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.
This commit is contained in:
grabowski committed 2026-10-14 11:03:34 +07:00
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@@ -137,6 +137,21 @@ reusing it before generating anything new:
(electric, LPG, or biomass), it supplies just the last step to 180 °C /
10 bar from already-hot feedwater.
**Order to investigate the feedwater heat recovery (October 2026).** For a
fired boiler (biomass such as rice husk, or LPG): first a flue-gas
economizer, recovering combustion heat into the boiler feedwater where the
flue-gas temperature and corrosion limits allow; second, as much clean, hot
condensate back to the feed tank as possible; third, the feedwater heat
pump above, where the press cooling return has enough heat and the
combined heating and cooling economics justify it. Each step shrinks the
next one's job: with most condensate returned the feed tank needs only a
fraction of the ~70 kW that heating all make-up would take (estimate), and
an electric boiler has no flue gas at all. One caution on condensate: the
press moulds take steam and cooling water through the same channels, with
one outlet valve and steam trap per mould (Newbilt offer 240620-04), so the
returned condensate is only as clean as the cooling loop; it is monitored
and diverted when off-spec ([steam and cooling](steam-cooling.html)).
Two honest exclusions, checked and ruled out:
- **Heat pumps cannot make the final steam**: commercial steam-generating