diff --git a/docs/cnx_vinyl_parametric_payap_parts-top.png b/docs/cnx_vinyl_parametric_payap_parts-top.png index fc1d764..55429a3 100644 Binary files a/docs/cnx_vinyl_parametric_payap_parts-top.png and b/docs/cnx_vinyl_parametric_payap_parts-top.png differ diff --git a/docs/cnx_vinyl_parametric_payap_parts.FCStd b/docs/cnx_vinyl_parametric_payap_parts.FCStd index f1c71a4..fd7b27e 100644 Binary files a/docs/cnx_vinyl_parametric_payap_parts.FCStd and b/docs/cnx_vinyl_parametric_payap_parts.FCStd differ diff --git a/docs/cnx_vinyl_parametric_payap_parts.png b/docs/cnx_vinyl_parametric_payap_parts.png index 329dfac..599c41f 100644 Binary files a/docs/cnx_vinyl_parametric_payap_parts.png and b/docs/cnx_vinyl_parametric_payap_parts.png differ diff --git a/docs/equipment/pressing-line.md b/docs/equipment/pressing-line.md index e966f24..c871a91 100644 --- a/docs/equipment/pressing-line.md +++ b/docs/equipment/pressing-line.md @@ -51,6 +51,20 @@ automated candidate). What it means: trench along the press rows. Open for the re-quote (below): whether the Single 2.1's own aggregate becomes part of the central plant or a standby, and whether the Classic can run from it. + + Built to grow from one press (October 2026): the plant room is built at + full size, and the hydraulic and air ring mains are sized for the whole + fleet from the start, with a valved, capped tee at every press position, + the empty ones included, so a new press is connected without stopping + the others. The proposal for the Single 2.1's own aggregate, already + sized for the second press, is to set it in the plant room as the first + pump set on the ring main instead of beside the press; system 2 and the + Classic add pump sets in parallel on one manifold with the accumulators, + and a standby set follows. Each branch gets its own isolation valves and + filter: with one shared oil system, a contamination event otherwise + reaches every press. Steam and cooling follow the same pattern; the + phased list for all three is in + [scale](../scale.md#utility-phasing-backbone-once-modules-with-the-presses). - **Cell layout (October 2026).** Each Duplex system is one operator's cell, as sketched in [duplex-cell-layout-sketch.png](duplex-cell-layout-sketch.png) (arrangement only, not to scale): @@ -84,7 +98,10 @@ automated candidate). What it means: 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 + and three 250 kW chillers, one module per press stage, in a boiler hall + and a chiller compound built for four modules each + ([scale](../scale.md#detached-utility-yard-parking-and-what-that-moves)); + 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 @@ -100,7 +117,10 @@ automated candidate). What it means: Classic's price, weight, power, steam and cooling figures; and the central hydraulic supply (an option the flyer offers) for the whole fleet, extendable to ten more Classics, including whether the Classic - can run from it. + can run from it, whether the presses hold their pressure from it over + the ring-main lengths of the hall, the filtration and isolation each + branch needs, and whether the Single 2.1's aggregate can be its first + pump set. The Pheenix AD12 leaves the plan; it stays in the [vendor landscape](../suppliers/vendor-landscape.md) as the comparison if diff --git a/docs/finance/phase1-construction-rfq.md b/docs/finance/phase1-construction-rfq.md index 3b35cd3..45208a0 100644 --- a/docs/finance/phase1-construction-rfq.md +++ b/docs/finance/phase1-construction-rfq.md @@ -130,10 +130,19 @@ Simple industrial enclosures beside the main building. | Building | Area | Height | |---|---|---| -| Boiler hall | 66 m² | 6.0 m | +| Boiler hall, laid out for four 500 kg/h boiler modules | ~162 m² (18 × 9 m) | 6.0 m | | Biomass fuel store | 42 m² | 5.0 m | -| Chiller room | 60 m² | 5.0 m | -| Cooling tower pad (concrete pad only) | 10 m² | - | +| Chiller compound: open to the sky, screened, four chiller pads (~4.0 × 2.6 m each) | ~135 m² (12.5 × 10.8 m) | screen ~2.5 m | +| Cooling pump and heat-exchanger room | ~40 m² (8 × 5 m) | 4.0 m | + +The boiler hall and the chiller compound are built once for four modules +each, and the plant goes in one module at a time as presses arrive +([scale](../scale.md#detached-utility-yard-parking-and-what-that-moves)): +price the floor, pads, plinths and wall openings for all four now. The +sizes are estimates until the boiler and chiller vendors send footprints. +Air-cooled chillers need open air, so the earlier "chiller room" is an open +compound; the cooling tower pad of the water-cooled concept is deleted (a +dry cooler, if bought, gets a pad sized with its quote). The 14 m flue stack comes with the boiler — excluded here. The boiler hall envelope should be non-combustible (mineral-wool panels or masonry), not @@ -168,8 +177,8 @@ things follow: **On drainage.