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Direct Reduction Iron Plant

Group Golf

Selimos, Blake A.Arrington, Deisy C.

Sink, BrandonCiarlette, Dominic F. (Scribe)

Advisor : Orest Romaniuk

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Table of Contents3 – Previous Questions4 – Design Basis5 – Block Flow Diagram6 – Overall ASPEN Simulation7 – Closer look: Primary Reformer and Heat Exchangers8 – ASPEN Sim: Primary Reformer and Heat Exchangers9 – Energy Sinks and Loads: Primary Reformer10– Energy Sinks and Loads: Heat Exchangers11– Energy Sinks and Loads: Overall Process12– Equipment Sizing13-14 – ASPEN Process Economic Analyzer15– Profit Economics16– Transportation17– Shipping & Storage

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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.

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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 CO2 to Industrial Gases Plant, 148.8 thousand lbmols/day.

•Air Separations and Syngas Plant will supply 0.5 thousand lbmols/day of O2 for the Oxy Fuel Booster.

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Block Flow Diagram

Oxy Fuel Boost Reformer

Removal

Guard Bed

Heater

Shaft Furnace

Top Gas Scrubber

Midrex Reformer

Main Air BlowerEjector Stack

Iron Ore

Iron Briquettes

Compressor

Fuel Gas

Recycle1.

2.

3.

4.

5.

6.

7.

9.10.

11.

12. 21.

14.

15.

16.

17.

18.

19.

20.

13.

22.

23.

24.

8.

Ejector Stack

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Overall ASPEN Simulation

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Closer look: Heat Exchangers & Primary Reformer

1 2 3 4 5 6 7 8 9 10Feed 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, O2 CH4, H2, CO, CO2, H20, N2

CH4, H2, CO, CO2, N2

CH4, N2 CH4, H2, CO, CO2, H20, N2,

O2

CO2, H2O, N2 CH4, H2, CO, CO2, H20, N2

CH4, H2, CO, H20,

N2

Heater Midrex Reformer

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4

5

3

9 7

6

10

8

2

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ASPEN simulation: Heat Exchangers & Primary Reformer

420 F14.7 psi

724 F14.7 psi

1878 F14.7 psi

1650 F75 psi

180 F14.7 psi

438 F14.7 psi

180 F75 psi

615 F14.7 psi

1076F75 psi

180 F 75 psi

77 F14.7 psi

Thousand lbmols/day 3 4 5 11 12 13 14 21 22 23 Stream Names FeedIn FeedOut Redux1 Air ToCombus Recycle CH4 Comb Exhaust1 Exhaust2CH4 88 88 5 - - 2 1 3 - -

H2 47 47 260 - - 31 - 31 - - CO 26 26 146 - - 17 - 17 - - CO2 223 223 270 - - - - 0 21 21 H2O 327 327 364 - - 218 - 218 256 256

N2 12 12 12 184 184 5 - 189 189 189

o2 - - - 52 52 - - 52 21 21 Total flow 724 724 1,056 236 236 274 1 511 486 486

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Energy Sinks and Loads: Primary Reformer

REFORMER

IN OU T

COMBUST

IN OU T

1650 ºF75 psi

1076ºF75 psi

438º F14.7 psi 1878 ºF

14.7 psi

Q= - 280 mmBtu/hrQ= 280 mmBtu/hr

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Energy Sinks and Loads: Heat Exchangers

FEEDHEAT

EXHAUST1 EXHAUST2

FEEDIN

FEEDOUT

1076º F75 psi

724 ºF14.7 psi

180º F75 psi

1878º F14.7 psi

AIRHEAT

EXHAUST2 EXHAUST3

AIRIN

AIROUT

724º F14.7 psi

420º F14.7 psi

77º F14.7 psi

1650 F75 psi

Q=27 mmBtu/hrQ=113 mmBtu/hr

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Energy Sinks and Loads:Overall process

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Equipment Sizing

Equipment Heat Duty

(mmBtu/day) Size (ft2)

Feed Heat Exchanger 113 1142

Air Heat Exchanger 27 1270

Reformer 28 57600 (foot print)

Primary Reformer

Tubes: 10 in. Diameter, 26 ft. length

f = Maximum heat flux thorough tube walls = 21,000 Btu/ft2*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 ft2

t = a / 73 ft2 per tube = 194 tubes needed

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Units analyzed•Primary Reformer•Heat Exchanger

ASPEN Process Economic Analyzer

Project Title: DRI Plant

Project Name: Golf

Proj. Location: North America

Estimate Date: 10MAR13 17:48:56

Component Component Total Equipment Piping Civil Steel Instrumentation Electrical Insulation Paint

REFORMER&COMBUST 34,190,000 21,500,000 3,800,000 890,000 920,000 4,000,000 240,000 2,600,000 240,000AIRHEAT 616,000 31,000 500,000 3,000 31,000 46,000 5,000FEEDHEAT 623,000 37,000 500,000 3,000 21,000 56,000 6,000

35,429,000 21,568,000 4,800,000 896,000 920,000 4,052,000 240,000 2,702,000 251,000

Other Reports - ProjectEquipment Summary - Total Cost

Heater Midrex Reformer

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5

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9 7

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8

2

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Profit EconomicsProduction (ton/year)

1,840,000

Production cost ($/ton)Materials, Utilities, Transportation, Wages 295

Product Sell Price ($/ton)425

Profit per ton ($/ton)130

Total profit per Year ($) 240,000,000

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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.

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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.

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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: 57600 ft2.• 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.

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Work in Progress

• Finish process simulation in ASPEN.• Run ASPEN economic analysis on whole

process.• Size all equipment.

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Questions

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Typical Plant layout

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