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.
User, October 2026: calculations for the later business plan, starting
from 2 Duplex + 1 Classic at 3 records a minute per Duplex and 2 per
Classic, as an interactive tool on the website: pick the yearly output
and the share of splatter/specials, get the machine mix and all the
requirements (people, hydraulics, power, ...).
docs/fleet-calculator.html (single static page, no dependencies):
- target mode sizes the fleet (specials only on Duplex with its EX 35;
grow with Classics or with Duplex systems; start fleet as the floor);
fleet mode takes a fleet and gives its output at the specials share;
- output, capacity, utilisation and the mix bar per machine type;
- needs: people per shift and in total, galvanics operators, machines,
connected kVA and average kW, MWh/yr, central hydraulics (flow, motor,
oil, accumulator), steam, cooling and cooling water, compressed air,
press floor, room climate, compound, trim, titles, electroformed parts
and plating units; checks against the 400 kg/h boiler, 250 kW chiller
and the 870 m2 Payap press hall;
- ladder from the start fleet to a full Payap press hall, click to load;
- every assumption editable with its source (Newbilt Duplex site
requirements V14 and offer 240620-04, scale.md, galvanics.md, revenue
model, Payap model; estimates labelled), shareable link via the hash.
The Classic counts as one HRP 12 press plus one extruder until Newbilt
states figures (Toolex Alpha leaflet as a cross-check).
Site: DEMOS entry (/demos/fleet-calculator/) and landing-page entry.
README bullet and layout line; backlinks from scale.md (capacity) and
pressing-line.md (current plan).
site/ builds the internal test site: public/ served as is (landing page,
robots.txt, static sites) plus demo pages copied out of docs/ (the plant
operation page at /demos/plant-operation/). build.sh fails on dead
internal links and stamps version.txt.
.gitea/workflows/deploy-site.yml rsyncs site/dist to the buildfor.life
web server with the blog's two-directory rename swap, checks version.txt
on the server, purges Cloudflare when a token is set, and checks the
public URL. Secret names match the blog's workflow.
site/Caddyfile is the virtual host to append on s1 (noindex everywhere,
Cloudflare-only like the blog apex, www redirect). site/README.md has the
one-time setup: DNS, Caddy, web root, secrets, runner.
grabowski