CNX Vinyl · Steam and cooling plant (five-press fleet)

Concept for the RFQs, not a construction drawing. Machine figures are Newbilt's published site requirements per press, extruder and hydraulic unit; boiler and chiller banks, tank sizes and pump duties are this repository's proposals and estimates until vendors quote. Click any piece of equipment.

Click any equipment

Each box explains what it does, the figures behind it with their source, and what the RFQ still has to settle. The buttons above switch between operating cases: which presses run, which modules are installed, and whether the plant covers the demand.

Design basis

Item	Figure	Source
Fleet	2 Duplex systems (4 HRP 12, 2 EX 50, 2 EX 35) + 1 Classic with built-in extruder; one central hydraulic and one air plant	pressing-line.mddoc
Steam per press	150 to 180 kg/h, min. 10 bar, 9.5 to 10.5 bar operating	Newbilt site requirements 3.2.3vendor
Press cooling water	up to 100 l/min, ~53 l/min used, in 20 to 25 °C at 10 bar, out ~60 °C, max. 2 bar (open)	site requirements 3.2.2vendor
Press cooling capacity	up to 125 kW per press, by cycle time	site requirements 3.2.2vendor
Extruder cooling	~4 l/min, 2 to 3 kW, in 20 to 25 °C, 5 to 10 bar	site requirements 3.3.3vendor
Hydraulic oil cooler	~8 l/min, up to 5 kW per aggregate (2.5 kW per press)	site requirements 3.4.2vendor
Cooling water quality	7 to 8 °dH, pH 7 to 9, ≤ 200 µm, ≤ 500 µS/cm, Cl ≤ 20 mg/l	site requirements 3.1.2vendor
Classic	counted as one HRP 12 + one extruder; Toolex Alpha cross-check 1.2 kg steam, 15 l water per cycle	fleet calculatorestimate
Five presses, full demand	steam 750 to 900 kg/h · cooling 652.5 kW · water 305 to 540 l/min	sum of the abovedoc
Chiller electrical input	~80 to 125 kW per 250 kW of cooling (air-cooled, hot season)	scale.mdestimate
Electric boiler alternative	~0.68 kWh per kg of steam at 98 %	fleet calculatorestimate
Annual steam heat	~1,170 MWh at 1.0 M records, ~1,750 MWh at the start fleet's full ~1.5 M	fleet calculator, biomass.mdestimate

Item

Figure

Source

Fleet

2 Duplex systems (4 HRP 12, 2 EX 50, 2 EX 35) + 1 Classic with built-in extruder; one central hydraulic and one air plant

pressing-line.mddoc

Steam per press

150 to 180 kg/h, min. 10 bar, 9.5 to 10.5 bar operating

Newbilt site requirements 3.2.3vendor

Press cooling water

up to 100 l/min, ~53 l/min used, in 20 to 25 °C at 10 bar, out ~60 °C, max. 2 bar (open)

site requirements 3.2.2vendor

Press cooling capacity

up to 125 kW per press, by cycle time

site requirements 3.2.2vendor

Extruder cooling

~4 l/min, 2 to 3 kW, in 20 to 25 °C, 5 to 10 bar

site requirements 3.3.3vendor

Hydraulic oil cooler

~8 l/min, up to 5 kW per aggregate (2.5 kW per press)

site requirements 3.4.2vendor

Cooling water quality

7 to 8 °dH, pH 7 to 9, ≤ 200 µm, ≤ 500 µS/cm, Cl ≤ 20 mg/l

site requirements 3.1.2vendor

Classic

counted as one HRP 12 + one extruder; Toolex Alpha cross-check 1.2 kg steam, 15 l water per cycle

fleet calculatorestimate

Five presses, full demand

steam 750 to 900 kg/h · cooling 652.5 kW · water 305 to 540 l/min

sum of the abovedoc

Chiller electrical input

~80 to 125 kW per 250 kW of cooling (air-cooled, hot season)

scale.mdestimate

Electric boiler alternative

~0.68 kWh per kg of steam at 98 %

fleet calculatorestimate

Annual steam heat

~1,170 MWh at 1.0 M records, ~1,750 MWh at the start fleet's full ~1.5 M

fleet calculator, biomass.mdestimate

Circulating water is not consumption: the loop recirculates. Boiler make-up is about 0.75 to 0.9 m³/h before condensate return, much less with it.

