Steam and cooling plant for the five-press fleet; utilities re-based
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New page docs/steam-cooling.html (site /demos/steam-cooling/): the
utility plant as a clickable process diagram. Steam side: raw water,
softener and dosing, feed tank with heat-pump feedwater recovery, feed
pumps, a bank of two 500 kg/h boilers (third for N+1 as an option),
separator and metering, optional accumulator, blowdown, the 10 bar
header with a valved, metered branch and trap per press, drip legs and
condensate return. Cooling side: Newbilt's press outlets are open (max.
2 bar), so returns drain to a warm tank, pass the heat pump, an optional
dry cooler and a plate heat exchanger to a cold buffer tank, and VFD
pumps feed the 20 to 25 C header at ~10 bar to every press, the
extruders and the central hydraulic oil cooler; the chiller loop
(three 250 kW air-cooled modules at 40 C ambient, fourth as option) stays
closed and clean. Galvanics cooling (12 to 20 C) is a separate circuit.
Operating cases (launch, Duplex system 1, five presses, one module down)
show demand against installed capacity; design basis with sources,
equipment schedule, RFQ questions. Static SVG, no per-frame work.

Design basis at Newbilt's per-machine figures: steam 750 to 900 kg/h,
cooling 652.5 kW (625 presses, 15 extruders, 12.5 hydraulics), 305 to
540 l/min circulating. Also found: Newbilt's 53 l/min at ~60 C out is
~140 kW, above its 125 kW peak; listed as a re-quote question.

Re-based in the same commit:
- scale.md: electrical table (chiller bank ~210 to 325 kW electrical,
  plant peak ~430 to 700 kW, ~950 to 1,330 kW with electric steam),
  grid 800 to 1,000 kVA (1,250 to 1,600 with electric steam, Schedule
  4 past 1,000 kW), tariff 4.5M to 6.8M THB/yr, battery ~1 h of chiller
  peak, boiler and chiller banks, biomass up to ~550 t/yr at 1.5 M
  records, utilities money line.
- sustainability.md, biomass.md: same figures; electric steam 5.2M to
  6.0M THB/yr mature, 1.6M to 1.8M early; fuel saving 4.0M to 5.4M.
- utilities CSV: boiler bank, chiller bank with HX and tanks, softener
  and loop treatment re-sized; baseline 23.98M-41.63M -> 30.07M-51.33M.
- total-investment.md: re-size as an added-scope row (+185k / +294k
  USD); headline 4.7M to 8.9M unchanged until the investment re-base.
- pressing-line, equipment-suppliers, facility-security, fleet
  calculator (boiler 1000 kg/h, chiller 750 kW), plant page detail
  texts; README, landing page, build.sh.
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grabowski committed 2026-10-14 09:58:27 +07:00
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@@ -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