** 4,387 m² of pavement is about 46 % of the 9,567 m² plot, but the figure that matters for attenuation is the **total sealed area**: -adding the main building (1,500 m²), utility yard (178 m²), guard house -(12 m²) and parking canopies (271 m²) gives **6,348 m², or 66 % of the +adding the main building (1,500 m²), utility yard (~379 m²), guard house +(12 m²) and parking canopies (271 m²) gives **~6,549 m², or 68 % of the plot**. Quote the contractor that number, not the paving one. Runoff increases materially over the agricultural baseline, and stormwater attenuation — quite possibly a detention pond — may be required diff --git a/docs/finance/total-investment.md b/docs/finance/total-investment.md index 8d11d44..578bbf7 100644 --- a/docs/finance/total-investment.md +++ b/docs/finance/total-investment.md @@ -49,7 +49,8 @@ building, software and stamper prep lines, and the contingency on top). | 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 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 | +| Utility yard built for four boiler and four chiller modules (October 2026): yard ~379 m² against 178 m² ([scale](../scale.md#detached-utility-yard-parking-and-what-that-moves)) | 73k – 122k | 2.4M – 4.0M | estimate: the building rate above on the ~200 m² the yard grows by; the open chiller compound costs less than a building, so this is the cautious end. The valved branches and feeders for the empty positions are not priced yet | +| **Added so far** | **~678k – 1,027k** | **~22.3M – 33.9M** | about 13 to 17% on the full-vision subtotal | ## Phased entry diff --git a/docs/scale.md b/docs/scale.md index 712ac74..9394ae8 100644 --- a/docs/scale.md +++ b/docs/scale.md @@ -92,20 +92,63 @@ fits; at the upper half, finished goods move to the phase 2 building. The massing model puts the boiler and chiller in a **detached utility yard** alongside the main building rather than inside it, which is what the boiler's own-room requirement in [facility security](facility-security.md) and biomass -fuel delivery both push toward: +fuel delivery both push toward. Its rooms are built once for **four boiler +and four chiller modules** (decided October 2026), while the modules +themselves arrive one press stage at a time +([utility phasing](#utility-phasing-backbone-once-modules-with-the-presses)): | | Area | Height | |---|---|---| -| Boiler hall | 66 m² | 6.0 m | +| Boiler hall, four 500 kg/h module positions | ~162 m² (18 × 9 m) | 6.0 m | | Biomass fuel store | 42 m² | 5.0 m | -| Chiller room | 60 m² | 5.0 m | -| Cooling tower (outdoor pad) | 10 m² | 3.5 m | +| Chiller compound, four 250 kW pads, open to the sky, screened | ~135 m² (12.5 × 10.8 m) | screen ~2.5 m | +| Cooling pump and heat-exchanger room | ~40 m² (8 × 5 m) | 4.0 m | | Flue stack | - | 14 m | -Boiler plus chiller at 126 m² lands inside the 100 to 150 m² the zone table -allows, but moving them out of the main shed frees that floor for -production, so either the main building shrinks by ~126 m² or the program -grows into it. Decide which before the building is priced. +All sizes are estimates until the boiler and chiller vendors send +footprints: + +- **Boiler hall.** The fuel is still open, so the fired case sets the + size. The largest piece of a 500 kg/h biomass boiler is about + 3.3 × 2.0 × 2.7 m (AIX DZL0.5 listing, checked October 2026). Four + 3.5 m bays plus a 4 m bay for the feed tank, softener, feed pumps and + steam header make 18 m. A 2.5 m firing aisle, 1.5 m of fuel feed, the + boiler and 1.3 m behind it make 9 m. Dust collectors, fans and the stack + stand outside along the back wall. An electric bank (~3.0 × 1.5 m per + 500 kg/h module, vendor listing) would need about half the hall. +- **Chillers.** Air-cooled chillers need open air, so the earlier + "chiller room" becomes an open, screened compound plus a small enclosed + room for the heat exchanger, the cold tank and the pumps. A 250 kW + module rated at 40 °C is about the size of a Carrier 30RB 080 to 090: + 2.4 to 3.6 × 2.24 × 2.28 m (Carrier's published dimensions, checked + October 2026). The pads are 4.0 × 2.6 m, in two rows of two, with + ~1.8 m to the screen and 2.0 m between the rows; the chosen unit's + clearance drawing governs. The cooling tower pad of the earlier + water-cooled concept is gone; a dry cooler, if bought, gets a pad sized + with its quote. +- **What four positions carry.** + - Steam: four boilers give 2,000 kg/h, or 1,500 kg/h with one held in + reserve, enough for about eight presses at 180 kg/h. The five-press + fleet runs on B-1 and B-2, B-3 is the reserve, and B-4 is room for + about three more presses. + - Cooling: four chillers give 1,000 kW. The five presses (~652.5 kW) + already need three, so CH-4 is the reserve and there is no growth + position. Each further press adds ~130 kW with its extruder and + hydraulics; a sixth eats into the reserve, and seven is the limit with + none. + - Pads laid out for the next frame up (Carrier 30RB 120 to 150 class, + ~4.8 m long, roughly 350 kW at 40 °C, estimate) would let four + chillers carry about eight presses with one in reserve, matching the + boiler hall. That is a priced option for the chiller RFQ. + +The yard grows from 178 m² to ~379 m². The old 126 m² of boiler hall and +chiller room fitted the 100 to 150 m² the zone table allows for them in the +main building; the four-module rooms would not, which is one more reason the +yard stays detached. Moving the plant out frees that zone-table floor for +production, so either the main building shrinks by that much or the program +grows into it. Decide which before the building is priced. The +[Payap parts model](site-candidates.md#roof-pv-and-parking-canopies-part-and-draft-model-october-2026) +draws the yard this way. Staff parking is roofed, in the front yard clear of the loading route: **10 car bays** (27.7 × 7.0 m canopy, 195 m²) and **~30 scooter spaces** @@ -240,12 +283,13 @@ small against the connection, but its own feeder and meter. 