 3 °C, impurities max 5 µm'],f:['14 m³/h for a Duplex system (site requirements)','Sibert: 6 to 8 bar, 3.1 to 4.5 L/s per machine in use; PASU 6 bar']}, hyd:{t:'Hydraulic aggregate (Duplex)',w:'One aggregate supplies ~150 t to both Duplex presses at 180 bar from a gas-loaded accumulator. A larger central supply shared by several systems is possible (Duplex flyer); how the Classics are supplied is a re-quote question.',c:['Oil temperature and pressure logged'],f:['200 l HLP 46, 15 kVA, 12 kW average, 600 kg (site requirements)']}, diro:{t:'RO / DI water',w:'Plating rinses need deionised water: the PMPB bench has a DI connection and the silvering chemistry is made up with it.',c:['Conductivity logged'],f:['The RO skid in the utilities CSV is an option row sized for boiler feed, not for this (galvanics.md)','0.2 m³/h make-up here (estimate)']}, zld:{t:'Water treatment, zero discharge',w:'Galvanics rinse water and the VSF\'s nickel-bearing loop water go through closed-loop treatment and metal recovery with an evaporator; nothing goes to the drain. Neither Pheenix nor Digital Matrix supplies this; it is a separate vendor.',c:['Rinse conductivity, evaporator state'],f:['Zero contaminated water commitment (sustainability.md)','USD 90k to 240k (total investment)']}, - energy:{t:'Energy',w:'247 kWp of roof PV, a 271 kWh battery for peak shaving and ride-through, and a medium-voltage PEA connection. Solar follows the clock; the battery covers the evening.',c:['Plant peak 300 to 450 kW without an electric boiler'],f:['Galvanics ~27 kVA connected per line, far less drawn (galvanics.md)','PV covers roughly 28 to 45 % of consumption without electric steam']}, + energy:{t:'Energy',w:'247 kWp of roof PV, a 271 kWh battery for ride-through, and a medium-voltage PEA connection. Solar follows the clock; the battery covers the evening.',c:['Plant peak ~430 to 700 kW without an electric boiler (five-press plan, scale.md)'],f:['Galvanics ~27 kVA connected per line, far less drawn (galvanics.md)','PV covers roughly 28 to 45 % of consumption without electric steam']}, trace:{t:'Traceability',w:'Every step logs at the source: press and rectifier PLCs, the lab, the XRF, the vision station; manual steps check in. Append-only, kept for the life of the customer relationship.',c:['Record key: stamper + press + cycle timestamp + side','Every part knows its parents: stamper, mother, father, lacquer'],f:['The part of the plan the industry responded to at Making Vinyl Europe 2026']}, hvac:{t:'Plant HVAC',w:'The press hall at 20 to 26 °C and 35 to 60 % RH; galvanics, archive and audio rooms in their own zones, logged on the production timeline.',c:['T, RH and PM per zone'],f:['~100 to 200 kW peak (estimate)']}, exh:{t:'Galvanics extraction',w:'Every tank unit is extracted (Ø63 mm per plating unit, Ø125 mm at 150 m³/h on the silvering unit) through a scrubber. The interlock is hard-wired: no extraction, no plating.',c:['Fan status logged, interlock hard-wired'],f:['Facility security: fume-extraction interlocks']}, diff --git a/docs/scale.md b/docs/scale.md index 6f60e4e..3cfff5c 100644 --- a/docs/scale.md +++ b/docs/scale.md @@ -174,34 +174,36 @@ conversion, which forestry land generally does not. | Load | Rough figure | |---|---| -| Pressing machinery (two Duplex systems + the Classic) | ~90 to 120 kW installed (estimate: 32 kVA per Duplex