Direct Reduction Iron Plant
Group Golf
Selimos, Blake A.
Arrington, Deisy C.
Sink, Brandon
Ciarlette, Dominic F. (Scribe)
Advisor : Orest Romaniuk
1
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
13-14 – ASPEN Process Economic Analyzer
15– Profit Economics
16– Transportation
17– Shipping & Storage
2
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.
3
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.
4
Block Flow Diagram
10.
19.
Compressor
9.
1.
8.
Recycle
Guard Bed
17.
Top Gas
Scrubber
Fuel Gas
2.
24.
7.
18.
Removal
5.
Main Air
Blower
3.
EjectorStack
Stack
Ejector
Iron Ore
Shaft Furnace
13.
11.
15.
22.
Oxy Fuel Boost
Reformer
6.
Midrex
Reformer
Heater
23.
12.
21.
16.
4.
20.
14.
Iron Briquettes
5
Overall ASPEN Simulation
6
Closer look: Heat Exchangers &
Primary Reformer
5
10
1
3
8
2
Midrex
Reformer
Heater
9
7
4
6
1
2
3
4
5
6
7
8
9
10
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, 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
7
ASPEN simulation: Heat Exchangers &
Primary Reformer
77 F
14.7 psi
180 F
75 psi
724 F
14.7 psi
420 F
14.7 psi
1650 F
75 psi
1878 F
14.7 psi
438 F
14.7 psi
1076F
75 psi
180 F
14.7 psi
615 F
14.7 psi
180 F
75 psi
Thousand lbmols/day
Stream Names
CH4
H2
CO
CO2
H2O
N2
o2
Total flow
3
4
5
11
12
13
14
21
22
23
FeedIn FeedOut Redux1 Air
ToCombus Recycle CH4 Comb Exhaust1 Exhaust2
88
47
26
223
327
12
724
88
47
26
223
327
12
724
5
260
146
270
364
12
1,056
184
52
236
184
52
236
2
31
17
218
5
274
1
1
3
31
17
0
218
189
52
511
21
256
189
21
486
8
21
256
189
21
486
Energy Sinks and Loads:
Primary Reformer
COMBUST
REFORMER
1076ºF
75 psi
IN
1650 ºF
75 psi
OUT
Q= 280 mmBtu/hr
438º F
14.7 psi
IN
1878 ºF
14.7 psi
OUT
Q= - 280 mmBtu/hr
9
Energy Sinks and Loads:
Heat Exchangers
1076º F
75 psi
77º F
14.7 psi
AIROUT
FEEDOUT
1878º F
14.7 psi
FEEDHEAT
724 ºF
14.7 psi
724º F
14.7 psi
EXHAUST2
EXHAUST1
420º F
14.7 psi
AIRHEAT
EXHAUST3
EXHAUST2
1650 F
75 psi
180º F
75 psi
AIRIN
FEEDIN
Q=113 mmBtu/hr
Q=27 mmBtu/hr
10
Energy Sinks and Loads:
Overall process
11
Equipment Sizing
Heat Duty
(mmBtu/day)
Size (ft2)
Feed Heat
Exchanger
113
1142
Air Heat
Exchanger
27
1270
Reformer
28
57600
(foot print)
Equipment
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
12
ASPEN Process Economic Analyzer
5
Units analyzed
• Primary Reformer
• Heat Exchanger
10
1
3
8
2
Midrex
Reformer
Heater
9
7
4
6
Other Reports - Project
Equipment Summary - Total Cost
Project Title:
Project Name:
Proj. Location:
Estimate Date:
Component
REFORMER&COMBUST
AIRHEAT
FEEDHEAT
DRI Plant
Golf
North America
10MAR13 17:48:56
Component Total Equipment
34,190,000
616,000
623,000
35,429,000
21,500,000
31,000
37,000
21,568,000
Piping
3,800,000
500,000
500,000
4,800,000
Civil
Steel
890,000
3,000
3,000
896,000
920,000
920,000
Instrumentation
4,000,000
31,000
21,000
4,052,000
Electrical
240,000
240,000
Insulation
Paint
2,600,000
46,000
56,000
2,702,000
240,000
5,000
6,000
251,000
13
14
Profit Economics
Production (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
15
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.
16
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/outloading conveyor system, a negative pressure
dust/climate management system, and a 150
ton capacity will cost around $10 million.
17
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.
18
Work in Progress
• Finish process simulation in ASPEN.
• Run ASPEN economic analysis on whole
process.
• Size all equipment.
19
Questions
20
21
Typical Plant layout
22
23
24
25