1. Senior Design Presentation Direct Fe Reduction Iron Plant Group Golf Selimos, Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette, Dominic F. Advisor : Orest Romaniuk Group Meeting 1 – 01/29/2013

2. 2 Table of Contents Page 3: Previous Questions Page 4: Design Basis Page 5-9: Process Flow Diagram Page 10-14: Material Balance Page 15-18: Energy Balance Page 19: Work in progress Page 20-22: Economics Page 23: Summary Page 24: Oxy Fuel Booster Page 25: References

3. 3 Previous Questions Will Sulfur in the methane stream poison the Nickel catalysis? What is our ore source? What is the largest Midrex plant currently in operation? What are our power requirements?

4. 4 Design Basis 2 million metric tons DRI produced yearly Receive methane from Gas Treatment Plant Receive oxygen from Air Separation Plant Send CO 2 to Gas Cleanup Water Reuse Plant

5. 5 Flow Diagram

6. 6 Flow Diagram - Reformers

7. 7 Flow Diagram – Top Gases

8. 8 Flow Diagram – Feed/Heat Recovery

9. 9 Flow Diagram - Furnace

10. 10 Calculating how much H 2 will be needed in stream 6 Hand Calculations

11. 11 Hand Calculations (2) Calculating how much CH 4 will be needed in stream 1

12. 12 Material Balance Assumptions Post reformer Assume following conversion rates Reaction 1: 80% Reaction 2: 80% Reaction 3: 80% Post OXY booster Assume booster adds 5.0% of stream 5 to stream 5. Assume conversion rate of 80% Post shaft furnace Assume reduction reaction conversion rates of 93% Process gas split Assume all steam is condensed and all water is sent to process recycle stream. Assume 60:40 split for streams 9:17.

13. 13 Material Balance Assumptions (2) Post CO2 removal Assume 100% removal of appreciable CO2. Top gas to combustion split Assume no water in this stream. Ore feed Assume only Fe2O3. In reality this stream will contain, in addition to Fe2O3, Fe3O4, and SiO2. Needs to be corrected to include other components. Product stream Assume only pure Fe and residual Fe2O3. Post reformer combustion Assume total combustion of fuel gases from stream 21.

14. 14 Material Balance Stream number 135679 Stream nameMethane process feed Methane and recycle process stream Reformed process gas Temperature boosted process gas Top gas 60% recycle gas split with water CH 4 45 9332 H2H2 -4828864 CO-2575942 CO 2 136335935 H2OH2O-82-- N2N2 232221 C3+C3+33---- Process Gas (million mol/day)

15. 15 Energy Balance Assumptions For the furnace temperature we used an average value of 800K. For the reformer we used a temperature of 1123K Energy balance of furnace based only on incoming and outgoing iron due to weight of iron being substantially higher than weight of incoming gases.

16. 16 Energy Balance Page 5-6: Process Flow Diagram (1) Page 7-12: Material Balance Page 13-15: Energy Balance Page 16: Work in progress Page 17-19: Economics Page 20: Summary Page 21: References Page 23: Process Flow Diagram (2) 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

17. 17 Energy Balance- Work in progress Flue Gas heat recovery steam. Combustion Flue gas provides energy to heat incoming combustion air and feed gas.

18. 18 Energy Hand Calculations

19. 19 Energy Balance SUMMARY REFORMER CH 4 + CO 2 → 2CO + 2H 2 213,000,000 38,000 CH 4 + H2O → CO + 3H 2 198,000,000 36,000 2CH 4 + O2 → 2CO + 4H 2 510,000,000 93,000 CO + H 2 O → CO2 + H 2 -14,000,000 -2,700 CH 4 → C(S) + 2H 2 65,000,000 12,000 OXY BOOST 2CH 4 + O 2 → 2CO + 4H 2 510,000,000 93,000 2CH 4 + 2O2 → CO 2 + 2H 2 O -170,000,000 -31,000 FURNACE Fe 2 O 3 + 3CO → 2Fe + 3CO 2 H reaction =-1.08743E+12[KJ] Fe 2 O 3 + 3H2 → 2Fe + 3H2O

20. 20 Total Capital Investment Page 5-6: Process Flow Diagram (1) Page 7-12: Material Balance Page 13-15: Energy Balance Page 16: Work in progress Page 17-19: Economics Page 20: Summary Page 21: References Page 23: Process Flow Diagram (2) Direct costs$(MM) Major Equipment Costs97 Installation/ Construction Costs 110 Piping30 Electrical19 Service Facilities55 Buildings/ Misc.19 Total330 Indirect Costs Land8 Engineering/ Supervision30 Legal/ Contingency38 Total76 Total Capital Investment406

21. 21 Major Equipment Cost Major Equipment Costs$(MM) Reformer35 Shaft Furnace32 Other Equipment30 Total97

22. 22 Profit Production (Tons/yr)2,000,000 Production Cost ($/ton)240 Product Sell Price ($/ton)425 Profit per ton ($/ton)185 Total Profit per Year ($)370,000,000

23. 23 Summary This process will produce 2 million metric tons DRI.

24. 24 Oxygen-Fuel Boost Reformer Relatively new technology for secondary oxygen reforming in Midrex Processes. Uses a two step partial combustion process in which oxygen and methane are mixed and combusted in the first stage. The combustion gases are then mixed in an elongated mixing tube with methane and oxygen in a swirling motion producing H2 on CO syngas along with H2O, CO2 and CH4 to be used as enrichment gases to combine with and enhance the reducing gas from the reformer. This increases the reducing gas amount and temperature of gas going to the furnace increasing productivity.

25. 25 References

26. 26 Report Outline

27. 27 Questions

28. 28 Complete Flow Diagram

29. 29