system by Newbilt's requirements; the second extruders and the Classic not yet published) | -| Process chiller (250 kW cooling) | ~80 to 125 kW electrical | +| Pressing machinery (two Duplex systems + the Classic, central hydraulics) | ~118 kVA connected, ~73 kW average while running (Newbilt per-machine figures; the EX 35 and the Classic counted like the EX 50 and an HRP 12 until published) | +| Chiller bank (up to ~650 kW cooling) | ~210 to 325 kW electrical at the peak (~80 to 125 kW per 250 kW of cooling, air-cooled, hot season; estimate) | | Whole-factory HVAC | ~100 to 200 kW peak (estimate) | -| Electric steam boiler (if chosen over biomass/LPG) | ~300 kW | +| Electric steam boiler bank (if chosen over biomass/LPG) | ~520 to 625 kW for 750 to 900 kg/h | | Compressed air, lighting, IT, misc | ~30 to 50 kW | -| **Plant peak demand** | **~300 to 450 kW without electric boiler; ~600 to 750 kW with it** | +| **Plant peak demand** | **~430 to 700 kW without electric boiler; ~950 to 1,330 kW with it** | -Grid connection: a medium-voltage connection with a transformer in the -**500 to 1,000 kVA** class from PEA, sized by the boiler decision. +Grid connection: a medium-voltage connection from PEA with a transformer in +the **800 to 1,000 kVA** class without electric steam, **1,250 to 1,600 kVA** +with it; past 1,000 kW of demand the plant moves to PEA Schedule 4, whose +time-of-use rates are the same. -**Not yet re-based for the five-press fleet** (October 2026). The chiller -and peak rows above are sized for one Duplex's ~250 kW of cooling; at -Newbilt's up to 125 kW of cooling per press, five presses need up to ~625 -kW, so the chiller's electrical draw and the plant peak rise accordingly. -Re-size with the Newbilt re-quote figures, together with the steam below -([pressing line](equipment/pressing-line.md)). The presses share one -central hydraulic plant and one compressed-air plant; their draw replaces -the per-system hydraulic units in the pressing row above. The optional -ten more Classics would need up to ~1.9 MW of cooling and ~2.3 to 2.7 t/h -of steam: a utility phase of its own. +**Re-based for the five-press fleet** (October 2026; the concept is drawn +in [steam and cooling](steam-cooling.html)). At Newbilt's per-machine +figures the two Duplex systems and the Classic need 750 to 900 kg/h of +steam and up to ~650 kW of cooling (625 kW presses, 15 kW extruders, 12.5 +kW hydraulic oil cooler) at 305 to 540 l/min of circulating water. The +peak rows assume all five presses cooling hard on a hot afternoon; the +Classic counts as one HRP 12 press plus one extruder until Newbilt states +its figures. The presses share one central hydraulic plant and one +compressed-air plant. The optional ten more Classics would need up to ~1.9 +MW of cooling and ~2.3 to 2.7 t/h of steam: a utility phase of its own. Tariff: PEA Schedule 3.2.2, Medium General Service on time of use at 22 kV (the flat rate is closed to new customers): 132.93 THB/kW demand charge on the peak-hour maximum, 4.1839 THB/kWh peak (09:00 to 22:00 on weekdays) and 2.6037 THB/kWh off-peak, plus Ft (0.1623 THB/kWh for September to December 2026) and VAT. Two-shift production lands at a -blended ~3.81 THB/kWh before the demand charge, roughly 4.3M to 6.4M THB a -year without electric steam (estimate); the deposit for the connection is +blended ~3.81 THB/kWh