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DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057MME Mines and Metals Engineering GmbH
M M
E
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
MME
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
MME
Head Quater – Germany, Düsseldorf
Affilations in following continents
• EUROPE – Geramny,Slovakia & Poland
• ASIA – Iran,India & China
• NORTH AMERICA - Canada
Company with Global Presence
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Quality management system
MME Quality management system (QMS) is oriented on basis of the company’s processes.
It is distinguished between value adding activities (core processes), which convert the demands of the customers directly and
supporting and managing processes, which support the core-processes or are necessary for the maintenance of the management system.
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
MME
Maint. & Spare parts
Start Up & Comm .
Systems & Automation
Projects Financing
Train. & Tech. Assist.
Projects Execution
Feasibility Studies
Engineering
MME
MME Provides Services
for Steel Plantsand
Other Industries
Mines and Metals Engineering GmbH
Mines
Iron MakingPlants
Steel MakingPlants
Rolling Mills
Non FerrousIndustries
Turn Key
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
MME Organization Chart
Projects Managers(1300)Projects Managers
(1300)Projects Managers(1300)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Persian Direct Reduction Technology
®
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
PERED TRADE MARK CERTIFICATE
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
PERED PATENT CERTIFICATE
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
The PERED® Direct Reduction Process converts iron oxide pellets into highly metallized Iron either in the form of direct reduced iron(DRI), which are ideal feed materials for high quality steelmaking.
METALLIZING FURNACEThe shaft type metallizing furnace utilizes a continuous process flow at highest known efficiencies. Within the furnace, the pelletsdescend by gravity and will be metallized by direct counter current contact with reducing gasses in the reduction zone.The shaft furnace is divided in three zones with separate gas system, the upper zone for reduction, transition zone for carburizing andthe lower zone for cooling.The iron oxide material descends from the reduction furnace charge hopper by gravity through a dynamic gas seal into speciallydesigned feed pipes into the reduction furnace.The actual reduction zone in which the oxide is heated up to required temperature and the same time being reduced, is located at theupper part. The reducing gas is introduced around the circumference of the reduction zone in two level with different composition andtemperatures through specially designed ports. If O2 injection is not there, the temp and composition of the reducing gas will be thesame.Material flowing thro the reduction zone passes into a transition zone prior to entering the cooling zone. This transition zone has sufficientheight to isolate the reduction zone and cooling zone gas circuits from each other and to allow independent control.In-situ reforming can be achieved by injecting NG into the Transition zone or allowing cooling gas to flow upward from the cooling zoneon a controlled basis. In –situ reforming has several beneficial functions:•It carburizes the metallic iron•It cools the metallic iron•It uses sensible heat in the metallic iron to heat and reform the natural gas into additional reducing gas•It increases plant productivity•It decreases overall energy consumption
PERED PROCESS DESCRIPTION
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Cooling of the hot metalized DRI will be effected in the cooling zone beneath the transition zone. The DRI is cooled by counter current flow of recycled cooling gas. The cooling gas is introduced through a specially designed nozzles in the lower part of the metallizing furnace.
At the top of the cooling zone, hot cooling gas is sucked through four off take channels & scrubbed, compressed and recycled after conditioning with NG.
The reduction furnace operates at fairly higher pressure with the reduction and cooling gases remaining within the furnace system by means of dynamic seal at both top and bottom of the reduction furnace.
The raw material entering and product discharged through the seal legs provide resistance to the furnace gas escape. The additional sealing gas given in the top and bottom seal legs prevents completely the gas escape from the furnace.Under optimized chemical and thermal utilization of the gas reduction of the pellets will take place according to the following reactions:
Hematite reduced to magnetite 3Fe2O3 + CO 2Fe3O4 + CO23Fe2O3 + H2 2Fe3O4 + H2O
Magnetite reduced to iron WustiteFe3O4 + CO 3FeO + CO2Fe3O4 + H2 3FeO + H2O
Wustite reduced to metallic iron and CementiteFe O + CO Fe + CO2Fe O + H2 Fe + H2O 3Fe + CH4 Fe3C + 2H2
PERED PROCESS DESCRIPTION
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
REFORMINGIn the reformer, natural gas is reacted with CO2 and H2O to produce a reducing gas rich in CO and H2 in presence of specially designed catalyst. The important reforming reactions are:CH4 + CO2 2CO + 2H2CH4 + H2O CO + 3H2
These reactions are endothermic and thus require heat input. The reducing gas quality and the temperature of the reformer are automatically controlled based on the set operating guidelines..
The feed gas for the reformer will be a mixture of natural gas and recycled top gas with adequate steam for stochioimetric reaction. Approx. 70% of the top gas is used as process gas and flows through the process gas compressor, which will be conditioned with steam and NG to feed to reformer, while the remaining gas will be utilized as fuel to the reformer. The top gas fuel surplus if any will be vented to atmosphere at appropriate height. But the process doesn’t anticipate any venting of fuel during normal operation.MATERIAL HANDLING SYSTEMFor unloading, stacking, reclaiming of oxide and feeding to direct reduction plant and also storage and supply DRI to battery limit is designed as per the requirement .Product material handling also designed to handle cold DRI with adequate amount of storage facilities.INERT GAS FOR DR MODULEFor direct reduction plant, Seal gas is provided for sealing and purging purposes. The DR module will produce enough seal gas for that purpose with exhaust flue gas. In addition an Inert gas generator will be provided to start on the generator power for plant emergencies.WATER SYSTEMThree circuits with corresponding cooling system provide the water requirement of the plant.The Machinery cooling water system essentially serves to cool the machinery and equipment.The Process water system has two circuits namely contaminated water system & clean water system which provides for cooling and cleaning of the gas circuits.Cleaning and recycling of the water is provided in order to minimize the requirement of fresh makeup water.
