Direct Reduction Iron Plant
Group Golf
Selimos, Blake A.
Arrington, Deisy C.
Sink, Brandon
Ciarlette, Dominic F. (Scribe)
Advisor : Orest Romaniuk
1
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
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.
3
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 O 2 for
the Oxy Fuel Booster.
4
Block Flow Diagram
Overall ASPEN Simulation
Closer look: Heat Exchangers &
Primary Reformer
10
Feed
CH4 &
recycle
stream
Exhaus
t going
to
ejector
Air
coming
from air
blower
Heate
d
proces
s gas
Reduction
gas going to
Oxy Fuel
booster
CH4 to
combustio
n chamber
Recycle
gas to
combustio
n chamber
Heated
gas from
combustio
n
Heated air
to
combustio
n chamber
Recycle
gas
from
CO2
Remov
al
CH4, H2,
CO, CO2,
H20, N2
CO2,
H2O, N2
N2, O2
CH4,
H2, CO,
CO2,
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,
7
CO, H20,
N2
ASPEN simulation: Heat
Exchangers & Primary
Reformer
420 F
14.7
psi
77 F
14.7
psi
180 F
75 psi
724 F
14.7
psi
1650
F
75 psi
1878
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
COMBUST
REFORMER
1650
F
75 psi
1076
F
75 psi
IN
OUT
Q= 280 mmBtu/hr
438 F
14.7
psi
IN
1878
F
14.7
psi
OUT
Q= - 280 mmBtu/hr
Energy Sinks and Loads:
Heat Exchangers
1076
F
75 psi
77 F
14.7
psi
AIROUT
FEEDOUT
1878
F
14.7
psi
724 F
14.7
psi
FEEDHEAT
724 F
14.7
psi
EXHAUST2
EXHAUST1
420 F
14.7
psi
AIRHEAT
EXHAUST3
EXHAUST2
1650
F
75 psi
180 F
75 psi
AIRIN
FEEDIN
Q=113 mmBtu/hr
Q=27 mmBtu/hr
10
Energy Sinks and Loads:
Overall process
11
Equipment Sizing
Heat Duty
(mmBtu/day)
Size (ft2)
Feed Heat
Exchanger
113
1142
Air Heat
Exchanger
27
1270
Reformer
28
57600
(foot print)
Equipment
Primary Reformer
Tubes: 10 in. Diameter, 26 ft. length
f = Maximum heat flux thorough tube walls = 21,000 Btu/ft2*hr
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
12
ASPEN Process Economic
Analyzer
Units analyzed
Primary Reformer
Heat Exchanger
13
14
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
15
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.
16
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 inloading/out-loading conveyor system,
a negative pressure dust/climate
management system, and a 150 ton
capacity will cost around $10 million.
17
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 ft 2.
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.
18
Work in Progress
Finish process simulation in ASPEN.
Run ASPEN economic analysis on
whole process.
Size all equipment.
19
Questions
20
21
Typical Plant layout
22
23
24
25