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 + third module for N+1 is an RFQ option, and the hall has a fourth position + for growth ([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) + plate heat exchanger with warm and cold tanks (estimate); the compound's + fourth pad takes the N+1 module - 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 @@ -253,6 +297,42 @@ small against the connection, but its own feeder and meter. - 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) +### Utility phasing: backbone once, modules with the presses + +The plant starts with one press. Everything that is cheap to oversize now +and costly to change in a running plant is built for the five-press fleet +at launch; the machines that make steam, cold water and oil pressure are +bought in identical modules as presses arrive. Identical modules mean one +set of spares and one service routine, and N+1 later is one more module, +not a redesign. + +| Stage | Steam | Cooling | Hydraulics and air | +|---|---|---|---| +| Launch: Newbilt Single 2.1, one press | Boiler hall for four modules; T-1, WT-1, P-1; steam main and condensate return with a valved, blanked branch at every press position; **B-1** | Compound with four pads; TK-2 and TK-3 at full size; HX-1 frame for ~650 kW with plates for the launch duty; P-2 to P-4 on VFDs; supply and return mains for ~540 l/min with a valved branch per position; **CH-1** | Plant room at full size; hydraulic and air ring mains along the service trench, sized for the fleet, with a valved, capped tee per position; the Single 2.1's own unit in the plant room as the first pump set on the manifold; one compressor | +| Duplex system 1 complete (second press, EX 35) | B-1 at 60 to 72 % load | CH-1 covers ~96 % of the hot-afternoon peak (~261 kW): the cold tank and cycle overlap carry the rest, or CH-2 comes forward if the hot season arrives first | Tap the ring main; the Single 2.1 unit is already sized for the second press | +| Duplex system 2 | **B-2** | **CH-2** | A pump set added on the manifold; a second compressor if the air demand needs it | +| Classic | Carried by B-1 and B-2 | **CH-3** | A pump set, if the Classic runs from the central plant (Newbilt re-quote) | +| Options | **B-3** (N+1); **B-4** for about three more presses; ACC-1 accumulator; ECON-1 on a fired bank | **CH-4** (N+1); TC-1 dry cooler; pads for the ~350 kW frame | A standby pump set, or the Single 2.1 unit as standby | + +Also built at launch: one controller that sequences the boilers, chillers +and pump sets lead and lag from the first module, and switchboard space and +feeders for every later module. Beyond four modules, the ten optional +Classics (~2.3 to 2.7 t/h, ~1.9 MW) are a utility phase of their own, on +reserved ground with its own header connection. + +Two things to watch early: + +- A fired 500 kg/h boiler serving one press runs at ~30 to 36 % and cycles. + Newbilt's steam accumulator (ACC-1) steadies it; or the first module is + electric and biomass follows at the expansion ([biomass](biomass.md)), + at the price of the demand charge. +- One large boiler or chiller bought at launch would run poorly at part + load, tie up capital in unused capacity and stop the plant when it fails. + +The hydraulic side and its re-quote questions are in +[pressing line](equipment/pressing-line.md); the plant diagram and its +operating cases in [steam and cooling](steam-cooling.html#phasing). + ## People Rough mature-operation headcount (estimate): 4 to 6 press/finishing diff --git a/docs/steam-cooling.html b/docs/steam-cooling.html index b6f70b3..29edcf5 100644 --- a/docs/steam-cooling.html +++ b/docs/steam-cooling.html @@ -131,24 +131,46 @@ td.low{color:var(--warn);font-weight:600} 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 + B-3Third module for N+1500 kg/hoption; position built at launchRFQ option + B-4Fourth position: pad, header branch, feeder500 kg/hgrowth, ~3 more pressesposition only ECON-1Flue-gas economizer, fired boilersfeed in 90 to 95 °C, out by vendorwith a fired bank1st measure ACC-1Steam accumulatorby cycle overlapoptionNewbilt option HP-1Heat-recovery heat pumpfeed tank to 90 to 95 °Cif it pays3rd measure 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 + CH-4Fourth module for N+1250 kWoption; pad built at launchRFQ option + HX-1Plate heat exchanger~650 kW, ~2 K approachlaunch: frame for 5, plates as presses arriveestimate 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 +
+

