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 – Previous Questions 4 – Design Basis 5 – Block Flow Diagram 6 – Overall ASPEN Simulation 7 – Closer look: Primary Reformer and Heat Exchangers 8 – ASPEN Sim: Primary Reformer and Heat Exchangers 9 – Energy Sinks and Loads: Primary Reformer 10– Energy Sinks and Loads: Heat Exchangers 11– Energy Sinks and Loads: Overall Process 12– Equipment Sizing – ASPEN Process Economic Analyzer 15– Profit Economics 16– Transportation 17– Shipping & Storage

3 Previous Questions What type of catalyst will we be using in the primary reformer? What is the lowest purity of oxygen the oxygen fuel booster can operate with? Impurity concerns iron ore feed.

4 Design Basis 106 thousand lbmols/day of natural gas feedstock will be supplied for process from Gas Treatment Plant; natural gas is the main source for Carbon for the reformer. Supply portion of top-gas CO 2 to Industrial Gases Plant, thousand lbmols/day. Air Separations and Syngas Plant will supply 0.5 thousand lbmols/day of O 2 for the Oxy Fuel Booster.

5 Block Flow Diagram

6 Overall ASPEN Simulation

7 Closer look: Heat Exchangers & Primary Reformer Feed CH4 & recycle stream Exhaust going to ejector Air coming from air blower Heated process gas Reduction gas going to Oxy Fuel booster CH4 to combustion chamber Recycle gas to combustion chamber Heated gas from combustion Heated air to combustion chamber Recycle gas from CO2 Removal CH4, H2, CO, CO2, H20, N2 CO2, H2O, N2 N2, O2CH4, H2, CO, CO2, H20, N2 CH4, H2, CO, CO2, N2 CH4, N2CH4, H2, CO, CO2, H20, N2, O2 CO2, H2O, N2CH4, H2, CO, CO2, H20, N2 CH4, H2, CO, H20, N2

8 ASPEN simulation: Heat Exchangers & Primary Reformer 420 F 14.7 psi 724 F 14.7 psi 1878 F 14.7 psi 1650 F 75 psi 180 F 14.7 psi 438 F 14.7 psi 180 F 75 psi 615 F 14.7 psi 1076F 75 psi 180 F 75 psi 77 F 14.7 psi

9 Energy Sinks and Loads: Primary Reformer 1650 ºF 75 psi 1076ºF 75 psi 438º F 14.7 psi 1878 ºF 14.7 psi Q= mmBtu/hrQ= 280 mmBtu/hr

10 Energy Sinks and Loads: Heat Exchangers 1076º F 75 psi 724 ºF 14.7 psi 180º F 75 psi 1878º F 14.7 psi 724º F 14.7 psi 420º F 14.7 psi 77º F 14.7 psi 1650 F 75 psi Q=27 mmBtu/hrQ=113 mmBtu/hr

11 Energy Sinks and Loads: Overall process

12 Equipment Sizing Equipment Heat Duty (mmBtu/day)Size (ft 2 ) Feed Heat Exchanger Air Heat Exchanger Reformer (foot print) Primary Reformer Tubes: 10 in. Diameter, 26 ft. length f = Maximum heat flux thorough tube walls = 21,000 Btu/ft 2 *hr d = Heat duty through primary reformer (from Aspen) = 279,515,872 Btu/hr a = Total needed surface area of reformer tubes = d/f = 14,167 ft 2 t = a / 73 ft 2 per tube = 194 tubes needed

13 Units analyzed Primary Reformer Heat Exchanger ASPEN Process Economic Analyzer

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15 Profit Economics Production (ton/year) 1,840,000 Production cost ($/ton) Materials, Utilities, Transportation, Wages295 Product Sell Price ($/ton) 425 Profit per ton ($/ton) 130 Total profit per Year ($) 240,000,000

16 Transportation Costs By Rail For Feed/Product Basis of 1.84 mm ton produced 5,041 (ton/day) Average rail car holds 80 tons. With a maximum load per train of approximately 15,000 ton and 150 cars Plant will need a train every 2 days of approximately 130 cars. Average cost to ship by rail 0.03($/ton mile) Assuming a discounted rate of 25% for large volume of material transported. Using northeast Minnesota for iron oxide source and northwest Indiana for product shipment. Cost to ship 23.00($/ton) to ship product 12.00($/ton) import raw material.

17 Shipping/Storage Installed equipment cost for a private rail line with loading/unloading site at our capacity will be around $15 million. Storage facility with installed in-loading/out- loading conveyor system, a negative pressure dust/climate management system, and a 150 ton capacity will cost around $10 million.

18 Summary Producing 1.84 mm Ton/year DRI. Heat from combustion drives primary reformer and preheats gas entering primary reformer and combustion. Typical primary reformer size: ft 2. Cost of reformer & heat xers: $38 million. Yearly profit: $240 million. Transportation: 130 car train every 2 days. Storage: 2-week buffer for unexpected delays.

19 Work in Progress Finish process simulation in ASPEN. Run ASPEN economic analysis on whole process. Size all equipment.

20 Questions

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22 Typical Plant layout

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