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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@@ -28,7 +28,8 @@ option per room.
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sensors logging in every zone, with alarms on excursions, tied into the
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plant monitoring below.
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- **Energy design**: conditioning a whole factory in a tropical climate is
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a major electrical load on top of the 250 kW process cooling, and it must
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a major electrical load on top of the process cooling (up to ~650 kW for
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the five presses), and it must
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be included in the solar PV and battery sizing from the start. Heat
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recovery from the press hall (steam, hydraulics, and hot PVC all reject
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heat) and from compressors should feed the design rather than fight it.
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