1. 1 Direct Reduction Iron Plant Group Golf Selimos, Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette, Dominic F. (Scribe) Advisor : Orest Romaniuk

2. Table of Contents 3 – Design Basis 4 – Process Flow Diagram 5 – Initial Control Scheme 6-7 –Plant layout 8 – Energy balance data and equations 9-15 – Economics with calculations 16 – Report 2

3. Questions from previous presentation Can our piping withstand the high temperatures of the streams? – Refractory lining will allow us to protect piping from high temperatures. Will we send combustion exhaust to resource recovery plant? – No. The exhaust cannot be separated economically. 3

4. Design Basis 4

5. Process Flow Diagram 5

6. Initial Control Scheme 6

7. Plant Layout (1) 7 1 2 3 4 5 6 1.Ejector 2.HX -1 3.HX -2 4.Reformer 5.Oxy booster 6.Furnace 7.Storage 8.Tankage 9.Building Road Railroad Wind 7 7 9 7

8. 8 Plant Layout (2)

9. Energy Balance Data and Equations 9 Heats of formation Heat capacity Empirical Constants ComponentsMWabcd CH416-64075666.380.034310.000054693.66E-09-1.10E-11 H2O18-207922613.90.03336-0.000006887.60E-09-3.59E-12 CO28-95038693.040.028950.000004113.55E-09-2.22E-12 CO244-338357695.60.036110.000042332.89E-087.46E-12 H2200.028847.65E-083.29E-09-8.70E-13 O23200.02910.00001158-6.08E-091.31E-12 TCp/RABD Fe10433.005-0.1116.11E-031.15E-05 Fe2O396012.4811.8129.70E-03-1.98E-05

10. Equipment 10 EquipmentEquipment Cost (USD)Total Installed Cost (USD) Primary Reformer46,000,000188,000,000 Shaft Furnace39,000,000168,000,000 Oxygen fuel booster11,000,00040,000,000 Scrubber650,0002,000,000 Main Air Blower500,0002,000,000 Heat Exchanger 1120,000510,000 Heat Exchanger 2 100,000436,000 Zinc Oxide Bed3,000,00010,000,000 Compressor4,000,00015,000,000 CO2 Removal (MDEA)7,000,00029,000,000 Storage facility-12,000,000 Rail and Loading-18,000,000 Total110,000,000483,000,000

11. Personnel EmployeesMan hours per day worked 28 Operators224 5 Engineers (shared with 3 plants)40/3 1 Complex manager (shared with whole plant)8/9 20 Administration (shared with whole plant)160/9 3 Safety (shared with whole plant)24/9 4 Medical staff (shared with plant)32/9 1 Maintenance (shared with plant)8/9 4 Supervisor24 Total292 11

12. Calculations: 12

13. Expenses 13 1 Year (USD)5 Year (USD)10 Year (USD) Loan29,000,00024,000,00017,000,000 Depreciation3,000,000 Electrical20,000,00022,000,00024,000,000 Natural Gas Cost Transfer From Alpha No Transfer CostBetween Groups Oxygen Cost Transfer From Matt’s group No Transfer CostBetween Groups Transportation Costs 72,000,00078,000,00086,000,000 Salaries and Fringes ($100/hr.) 11,000,00012,000,00014,000,000 Maintenance15,000,00016,000,00017,000,000 Feed Ore406,000,000439,000,000485,000,000 Total Expenses556,000,000594,000,000646,000,000

14. Revenue 14 Products Sell Cost/Ton ($) TPD$/Day$/Year DRI4255,0002,000,000790,000,000 Carbon Dioxide 15 Giving to India No Transfer Costs Between Groups Total-5,0002,000,000790,000,000

15. Profit 15 1 Year (USD)10 Year (USD)17 Year (USD) Total Expenses550,000,000640,000,000720,000,000 Total Revenue790,000,000860,000,0001,000,000,000 Income Before Taxes 240,000,000270,326,000370,000,000 Taxes (40%)97,000,000110,000,000150,000,000 Income After Taxes 150,000,000160,000,000220,000,000 Total Cumulative Income 150,000,0001,665,000,0003,000,000,000

16. Payback Period 16 NPV1,030,000,000 IRR32.85% Payback Period4 Years

17. Report 17 Executive Summary Discussion Recommendations Appendix i.Design Basis ii.Block Flow Diagram iii.Process Flow Diagram (Major Equipment) iv.Material and Energy Balances v.Calculations vi.Annotated Equipment List (Data Sheet) vii.Economic Evaluation (Equipment Cost) viii.Utilities ix.Conceptual Control Scheme x.General Arrangement (Major Equipment Layout) xi.Distribution and End-use Issues Review xii.Constraints Review xiii.Applicable Standards xiv.Project Communication File xv.Information Sources and References Reference Not started In progress Completed

18. Questions 18