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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. Table of Contents. 3 – Previous Questions 4 – Design Basis 5 – Block Flow Diagram 6 – Overall ASPEN Simulation
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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
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 • 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 • 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 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 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 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 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 Units analyzed • Primary Reformer • Heat Exchanger
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 • 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 • 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 • Finish process simulation in ASPEN. • Run ASPEN economic analysis on whole process. • Size all equipment.
