Production of 5000 TPD of Direct Reduced Iron(DRI)

Project Advisor Engr. Zia -ul-Haq Session: 2009-2013 Group members: Waseem-ur-Rehman 09-CH-02 M.Faiq Ilyas 09-CH-10 Muddsir Munir 09-CH-38 M.Yasar Zia 09-CH-98 M. Kamran Hyder 09-CH-104

Presentation Sequence
Introduction Comprehensive Flow Sheet Overall Material Balance Overall Energy Balance Designing

Introduction
Direct-reduced iron (DRI) also called sponge iron is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas. The reducing gas is a mixture majority of hydrogen (H2) and carbon monoxide (CO) which acts as reducing agent. Fe2O3 + CO > 2Fe + CO2 Fe2O3 + H2 > 2FeO + H2O

Process Description
The direct reduction of the oxide is carried out on a continuous basis. The iron oxide, fed to the top of the shaft furnace, flows downward under gravity and is discharged from the bottom in the form of direct reduced iron. Reduced Gases having major components of Hydrogen and Carbon monoxide is fed into the Shaft Furnace. Reaction between Iron Oxide and Reduced Gases occurs at 950oC and Reduced iron in form of Pellets is achieved at the bottom of the Furnace. At the top of the Furnace, Spent gases are exists.

Cont.
Spent gases are recompressed and mixed with Natural gas and transported to the Reformer. Hence a Continuous process occurs.

Direct Reduction Technology

2003 World DRI Production by Process
In 2003 the MIDREX Direct Reduction Process was the leading direct reduction technology with more than 60% of world DRI production for the 17th consecutive year.

2003 World Direct Reduction Capacity Utilization by Process

 Reduction Process DRI Direct MIDREX Direct Reduction Flowsheet

Flowsheet
Flue Flue Gas Gas Natural Natural Gas Gas

Iron Iron Oxide Oxide

Process Process Gas Gas System System

Process Process Gas Gas Compressors Compressors Top Top Gas Gas Scrubber Scrubber

Shaft Furnace

Reformer Reformer
Main Main Air Air Blower Blower Reducing Reducing Gas Gas Cooling Cooling Gas Gas Scrubber Scrubber

Flue Flue Gas Gas

Fuel Fuel Gas Gas

Ejector Ejector Stack Stack Heat

Feed Feed Gas Gas Combustion Combustion Air Air

Cooling Cooling Gas Gas Compressor Compressor

Heat Recovery Recovery

Direct MIDREX MIDREX Direct Reduced Iron Reduced Iron

 MIDREX

Technology Benefits

Highly Competitive Operating Costs Process Reliability / Proven Processes Low Capital Costs / Quick Payback Predictable Operating Costs Hot Steelmaking Options Environmentally Friendly Feed Material Flexibility Waste Process Options

 MIDREX Direct

Reduction Plants

MIDREX Direct Reduction Plants

worldwide

1. Acindar 2. American Iron Reduction 3. Amsteel Mills 4. ANSDK 5. Caribbean Ispat Ltd. 6. COMSIGUA

7. Delta Steel 8. Essar Steel 9. Georgetown Steel 10. Hadeed 11. Hanbo Steel 12. IMEXSA 13. Ispat HSW 14. Ispat Industries 15. Khouzestan Steel 16. LISCO

17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

OPCO NISCO OEMK QASCO Saldanha Steel Ispat Sidbec SIDERCA SIDOR CORUS Mobile VENPRECAR

27. TSML(Pak)

Material Balance Sheet

Reformer
Methane+ Process Gases= Reformed Gases 33169.73 + 311383.613 =344553.343 Fuel gas + Air=Flue Gases 120021.7+166286.2=286307.4 286307.9=286307.4

Furnace
Reformed Gases + Iron Oxide= DRI + Top gases 344553.343 + 331006.3 = 241718.2 + 433804.6 675559.64 = 675522.8

Overall Material Balance Sheet

Streams in (Kg/hr)
Methane= 33169.73 Process Gases= 311383.613 Fuel gas=120021.7 Air Supplied=166286.2 Iron Oxide= 331006.3 Total=961867.54

Streams out(Kg/hr)
Flue Gases=286307.4 DRI= 241718.2 Top gases= 433804.6

Total=961830.2

Overall Energy Balance Sheet

Furnace
Streams in(MW) Reduced Gases=-0.60779 Iron Oxide =-0.47317805 Streams out(MW) Top Gases =-1.08017565 DRI =0.005210552 Reduced Gases=596.85 Fuel Gases=204.6733 Flue Gases= 341018

Reformer
Feed Gases=801.53

Heat Exchanger
Feed Gases= 278993 Air Supplied= 62027.39

Designing of Tubular Reformer

Reformer and its types

Definition of Reforming
Reforming is the process that converts straight-chained hydrocarbons into branch-chained, cyclic and aromatic hydrocarbons. Through reforming Synthesis gases(CO+H2) are produced.