before the demand charge, roughly 4.5M to 6.8M THB a +year without electric steam, 0.7M to 1.1M of it demand charge (estimate); the deposit for the connection is 400 THB per kVA. Detail and what it decides for steam, PV and the battery in [sustainability](sustainability.md#grid-tariff-pea-and-what-it-decides). @@ -225,19 +227,28 @@ small against the connection, but its own feeder and meter. without electric steam, falling to **~17%** with it; a bigger array shifts that up - Battery: **271 kWh** Gobel stack (ride-through, roughly - two to three hours of the chiller's electrical draw; peak shaving earns + an hour of the chiller bank's peak electrical draw; peak shaving earns little under PEA's time-of-use tariff, see [sustainability](sustainability.md#grid-tariff-pea-and-what-it-decides)) ## Steam and fuel -- Boiler: **400 kg/h at 10 bar / 180 °C** (~300 kW thermal), sized for - one Duplex. The current five-press fleet draws **~750 to 900 kg/h** at - Newbilt's 150 to 180 kg/h per press: not yet re-based, and the fuel - figures below scale with it -- If biomass: **~350 to 400 t/yr** air-dry wood at mature operation, of - which the 60 rai coppice could supply **~80 to 135 t/yr** -- If LPG: **~2.5 to 5 t** bulk tank on site (no gas pipeline in the North) +- Boiler bank: the five-press fleet draws **~750 to 900 kg/h at 10 bar / + 180 °C** (~510 to 610 kW thermal) at Newbilt's 150 to 180 kg/h per press. + Proposed: **two 500 kg/h modules** (B-1 with the launch press and Duplex + system 1, B-2 with system 2 and the Classic), 1,000 kg/h installed; a + third module for N+1 is an RFQ option + ([steam and cooling](steam-cooling.html)). The 2024 Newbilt quote's + ~400 kg/h covers one Duplex system +- Chiller bank: up to **~650 kW** of cooling; proposed **three 250 kW + air-cooled modules** rated at 40 °C ambient, one per press stage, behind a + plate heat exchanger with warm and cold tanks (estimate) +- If biomass: **~350 to 400 t/yr** air-dry wood at ~1.0 to 1.1 million + records a year, up to **~550 t/yr** at the start fleet's full ~1.5 + million (fuel follows records pressed, not presses installed); the 60 rai + coppice could supply **~80 to 135 t/yr** +- If LPG: a bulk tank on site sized with the boiler bank (the ~2.5 to 5 t + first estimated was for one Duplex; no gas pipeline in the North) ## People @@ -258,8 +269,8 @@ keep their original currency alongside. - Newbilt semi-auto line: **~USD 232k (~7.7M THB)**, from the June 2024 quote of EUR 200,500 — expired, in [pressing-line](equipment/pressing-line.md) -- Thai-sourced utilities, HVAC, racking, solar, BESS baseline: **~24M to - 42M THB (~USD 730k to 1.27M)**, detail in the +- Thai-sourced utilities, HVAC, racking, solar, BESS baseline: **~30M to + 51M THB (~USD 910k to 1.56M)** for the five-press fleet, detail in the [utilities CSV](finance/utilities-investment.csv) - Not yet priced: the second Duplex system and the Newbilt Classic (estimates in [total investment](finance/total-investment.md)), diff --git a/docs/steam-cooling.html b/docs/steam-cooling.html new file mode 100644 index 0000000..a918ec7 --- /dev/null +++ b/docs/steam-cooling.html @@ -0,0 +1,345 @@ + + + + + +CNX Vinyl · Steam and cooling plant (five-press fleet) + + + + +
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CNX Vinyl · Steam and cooling plant · five-press fleet · proposed concept

