Direct Reduction Iron Plant

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Direct Reduction Iron Plant

• Group Golf
• Selimos, Blake A.
• Arrington, Deisy C.
• Sink, Brandon
• Ciarlette, Dominic F. (Scribe)
• Advisor Orest Romaniuk

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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

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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.

5
Block Flow Diagram
6
Overall ASPEN Simulation
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Closer look Heat Exchangers Primary Reformer
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
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ASPEN simulation Heat Exchangers Primary
Reformer
1650 F 75 psi
77 F 14.7 psi
180 F 75 psi
1878 F 14.7 psi
420 F 14.7 psi
724 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
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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
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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
Q27 mmBtu/hr
Q113 mmBtu/hr
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Energy Sinks and LoadsOverall process
12
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/ft2hr 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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ASPEN Process Economic Analyzer

• Units analyzed
• Primary Reformer
• Heat Exchanger

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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
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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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