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Senior Design Presentation Direct Fe Reduction Iron Plant. Group Golf Selimos , Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette , Dominic F . (Scribe) Advisor : Orest Romaniuk Group Meeting 1 – 01/29/2013. Table of Contents. Page 3: Previous Questions Page 4: Design Basis

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Presentation Transcript
slide1

Senior Design PresentationDirect Fe Reduction Iron Plant

Group Golf

Selimos, Blake A.

Arrington, Deisy C.

Sink, Brandon

Ciarlette, Dominic F. (Scribe)

Advisor : OrestRomaniuk

Group Meeting 1 – 01/29/2013

slide2

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

2

slide3

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?

3

slide4

Design Basis

  • 2 million metric tons DRI produced yearly
  • Receive methane from Gas Treatment Plant
  • Receive oxygen from Air Separation Plant
  • Send CO2 to Gas Cleanup Water Reuse Plant

4

slide10

Hand Calculations

Calculating how much H2 will be needed in stream 6

10

slide11

Hand Calculations (2)

Calculating how much CH4 will be needed in stream 1

11

slide12

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.

12

slide13

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.

13

slide14

Material Balance

Process Gas (million mol/day)

14

slide15

Energy Balance Assumptions

For the furnace temperature we used an average value of 980F.

For the reformer we used a temperature of 1562F

Energy balance of furnace based only on incoming and outgoing iron due to weight of iron being substantially higher than weight of incoming gases.

15

slide16

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)

16

slide17

Energy Hand Calculations

Endothermic Reaction in the Primary Reformer

CH4+ CO2 → 2CO + 2H2

ΣH°f=(2*-95038693.04)+(2*0)-(-64075666.38)-(-338357695.6)

ΣH°f= 40,729,381

(h2-h1)CH4=0.03431(850-25)+(8502-252)+

(8503-503)+*(8504-504)

(h2-h1)CH4=212,355,976

∆H=212355976+(2*22191541)+(2*20967220)-40729381-44680237

∆H=213,263,879.8

17

slide19

Energy Balance-Work in progress

Flue Gas heat recovery steam.

Combustion Flue gas provides energy to heat incoming combustion air and feed gas.

19

slide20

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)

20

slide23

Summary

This process will produce 2.2 million tons DRI.

This plant will consume roughly 210,000 MW-h annually.

23 million mols of CO2 will be sent to the gas treatment plant.

Based on our economic analysis, this plant will cost approximately $97 million.

23

slide24

Oxygen-Fuel Boost Reformer

Relatively new technology for secondary oxygen reforming in MidrexProcesses. 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.

24

slide25

References

  • http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf
  • http://www.midrex.com/uploads/documents/MidrexCorporateBrochure1.pdf
  • US patent # 6602317 b2
  • US patent # 6524356 b2
  • US patent # 6506230 b2
  • http://www./handler.cfm/cat_id/163/section/global
  • http://www.midrex.com/uploads/documents/SSS.pdf
  • http://www.midrex.com/uploads/documents/DFM1Q041.pdf
  • http://www.midrex.com/uploads/documents/New%20Developments%20in%20the%20Midrex%20DR%20Process.pdf

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