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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.

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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.

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Design basis

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ItemFigureSource
Fleet2 Duplex systems (4 HRP 12, 2 EX 50, 2 EX 35) + 1 Classic with built-in extruder; one central hydraulic and one air plantpressing-line.mddoc
Steam per press150 to 180 kg/h, min. 10 bar, 9.5 to 10.5 bar operatingNewbilt site requirements 3.2.3vendor
Press cooling waterup 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 capacityup to 125 kW per press, by cycle timesite requirements 3.2.2vendor
Extruder cooling~4 l/min, 2 to 3 kW, in 20 to 25 °C, 5 to 10 barsite 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 quality7 to 8 °dH, pH 7 to 9, ≤ 200 µm, ≤ 500 µS/cm, Cl ≤ 20 mg/lsite requirements 3.1.2vendor
Classiccounted as one HRP 12 + one extruder; Toolex Alpha cross-check 1.2 kg steam, 15 l water per cyclefleet calculatorestimate
Five presses, full demandsteam 750 to 900 kg/h · cooling 652.5 kW · water 305 to 540 l/minsum 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 Mfleet calculator, biomass.mdestimate
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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.

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Equipment schedule (proposed)

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TagItemDutyPhaseStatus
WT-1Duplex softener, dosing~1.0 to 1.2 m³/hlaunchestimate
T-1Feed tank / hotwell~1.5 m³, 90 to 95 °Claunchestimate
P-1Feed pumps, duty/standby~1 m³/h, ~13 barlaunchestimate
B-1, B-2Boiler modules, lead/lag2 × 500 kg/h, 10.5 barB-1 launch, B-2 with Duplex 2proposal
B-3Third module for N+1500 kg/hoptionRFQ option
ACC-1Steam accumulatorby cycle overlapoptionNewbilt option
HP-1Heat-recovery heat pumpfeed to 90 to 95 °Claunch or laterproposal
CH-1 to CH-3Air-cooled chillers at 40 °C ambient3 × 250 kWone per press stageproposal
CH-4Fourth module for N+1250 kWoptionRFQ option
HX-1Plate heat exchanger~650 kW, ~2 K approachlaunch, sized for 5estimate
TK-3, TK-2Warm return / cold buffer tanks~5 m³ eachlaunchestimate
P-2, P-3, P-4Transfer, VFD supply, primary pumpsup to ~540 l/minlaunch, stagedestimate
TC-1Dry cooler ahead of HX-1~650 to 750 kW rejectoptionRFQ option
GCGalvanics cooling, separate12 to 20 °C, 10 L/min per PDPUphase 5open
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Open for the RFQs

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Newbilt (re-quote)

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Boilers (Miura, Bangkok Industrial Boilers, STE)

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Chillers (Trane, Carrier, Daikin Applied, Hitachi)

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Site

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Legend

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Saturated steam 10 bar
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Condensate return
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Treated feedwater
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Raw / make-up water
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Process cooling supply 20 to 25 °C
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Process cooling return, open
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Chiller loop, cold
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Chiller loop, warm
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Heat recovery feedwater loop
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Blowdown, drains
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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; 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.