Equipment schedule (proposed)

Tag	Item	Duty	Phase	Status
WT-1	Duplex softener, dosing	~1.0 to 1.2 m³/h	launch	estimate
T-1	Feed tank / hotwell	~1.5 m³, 90 to 95 °C	launch	estimate
P-1	Feed pumps, duty/standby	~1 m³/h, ~13 bar	launch	estimate
B-1, B-2	Boiler modules, lead/lag	2 × 500 kg/h, 10.5 bar	B-1 launch, B-2 with Duplex 2	proposal
B-3	Third module for N+1	500 kg/h	option	RFQ option
ECON-1	Flue-gas economizer, fired boilers	feed in 90 to 95 °C, out by vendor	with a fired bank	1st measure
ACC-1	Steam accumulator	by cycle overlap	option	Newbilt option
HP-1	Heat-recovery heat pump	feed tank to 90 to 95 °C	if it pays	3rd measure
CH-1 to CH-3	Air-cooled chillers at 40 °C ambient	3 × 250 kW	one per press stage	proposal
CH-4	Fourth module for N+1	250 kW	option	RFQ option
HX-1	Plate heat exchanger	~650 kW, ~2 K approach	launch, sized for 5	estimate
TK-3, TK-2	Warm return / cold buffer tanks	~5 m³ each	launch	estimate
P-2, P-3, P-4	Transfer, VFD supply, primary pumps	up to ~540 l/min	launch, staged	estimate
TC-1	Dry cooler ahead of HX-1	~650 to 750 kW reject	option	RFQ option
GC	Galvanics cooling, separate	12 to 20 °C, 10 L/min per PDPU	phase 5	open

Tag

Item

Duty

Phase

Status

WT-1

Duplex softener, dosing

~1.0 to 1.2 m³/h

launch

estimate

T-1

Feed tank / hotwell

~1.5 m³, 90 to 95 °C

launch

estimate

P-1

Feed pumps, duty/standby

~1 m³/h, ~13 bar

launch

estimate

B-1, B-2

Boiler modules, lead/lag

2 × 500 kg/h, 10.5 bar

B-1 launch, B-2 with Duplex 2

proposal

B-3

Third module for N+1

500 kg/h

option

RFQ option

ECON-1

Flue-gas economizer, fired boilers

feed in 90 to 95 °C, out by vendor

with a fired bank

1st measure

ACC-1

Steam accumulator

by cycle overlap

option

Newbilt option

HP-1

Heat-recovery heat pump

feed tank to 90 to 95 °C

if it pays

3rd measure

CH-1 to CH-3

Air-cooled chillers at 40 °C ambient

3 × 250 kW

one per press stage

proposal

CH-4

Fourth module for N+1

250 kW

option

RFQ option

HX-1

Plate heat exchanger

~650 kW, ~2 K approach

launch, sized for 5

estimate

TK-3, TK-2

Warm return / cold buffer tanks

~5 m³ each

launch

estimate

P-2, P-3, P-4

Transfer, VFD supply, primary pumps

up to ~540 l/min

launch, staged

estimate

TC-1

Dry cooler ahead of HX-1

~650 to 750 kW reject

option

RFQ option

Galvanics cooling, separate

12 to 20 °C, 10 L/min per PDPU

phase 5

open

Open for the RFQs

Newbilt (re-quote)

Classic: steam, cooling, power, weight; can it run from the central hydraulic plant?

Press return temperature over the cycle: 53 l/min at ~60 °C out of 20 to 25 °C is ~140 kW, more than the stated 125 kW peak. The real profile sizes HP-1, HX-1 and TC-1.

Is the accumulator needed with a modular boiler bank, and how big?

Condensate: the 2024 offer has one steam/water outlet valve and a steam trap per mould. How much cooling water reaches the trap per cycle, and can that condensate go back to boiler feed?

Boilers (Miura, Bangkok Industrial Boilers, STE)

2 × 500 kg/h against 3 × 500 kg/h and 1 × 1 t/h: price, footprint, lead/lag control, service from Chiang Mai.

Fuel: electric, biomass or LPG (sustainability.md, biomass.md); the electric bank draws ~520 to 625 kW.

Economizer on a fired bank: 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.

Blowdown cooling to the effluent limit; boiler registration and licensed operator (facility-security.md).

Chillers (Trane, Carrier, Daikin Applied, Hitachi)

3 × 250 kW against 3 × 350 kW (N+1), rated at 40 °C ambient; part-load efficiency.

Plate heat exchanger and tanks in scope; dry cooler TC-1 as a priced option.

Site

Water analysis before either RFQ: it decides softener or RO and the loop treatment.

Grid: ~800 to 1,000 kVA without electric steam, 1,250 to 1,600 kVA with it (scale.md).

Legend

Saturated steam 10 bar

Condensate return

Treated feedwater

Raw / make-up water

Process cooling supply 20 to 25 °C

Process cooling return, open

Chiller loop, cold

Chiller loop, warm

Heat recovery feedwater loop

Blowdown, drains

Flue gas

°CTemperature, Newbilt figure

°CDesign target or estimate

TBDSet by the vendor or by measurement

Dashed boxes are options. Bow-ties are isolation or control valves (a stem marks a control valve), squares strainers, T a steam trap. Circles are instruments: PT pressure, TT temperature, FT flow, AT conductivity (off-spec condensate goes to the warm tank); every one is logged to the plant data platform (digital-factory.md). Flow times supply and return temperature on each branch gives that press's cooling load; steam flow against records pressed gives steam per record.