Senior Design Presentation
Direct Fe Reduction Iron Plant
Group Golf
Selimos, Blake A.
Arrington, Deisy C.
Sink, Brandon
Ciarlette, Dominic F.
Advisor : Orest Romaniuk
Group Meeting 1 – 01/29/2013
Table of Contents
Page: Previous Questions
Page : Design Basis
Page : Process Flow Diagram (1)
Page : Material Balance
Page : Energy Balance
Page : Work in progress
Page : Economics
Page : Summary
Page : References
Page : Process Flow Diagram (2)
2
Report Outline
W
3
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?
4
Flow Diagram
10.
19.
Compressor
1.
9.
Iron Ore
8.
Recycle
Guard
Bed
17.
Top Gas
Scrubber
Fuel Gas
2.
7.
18.
Main Air
Removal
Shaft Furnace
24.
3.
Ejector Stack
13.
11.
15.
5.
22.
Oxy Fuel Boost
Reformer
6.
Midrex
Reformer
Heater
2
12.
21.
16.
4.
20.
14.
5
Iron Briquettes
Flow Diagram - Reformers
13.
15.
5.
22.
Oxy Fuel Boost
Reformer
Midrex
Reformer
12.
21.
16.
14.
6
6.
Flow Diagram – Top Gases
10.
Compressor
9.
8.
Recycle
Top Gas
Scrubber
17.
Fuel Gas
18.
Removal
13.
7
7.
Flow Diagram – Feed/Heat Recovery
1.
Guard
Bed
10.
2.
24.
Main Air
3.
Ejector Stack
11.
22.
Heater
22.
2
12.
4.
8
12.
Flow Diagram - Furnace
Iron Ore
19.
7.
Shaft Furnace
6.
6.
20.
Iron Briquettes
9
Hand Calculations
10
Mass Balance Assumptions
11
Mass Balance
12
Energy Balance Assumptions
For the furnace temperature we used an average
value of 800K.
For the reformer we used a temperature of
1123K
Energy balance of furnace based only on
incoming and outgoing iron due to weight of
iron being substantially higher than weight of
incoming gases.
Page 23: Process Flow Diagram (2)
13
Energy Balance
Heat capacity Empirical Constants
Heats of formation
Components
MW
Btu
∆Hf tonmol
a
b
c
d
0.03431
0.00005469
3.66E-09
-1.10E-11
-207922613.9
0.03336
-0.00000688
7.60E-09
-3.59E-12
-95038693.04
7-12: 28
Material Balance
0.02895
0.00000411
3.55E-09
-2.22E-12
0.03611
0.00004233
2.89E-08
7.46E-12
0.02884
7.65E-08
3.29E-09
-8.70E-13
0
0.0291
0.00001158
-6.08E-09
1.31E-12
T
Cp/R
A
B
D
1043
Page 17-19:
Economics
3.005
-0.111
6.11E-03
1.15E-05
12.48
11.812
9.70E-03
-1.98E-05
CH4
16
Page 5-6: Process
Flow-64075666.38
Diagram (1)
H2O
CO
Page
CO2
Page
H2
O2
18
44
-338357695.6
13-15:2 Energy Balance
0
32
Page 16: Work in progress
Fe
Fe2O3
960
Page 20: Summary
Page 21: References
Page 23: Process Flow Diagram (2)
14
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
Btu
tonmol
0.00005469
(8502-252)+
2
−1.10E−11
(8503-503)+
*(8504-504)
(h2-h1)CH4=0.03431(850-25)+
3.66𝐸−09
3
4
(h2-h1)CH4=212,355,976
Btu
tonmol
∆H=212355976+(2*22191541)+(2*20967220)-40729381-44680237
∆H=213,263,879.8
15
Btu
tonmol
Energy Balance
SUMMARY
REFORMER
CH4+ CO2 → 2CO + 2H2
213,000,000
38,000
CH4+ H2O → CO + 3H2
198,000,000
36,000
2CH4+ O2 → 2CO + 4H2
510,000,000
93,000
CO + H2O → CO2 + H2
-14,000,000
-2,700
65,000,000
12,000
CH4→ C(S) + 2H2
OXY BOOST
2CH4+ O2 → 2CO + 4H2
2CH4+ 2O2 → CO2 + 2H2O
510,000,000
93,000
-170,000,000
-31,000
FURNACE
Fe2O3 + 3CO → 2Fe + 3CO2
Hreaction =-1.08743E+12[KJ]
Fe2O3 + 3H2 → 2Fe + 3H2O
16
Energy Balance- Working in progress
Flue Gas heat recovery steam.
Page 5-6: Process Flow Diagram (1)
Combustion Flue gas provides energy to
heat incoming combustion air and feed
gas.
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)
17
Total Capital Investment
Direct costs
$(MM)
Major Equipment Costs
Page 5-6:
Process Flow
Diagram (1)
Installation/
Construction
Costs
Page 7-12: Material Balance
Piping
97
110
30
Page 13-15: Energy
Balance
Electrical
19
Service Facilities
Page 16: Work in progress
Buildings/ Misc.
Page 17-19: Economics
Total
55
19
330
Indirect Costs
Page 20: Summary
Land
Page 21:
References Supervision
Engineering/
8
30
Page 23: Legal/
ProcessContingency
Flow Diagram (2)
Total
Total Capital Investment
38
76
406
18
Major Equipment Cost
Major Equipment Costs
$(MM)
Page 5-6: Process Flow
Diagram (1)
Reformer
35
Page 7-12: Material
Balance
Shaft
Furnace
32
Page 13-15: Energy Balance
Other Equipment
30
Page 16: Work in progress
Page 17-19: Economics
Total
97
Page 20: Summary
Page 21: References
Page 23: Process Flow Diagram (2)
19
Profit
Production (Tons/yr)
2,000,000
Page 5-6: Process Flow Diagram (1)
Production Cost ($/ton)
Page 7-12: Material Balance
240
Price ($/ton)
Page 13-15:Product
Energy Sell
Balance
425
Page 16: Work in progress
Profit per ton ($/ton)
185
Page 17-19: Economics
Total Profit per Year ($)
Page 20: Summary
370,000,000
Page 21: References
Page 23: Process Flow Diagram (2)
20
Oxygen-Fuel Boost Reformer
Relatively new technology for secondary oxygen reforming in Midrex
Processes. 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.
Page 5-6: Process Flow Diagram (1)
21
Summary
Page 5-6: Process Flow Diagram (1)
Page 7-2: 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)
22
References
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)
23
Questions
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)
24