direct reduction iron plant n.
Download
Skip this Video
Loading SlideShow in 5 Seconds..
Direct Reduction Iron Plant PowerPoint Presentation
Download Presentation
Direct Reduction Iron Plant

Loading in 2 Seconds...

play fullscreen
1 / 25

Direct Reduction Iron Plant - PowerPoint PPT Presentation


  • 102 Views
  • Uploaded on

Direct Reduction Iron Plant. Group Golf Selimos, Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette, Dominic F. (Scribe) Advisor : Orest Romaniuk. Table of Contents. 3 – Previous Questions 4 – Design Basis 5 – Block Flow Diagram 6 – Overall ASPEN Simulation

loader
I am the owner, or an agent authorized to act on behalf of the owner, of the copyrighted work described.
capcha
Download Presentation

PowerPoint Slideshow about 'Direct Reduction Iron Plant' - lefty


An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -
Presentation Transcript
direct reduction iron plant
Direct Reduction Iron Plant

Group Golf

Selimos, Blake A.

Arrington, Deisy C.

Sink, Brandon

Ciarlette, Dominic F. (Scribe)

Advisor : Orest Romaniuk

table of contents
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

previous questions
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.
design basis
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-gasCO2 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.
aspen simulation heat exchangers primary reformer
ASPEN simulation: Heat Exchangers & Primary Reformer

1650 F

75 psi

77 F

14.7 psi

180 F

75 psi

1878 F

14.7 psi

724 F

14.7 psi

420 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

energy sinks and loads primary reformer
Energy Sinks and Loads: Primary Reformer

1650 ºF

75 psi

1076ºF

75 psi

438º F

14.7 psi

1878 ºF

14.7 psi

Q= 280 mmBtu/hr

Q= - 280 mmBtu/hr

energy sinks and loads heat exchangers
Energy Sinks and Loads: Heat Exchangers

1076º F

75 psi

77º F

14.7 psi

724º F

14.7 psi

420º F

14.7 psi

1878º F

14.7 psi

724 ºF

14.7 psi

1650 F

75 psi

180º F

75 psi

Q=113 mmBtu/hr

Q=27 mmBtu/hr

equipment sizing
Equipment Sizing

Primary Reformer

Tubes: 10 in. Diameter, 26 ft. length

f = Maximum heat flux thorough tube walls = 21,000 Btu/ft2*hrd = Heat duty through primary reformer (from Aspen) = 279,515,872 Btu/hra = Total needed surface area of reformer tubes = d/f = 14,167 ft2t = a / 73 ft2 per tube = 194 tubes needed

aspen process economic analyzer
ASPEN Process Economic Analyzer

Units analyzed

  • Primary Reformer
  • Heat Exchanger
transportation costs by rail for feed product
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.
shipping storage
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.
summary
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.
work in progress
Work in Progress
  • Finish process simulation in ASPEN.
  • Run ASPEN economic analysis on whole process.
  • Size all equipment.