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+ + + diff --git a/docs/suppliers/equipment-suppliers.md b/docs/suppliers/equipment-suppliers.md index 2f784ee..afcb1b5 100644 --- a/docs/suppliers/equipment-suppliers.md +++ b/docs/suppliers/equipment-suppliers.md @@ -92,10 +92,12 @@ What we need (target fleet: 50% fully automated, 50% semi-automatic): - Semi-automatic press line: extruder, presses, hydraulic aggregate, molds (12" 140/180 g, 7" and 10" insert sets), trimmer - Fully automated press line: automatic presses incl. extruders, molds -- Steam generator (~400 kg/h for the semi-auto Duplex alone; grows with the - automated line), local sourcing planned -- Cooling water system (~250 kW for the semi-auto Duplex alone; closed loop), - local sourcing planned +- Steam generator: 750 to 900 kg/h for the five-press fleet (~400 kg/h for + one Duplex), proposed as two 500 kg/h modules, local sourcing planned + ([steam and cooling](../steam-cooling.html)) +- Cooling water system: up to ~650 kW for the five-press fleet (~250 kW for + one Duplex), proposed as three 250 kW chillers, closed loop, local + sourcing planned - Workshop compressor / compressed air supply - PVC grinder (recycling loop) - Record separator plates, buffer spindles diff --git a/docs/sustainability.md b/docs/sustainability.md index 5da85e7..d702fba 100644 --- a/docs/sustainability.md +++ b/docs/sustainability.md @@ -11,9 +11,10 @@ from day one. ## Renewable energy: large solar installation The pressing machinery itself is a modest electrical load: 32 kVA connected, -~21 kW average for a full Duplex line. The real energy demand sits in the -utilities around it, above all the steam generator (400 kg/h saturated steam -at 10 bar / 180 °C) and the 250 kW cooling system. +~21 kW average for a full Duplex line, ~118 kVA for the five-press fleet. +The real energy demand sits in the utilities around it, above all the steam +(750 to 900 kg/h of saturated steam at 10 bar / 180 °C for five presses) and +process cooling (up to ~650 kW), drawn in [steam and cooling](steam-cooling.html). - A large rooftop/ground PV installation is planned. Northern Thailand's solar irradiance is favorable, and daytime-heavy production shifts align well with @@ -28,7 +29,8 @@ at 10 bar / 180 °C) and the 250 kW cooling system. can exceed the 800 V window of the smaller Deye series), and obtaining Gobel's safety certifications (not published) for a Thai commercial install. At 271 kWh the stack is a ride-through buffer, not full - off-grid autonomy, against loads like the 250 kW cooling system; under + off-grid autonomy, against loads like the chiller bank's ~210 to 325 kW + peak draw; under PEA's time-of-use tariff it earns little from peak shaving ([grid tariff](#grid-tariff-pea-and-what-it-decides)). - The machine load and cooling system are straightforward PV targets. @@ -108,9 +110,11 @@ the electric-boiler route is chosen. The deepest efficiency in this plant comes from its own thermodynamics: the steam's job is to heat the molds, and the cooling water's job is to remove -that same heat again, so roughly 98% of the 250 kW cooling load is heat -leaving the press molds, put there almost entirely by the steam, and the -press cooling return exits at ~60 °C. That +that same heat again, so roughly 98% of the press cooling load (up to 125 kW a +press, ~650 kW for the five-press fleet) is heat leaving the press molds, +put there almost entirely by the steam, and the press cooling return exits +at ~60 °C (Newbilt site requirements; the concept is drawn in +[steam and cooling](steam-cooling.html)). That warm return is a premium heat source, and the architecture is built around reusing it before generating anything new: @@ -163,7 +167,8 @@ PEA's [Ft page](https://www.pea.co.th/en/our-services/tariff/ft), both checked 7 October 2026. Plant consumption and demand are this repo's estimates ([scale](scale.md)). -**Which tariff applies.** At 300 to 750 kW of peak demand the plant is +**Which tariff applies.** At ~430 to 700 kW of peak demand without +electric steam (five presses, [scale](scale.md)) the plant is Schedule 3, Medium General Service (30 to under 1,000 kW and at most 250,000 kWh a month on a three-month average). The flat-rate 3.1 is closed to customers classified after November 2015, so a new plant is on **3.2, @@ -183,35 +188,39 @@ transformer adds 2 % to kW and kWh, so meter at 22 kV; the minimum bill is 70 % of the highest demand charge of the last twelve months; a power factor below about 0.85 (reactive demand above 61.97 % of active) costs 56.07 THB per kVAR, so the motor loads need correction. With electric steam the plant -would average ~210,000 kWh a month (estimate) and busy months could cross -250,000, which moves it to Schedule 4; that schedule's TOU rate 4.2.2 is +would average ~210,000 kWh a month (estimate) and its ~950 to 1,330 kW +peak crosses 1,000 kW, which moves it to Schedule 4; that schedule's TOU rate 4.2.2 is identical, so the price does not change. Connecting a high-voltage meter below 69 kV costs a 15,000 THB inspection fee plus a security deposit of -400 THB per kVA (PEA tariff page, rates from January 2020): 200k to 400k -THB for a 500 to 1,000 kVA transformer. +400 THB per kVA (PEA tariff page, rates from January 2020): ~320k to 400k +THB for the 800 to 1,000 kVA transformer the five-press plant needs +without electric steam, 500k to 640k THB for 1,250 to 1,600 kVA with it. **What it costs the plant.