Feedwater heat recovery: economizer, condensate, then HP-1
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The order to investigate for a fired boiler (biomass such as rice husk, or LPG): first a flue-gas economizer, second as much clean, hot condensate back to T-1 as possible, third the heat pump HP-1 where the press return has enough heat and the combined heating and cooling economics justify it. - Diagram: new ECON-1 (option, fired boilers only) between the feed pumps and the boiler manifold, with a bypass for an electric bank and the flue-gas path from the boilers; feed in 90 to 95 C, outlet and stack temperature are vendor figures. HP-1 is now drawn as an option and labelled the third measure. AT conductivity on the condensate return to T-1; off-spec condensate goes to the warm tank. - Found in Newbilt's offer 240620-04: steam and cooling water share the mould channels, with one steam/water outlet valve and steam trap per mould, so the condensate is only as clean as the cooling loop. Noted in the T-1 detail, sustainability.md and as a Newbilt RFQ question. - With most condensate returned (about 15 % flashes at atmospheric pressure, estimate) the feed tank needs only a fraction of the ~70 kW that heating all make-up takes, so HP-1 may not pay. - RFQ: economizer 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. - sustainability.md: the order, before the exclusions. biomass.md: new "Recovering heat at the boiler". Checked headless (scripts/pw_sc_check.py): 33 boxes, 20 tags, no overlap or overflow, no unstyled pipes, no card or page overflow at 1600, 1258 and 390 px in all four cases, every box opens its detail, no errors.
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@@ -137,6 +137,21 @@ reusing it before generating anything new:
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(electric, LPG, or biomass), it supplies just the last step to 180 °C /
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10 bar from already-hot feedwater.
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**Order to investigate the feedwater heat recovery (October 2026).** For a
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fired boiler (biomass such as rice husk, or LPG): first a flue-gas
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economizer, recovering combustion heat into the boiler feedwater where the
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flue-gas temperature and corrosion limits allow; second, as much clean, hot
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condensate back to the feed tank as possible; third, the feedwater heat
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pump above, where the press cooling return has enough heat and the
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combined heating and cooling economics justify it. Each step shrinks the
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next one's job: with most condensate returned the feed tank needs only a
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fraction of the ~70 kW that heating all make-up would take (estimate), and
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an electric boiler has no flue gas at all. One caution on condensate: the
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press moulds take steam and cooling water through the same channels, with
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one outlet valve and steam trap per mould (Newbilt offer 240620-04), so the
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returned condensate is only as clean as the cooling loop; it is monitored
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and diverted when off-spec ([steam and cooling](steam-cooling.html)).
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Two honest exclusions, checked and ruled out:
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- **Heat pumps cannot make the final steam**: commercial steam-generating
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