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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. Slide 3 – Previous Questions Slide 4 – Design Basis Slide 5 – Block Flow Diagram Slide 6 – Overall ASPEN Simulation

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Direct Reduction Iron Plant

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  1. Direct Reduction Iron Plant Group Golf Selimos, Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette, Dominic F. (Scribe) Advisor : Orest Romaniuk

  2. Table of Contents Slide 3 – Previous Questions Slide 4 – Design Basis Slide 5 – Block Flow Diagram Slide 6 – Overall ASPEN Simulation Slide 7 – Flow Diagram 1 Slide – Flow Diagram 2 Slide – Flow Diagram 3 Slide – Flow Diagram 4 Slide – Energy Sinks and Loads Slide – Sizing, Cost, and Utilities Slide – Summary, and Work in progress

  3. 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.

  4. Design Basis • 0.126 mmlbmols/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 the back-end CO2 to Industrial Gases Plant, 0.0518 mmlbmols/day • Air Separations and Syngas Plant will supply 0.004 mmlbmols/day of O2 for the Oxy Booster in ration (0.9 O2 : 0.1 N2)

  5. Block Flow Diagram

  6. Overall ASPEN Simulation

  7. Flow Diagram 1Heat Exchangers & Primary Reformer

  8. Flow Diagram 2Oxygen Fuel Booster 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

  9. Energy Sinks and loads 1650 F 75 psi 1076F 75 psi 438 F 8 psi 1878 F 14.7 psi Q= 28 mmBtu/hr Q= - 28 mmBtu/hr

  10. Energy Sinks and loads 1076 F 75 psi 77 F 14.7 psi 724 F 14.7 psi 420 F 14.7 psi 1878 F 14.7 psi 724 F 14.7 psi 1650 F 75 psi 180 F 75 psi Q=112,699,282 Btu/hr Q=26,739,452 Btu/hr

  11. Energy Sources and Sinks

  12. 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

  13. Cost

  14. Transportation Costs By Rail For Feed/Product • Basis of 1.84mm ton produced 5,041 (ton/day) • Average rail car holds 80tons. With a maximum load per train of approximately 15,000ton and 150 cars • Plant will need a train every 2days 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.

  15. Shipping/Storage • Installed equipment cost for a private rail line with loading/unloading site at our capacity will be around 15mil • Storage facility with installed in-loading/out-loading conveyor system, a negative pressure dust/ climate management system, and a 150ton capacity will cost around 10mil

  16. Summary, and Work in progress

  17. Questions

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