direct reduction iron plant
DESCRIPTION
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 - PowerPoint PPT PresentationTRANSCRIPT
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Direct Reduction Iron Plant
Group Golf
Selimos, Blake A.Arrington, Deisy C.
Sink, BrandonCiarlette, Dominic F. (Scribe)
Advisor : Orest Romaniuk
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Table of Contents3 – Previous Questions4 – Design Basis5 – Block Flow Diagram6 – Overall ASPEN Simulation7 – Closer look: Primary Reformer and Heat Exchangers8 – ASPEN Sim: Primary Reformer and Heat Exchangers9 – Energy Sinks and Loads: Primary Reformer10– Energy Sinks and Loads: Heat Exchangers11– Energy Sinks and Loads: Overall Process12– Equipment Sizing13-14 – ASPEN Process Economic Analyzer15– Profit Economics16– Transportation17– Shipping & Storage
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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.
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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 O2 for the Oxy Fuel Booster.
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Block Flow Diagram
Oxy Fuel Boost Reformer
Removal
Guard Bed
Heater
Shaft Furnace
Top Gas Scrubber
Midrex Reformer
Main Air BlowerEjector Stack
Iron Ore
Iron Briquettes
Compressor
Fuel Gas
Recycle1.
2.
3.
4.
5.
6.
7.
9.10.
11.
12. 21.
14.
15.
16.
17.
18.
19.
20.
13.
22.
23.
24.
8.
Ejector Stack
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Overall ASPEN Simulation
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Closer look: Heat Exchangers & Primary Reformer
1 2 3 4 5 6 7 8 9 10Feed CH4 & recycle
stream
Exhaust going to ejector
Air coming from air blower
Heated process
gas
Reduction gas going to Oxy Fuel booster
CH4 to combustion
chamber
Recycle gas to
combustion chamber
Heated gas from
combustion
Heated air to combustion
chamber
Recycle gas from
CO2 Removal
CH4, H2, CO, CO2, H20,
N2
CO2, H2O, N2
N2, O2 CH4, H2, CO, CO2, H20, N2
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, CO, H20,
N2
Heater Midrex Reformer
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4
5
3
9 7
6
10
8
2
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ASPEN simulation: Heat Exchangers & Primary Reformer
420 F14.7 psi
724 F14.7 psi
1878 F14.7 psi
1650 F75 psi
180 F14.7 psi
438 F14.7 psi
180 F75 psi
615 F14.7 psi
1076F75 psi
180 F 75 psi
77 F14.7 psi
Thousand lbmols/day 3 4 5 11 12 13 14 21 22 23 Stream Names FeedIn FeedOut Redux1 Air ToCombus Recycle CH4 Comb Exhaust1 Exhaust2CH4 88 88 5 - - 2 1 3 - -
H2 47 47 260 - - 31 - 31 - - CO 26 26 146 - - 17 - 17 - - CO2 223 223 270 - - - - 0 21 21 H2O 327 327 364 - - 218 - 218 256 256
N2 12 12 12 184 184 5 - 189 189 189
o2 - - - 52 52 - - 52 21 21 Total flow 724 724 1,056 236 236 274 1 511 486 486
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Energy Sinks and Loads: Primary Reformer
REFORMER
IN OU T
COMBUST
IN OU T
1650 ºF75 psi
1076ºF75 psi
438º F14.7 psi 1878 ºF
14.7 psi
Q= - 280 mmBtu/hrQ= 280 mmBtu/hr
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Energy Sinks and Loads: Heat Exchangers
FEEDHEAT
EXHAUST1 EXHAUST2
FEEDIN
FEEDOUT
1076º F75 psi
724 ºF14.7 psi
180º F75 psi
1878º F14.7 psi
AIRHEAT
EXHAUST2 EXHAUST3
AIRIN
AIROUT
724º F14.7 psi
420º F14.7 psi
77º F14.7 psi
1650 F75 psi
Q=27 mmBtu/hrQ=113 mmBtu/hr
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Energy Sinks and Loads:Overall process
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Equipment Sizing
Equipment Heat Duty
(mmBtu/day) Size (ft2)
Feed Heat Exchanger 113 1142
Air Heat Exchanger 27 1270
Reformer 28 57600 (foot print)
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
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Units analyzed•Primary Reformer•Heat Exchanger
ASPEN Process Economic Analyzer
Project Title: DRI Plant
Project Name: Golf
Proj. Location: North America
Estimate Date: 10MAR13 17:48:56
Component Component Total Equipment Piping Civil Steel Instrumentation Electrical Insulation Paint
REFORMER&COMBUST 34,190,000 21,500,000 3,800,000 890,000 920,000 4,000,000 240,000 2,600,000 240,000AIRHEAT 616,000 31,000 500,000 3,000 31,000 46,000 5,000FEEDHEAT 623,000 37,000 500,000 3,000 21,000 56,000 6,000
35,429,000 21,568,000 4,800,000 896,000 920,000 4,052,000 240,000 2,702,000 251,000
Other Reports - ProjectEquipment Summary - Total Cost
Heater Midrex Reformer
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5
3
9 7
6
10
8
2
14
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Profit EconomicsProduction (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
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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.
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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.
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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.
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Work in Progress
• Finish process simulation in ASPEN.• Run ASPEN economic analysis on whole
process.• Size all equipment.
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Questions
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Typical Plant layout
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