Phasing: backbone once, modules with the presses

+

Everything that is cheap to oversize now and costly to change in a running plant is built for the five-press fleet at launch; boilers, chillers and hydraulic pump sets come in identical modules as presses arrive. One controller sequences them lead and lag from the first module.

+ + + + + + + +
StageSteamCoolingHydraulics, air
Launch (Single 2.1, one press)hall for four modules; T-1, WT-1, P-1; mains with a valved, blanked branch per press position; B-1compound with four pads; TK-2, TK-3 full size; HX-1 frame for ~650 kW, plates for one press; P-2 to P-4 on VFDs; CH-1plant room full size; ring mains for the fleet, a capped tee per position; the Single 2.1 unit as the first pump set; one compressor
Duplex system 1B-1 at 60 to 72 % loadCH-1 covers ~96 % of the peak: cold tank and cycle overlap, or CH-2 earliertap the ring main
Duplex system 2B-2CH-2pump set on the manifold
ClassicB-1 and B-2CH-3pump set, if the Classic runs from the central plant
OptionsB-3 (N+1), B-4 (growth), ACC-1, ECON-1CH-4 (N+1), TC-1, pads for ~350 kW unitsstandby pump set
+

Rooms, four modules each (estimate)

+ + + + + +
RoomSizeBasis
Boiler hall~18 × 9 m, 6 m highfour 3.5 m bays plus 4 m for T-1, WT-1, P-1 and the header; fired case (500 kg/h biomass body ~3.3 × 2.0 m); electric needs about half
Chiller compound~12.5 × 10.8 m, openfour pads 4.0 × 2.6 m in two rows, screened; 250 kW at 40 °C is about a Carrier 30RB 080 to 090, 2.4 to 3.6 × 2.24 m
Pump and HX room~8 × 5 mHX-1, TK-2, P-2 to P-4, drives
+

Four boilers carry about eight presses with one in reserve. Four 250 kW chillers carry the five presses with CH-4 in reserve and leave no growth position, unless the pads take the larger frame (scale.md).

+

Open for the RFQs

Newbilt (re-quote)

Chillers (Trane, Carrier, Daikin Applied, Hitachi)

Site