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PERED PROCESS DESCRIPTION
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
MME ACTIVITIES
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES (IRAN)
South Kaveh DRI MIDREX ( 2 X 0.8 MTPY)
SHADEGAN DRI PERED (0.8 MTPY) Turn Key
BAFT DRI PERED (0.8 MTPY) Turn Key
MIYANEH DRI PERED (0.8 MTPY) Engineering & Procurement
NIRIZ DRI PERED (0.8 MTPY) Engineering & Procurement
Chaharmahal Steelmaking Plant – (1.2 MTPY) Turn Key
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES (IRAN)
Neiriz Steelmaking Plant Eng. &supply
Oxin Steel Wide Plate Mill Consultancy
KSC Wide Plate Mill (Turn Key)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
SHADEGAN (IRAN)
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CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES – NIERIZ (IRAN)
NIERIZ (IRAN)
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CURRENT PROJECT ACTIVITIES – NIERIZ (IRAN)
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CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
KSC - 3 DRI (MIDREX ) Module up gradation to 1.6 MMTPY (1996 - 99)
KSC - Slab casters increase of product length from 6 to 9 and 12 meters (1997)
KSC - Master Plan for up gradation to 3.2 MMTPY with SMS-DEMAG & Techint (1999)
INSIG - Pipe rolling mill technical assistance (2000)
KSC EAF No. 1&2 upgraded to 1.25 MMTPY (2001)
KSC ZAMZAM DRI (MIDREX ) Plant 0.8 MMTPY (turn-key) (2002)
KSC Oxide coating for DRI Modules (2002)
PROJECTS COMPLETED
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
PROJECTS COMPLETED
KSC - Engineering - oxygen injection system for DRI modules (2002)
MSC - pelletizing plant technical assistance (2003)
Gol-E-Gohar hematite recovery, feasibility study (laboratory & pilot plant testing) (2003)
INSIG , Automation system for new steelmaking plant (2005)
Gol-E-Gohar Polycom Project Engineering (2005)
KSC - ZAMZAM II (MIDREX) DRI Plant 800,000 t/y (turn-key) (2008)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
PROJECTS – BID STAGE
OXIN – COMBO HDRI JUMBO PERED 1.76 MTPY (IRAN) ISAPAT INDUS. LIMITED – MIDREX HDRI CONVERSION (INDIA)KSC, ZAM ZAM III – DRI JUMBO PERED (IRAN) GOL-E-GOHAR – HBI JUMBO PERED (IRAN)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
SUPPORT SERVICES
TRAINING – OPERATORS & ENGINEERS
COMMISSIONING OF DRI AND STEEL PLANTS
FEASIBILITY STUDIES
PROCUREMENT SERVICES
SUPPLY OF TECHNICAL EXPERTS
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
PERED TECHNOLOGY
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Major area of plant
Core area
Non Core Area
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Core Area
REDUCTION SHAFT FURNACE
GAS SCRUBBERS (COOLING AND TOP GAS)
COMPRESSOR STATION
REFORMER
RECUPERATOR & WASTE FLUE GAS SYSTEM
WATER SYSTEM
SEAL GAS SYSTEM
AUTOMATION
ELECTRICAL SYSTEM (MAIN SUBSTATION/RECEVING & DISTRIBUTION STATION)
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Non Core Area
INSTRUMENT / PLANT AIR SYSTEM
QUALITY CONTROL LABORATORY
WORKSHOP
MATERIAL HANDLING ( PRODUCT + IRON OXIDE)
RAW WATER TREATMENT
SHIPPING & RECEIVING
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
TYPICAL PERED REACTOR
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TYPICAL PERED REACTOR – GAS SYSTEM
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DUAL TOP GAS OFFTAKE
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PERED REACTOR SUPPORT & DOUBLE GAS ENTERY
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
TYPICAL PERED REFORMER
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TYPICAL PERED REACTOR COOLING GAS ARRANGEMENT
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PERED PROCESS SIMULATIONS (CFD/FEA)
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Gas pathlines based on pressure
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Pellet velocity & Residence time in furnace
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Effect of residence time of Pellets in Shaft Furnace
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Furnace 3D stress analysis
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Furnace 3D stress analysis
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PERED & OTHER TECHNOLOGY
Parameter Unit PERED(Estimated)
Midrex HYL
Capacity Ton per Year 400000-1800000 400000-1800000 400000-1800000
Option - DRI/HBI/HDRI/COMBO DRI/HBI/HDRI/COMBO DRI/HBI/HDRI/COMBO
Metallization % 92-95 92-95 92-95
Carbon % % 1.5 – 3.0 1.5 – 2.5 1.5 – 3.0
Pellet / DRI Ton / Ton DRI ~ 1.42 less dust 1.45 1.40
Gas Gcal / Ton DRI 2.4 – 2.6 2.5 – 2.8 2.5 – 3.0
Power Kwh / Ton DRI 100 - 120 100 - 130 60 – 70(with O2)
Water M3 / Ton DRI 0.9 – 1.4 1.0 – 1.5 1.2 – 1.6
Efficiency Ton / Day – M3 10-11 9.5-10 -
Maintenance Costs Euro / Ton DRI 3.0 4.3 4.7
Man-Hour Man-Hour / Ton DRI 0.30 0.45 0.50
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
Conclusion
PERED technology brings the following advantages
Latest technologyLower capital investmentLower energy & operation costsEnvironment friendly technologyJumbo module for more than 1.76 MTPYOption for Hot DRI / COMBOFlexibility to use local ore
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