** Two shifts from 06:00 to 22:00 on ~300 days (about 243 weekdays and 57 Saturdays, estimate) put ~66 % of process energy into peak hours: a blended **~3.81 THB/kWh** including Ft, before the -demand charge. Without electric steam (1,000 to 1,500 MWh a year, 300 to -450 kW peak) the bill comes to roughly **4.3M to 6.4M THB a year** before -solar, 0.5M to 0.7M of it demand charge (estimate). +demand charge. Without electric steam (1,000 to 1,500 MWh a year, 430 to +700 kW peak) the bill comes to roughly **4.5M to 6.8M THB a year** before +solar, 0.7M to 1.1M of it demand charge (estimate). **Electric versus biomass steam**, for the same heat as in [biomass](biomass.md): 350 to 400 t of wood at 80 % boiler efficiency, -~1,120 to 1,280 MWh of heat a year at maturity. +~1,120 to 1,280 MWh of heat a year at maturity (about 1.0 million records; +the start fleet at its full ~1.5 million needs ~1,750 MWh, and both +columns scale with it). | | Electric boiler (~98 %) | Biomass boiler (~80 %) | |---|---|---| | Price of heat | ~3.9 THB/kWh, plus the demand charge | ~0.5 to 0.9 THB/kWh at 1.35 to 2 THB/kg delivered ([reported market prices](biomass.md#fuel-prices-market-check-october-2026), October 2026; no supplier quote yet) | -| Running cost, mature two shifts | **~4.7M to 5.5M THB/yr**: 1,140 to 1,310 MWh plus 200 to 300 kW of extra peak demand (0.3M to 0.5M) | **~0.6M to 1.2M THB/yr** of fuel, plus fuel handling and ash | -| Boiler package ([utilities CSV](finance/utilities-investment.csv)) | 2.5M to 4M THB | 4M to 7M THB, plus the fuel store | -| Grid | peak demand 600 to 750 kW: bigger transformer and deposit | unchanged | +| Running cost, mature two shifts | **~5.2M to 6.0M THB/yr**: 1,140 to 1,310 MWh plus 520 to 625 kW of extra peak demand for the five-press boiler bank (0.8M to 1.0M) | **~0.6M to 1.2M THB/yr** of fuel, plus fuel handling and ash | +| Boiler package ([utilities CSV](finance/utilities-investment.csv)) | 4.5M to 7M THB for 2 × 500 kg/h | ~6M to 10M THB, plus the fuel store | +| Grid | peak ~950 to 1,330 kW: Schedule 4, 1,250 to 1,600 kVA transformer and deposit | unchanged (~800 to 1,000 kVA) | The electric boiler is the more efficient machine; biomass is by far the -cheaper heat. At maturity the fuel saving of ~3.5M to 4.9M THB a year +cheaper heat. At maturity the fuel saving of ~4.0M to 5.4M THB a year repays the biomass premium in under a year (estimate). Even early, at a -quarter of the heat, electric steam costs ~1.4M to 1.7M THB a year against +quarter of the heat, electric steam costs ~1.6M to 1.8M THB a year (one 500 kg/h +module) against ~0.15M to 0.3M of fuel, because the demand charge is set by the boiler's full-power draw, not by its average. Moving electric steam to off-peak hours barely helps: the presses need steam while they run, and the peak window covers @@ -286,7 +295,8 @@ either tank is ordered. The reference process schematic shows a conventional open "dirty water" cooling loop. We will not build it that way. -- Cooling (up to 250 kW, 220 l/min peak, roughly 98% of it mold cooling) will +- Cooling (up to ~650 kW and 540 l/min for the five presses, roughly 98% of + it mold cooling) will run as a closed loop with a cooling tower/chiller, so process water is recirculated rather than discharged. - Steam condensate will be recovered and returned to the treated feedwater diff --git a/site/build.sh b/site/build.sh index b3caf04..29625c8 100644 --- a/site/build.sh +++ b/site/build.sh @@ -20,6 +20,7 @@ cp -R site/public/. "$out/" DEMOS=( "docs/plant-operation.html demos/plant-operation/index.html" "docs/fleet-calculator.html demos/fleet-calculator/index.html" + "docs/steam-cooling.html demos/steam-cooling/index.html" ) for entry in "${DEMOS[@]}"; do read -r src dst <<<"$entry" diff --git a/site/public/index.html b/site/public/index.html index 18d62a7..4949da8 100644 --- a/site/public/index.html +++ b/site/public/index.html @@ -93,6 +93,16 @@ document.documentElement.setAttribute("data-theme",t);})(); link. +
  • + + Steam and cooling plant + The utilities for the five-press fleet as a clickable process + diagram: boiler bank, steam header and condensate return, chiller + bank, plate heat exchanger and a branch to every press. Switch + between the launch press, the full fleet and one module down to see + demand against installed capacity. + +