Types of Reforming
Reformer is classified into 3 types, which are as follows
1- Thermal Reforming 2- Steam Reforming

Thermal Reforming
Thermal Reforming is the oldest and the first form of reforming that was developed in the late 1920s. As its name indicates, this process is carried out under a lot of temperature and pressure. Mostly used in Petroleum industries. Most of the problems occur in this type of reforming Such as the impurity of Product and the By products.

Selection of Steam Reforming

Using natural gas as a feedstock the basic reforming reaction is: CH4 + H2O => CO + 3H2 There can be many catalysts for this reaction, but for commercial ease, nickel catalysts are commonly employed. This reaction is endothermic. During the reforming process, there are many reactions that can occur to result in carbon formation, which is not preferred because the solid carbon can deposit on the catalyst and deactivate it. This problem is solved with the use of excess steam to shift the carbon formation reaction to the right:

Cont..
We have used Steam Reformer because: The burning value of the fuel is increased, because steam reforming is an endothermic process, resulting in a more efficient fuel. Steam reforming produces less exhaust emissions than burning the feedstock fuel.

Types of Steam Reformer according to design

Radiant wall or side fired Top fired Bottom fired/Terrace wall fired

High Flux Steam Reforming by Thomas Rostrup-Nielsen Haldor Topsoe A/S, Lyngby, Denmark

Radiant wall or side fired Reformer

These Reformer contains tubes mounted in a single row along the centerline of the furnace. In larger installations, two such furnaces are erected side by side with common inlet and outlet systems and with common fuel supply, flue gas duct, and waste heat section. Burners are mounted in several levels in the furnace walls, and the flames are directed backwards towards the walls. The tubes are heated by radiation from the furnace walls and the flue gas and to a minor extent by convection. The flue gas leaves the furnace at the top so that the flow of process gas and flue gas is counter-current.
STEAM-HYDROCARBON REFORMER FURNACE DESIGN by Foster Wheeler

Top fired Reformer

The top fired reformer features of a furnace box with several rows of tubes. Burners are mounted in the furnace ceiling between the tube rows and between the tubes and the furnace wall. From the burners, long flames are directed downwards, and the tubes are heated by radiation from the flames and the hot flue gas and by convection. The flue gas leaves the furnace box at the bottom, so that the flow of process gas and flue gas is co-current.

Bottom fired/Terrace wall fired

The bottom fired type has easy access to the burners and gives an almost constant heat flux profile along the length of the tube. Since the tubes are hot in the bottom a substantial margin is required on the tube design temperature limiting the outlet temperature. The terrace wall fired type reformer is a modification of the bottom fired type, having slightly lower tube wall temperatures.

Reformer
Reducing Gas Flue Gas

Gas-tight refractory-lined furnace with catalyst tubes through which gas flows upward NG plus recycled top gas (feed gas) is catalytically reformed
Fuel Gas and Combustion Air

Feed Gas

Reducing gas is approximately 90% (H2 + CO), used without quench

Reformer Tubes with Catalyst

Reformer Detail
(Side View)

Reducing Gas Flue Gas

Feed Gas

Fuel Gas and Combustion Air

Design Approach
Minimize Gibbs Free energy of the system Area required Volume & Weight of catalyst Volume of reactors

Temperature Parameter Effectiveness Design Approach Rate of reaction Heat flux

Space time

Weight of catalyst

Design Specifications

 MIDREX Reformer Reactions

Reaction CH4 + CO2 CH4 + H2 O

2CO + 2H2 CO + 3H2

Heat Endothermic Endothermic

Description CO2 reforming H2O reforming

At operating Condition of Temperature and Heat Flux

These reactions occurs in reformer

Beggs and If Temperature Then Bourden reaction and Heat Flux occurs, where carbon changes deposit occur on catalyst

Designing Calculations
Heat Load(Heat Duty)=286941333 KJ/hr
Average heat flux= 113556.49 KJ/hr.m2 Heated Length=ZH=L=11.27m Diameter of Tube=D=0.13m Area for Single tube=A1=DL =4.600414 m2 Area required for Heat Load= Heat Load(Q) Heat Flux

(from Process Heat Transfer by DQ.KernChap#19& Chemical Reactor Design for Process Plants Case Study 111 by Howard F.Rase) (Rule of Thumb, Chapter#19 Process Heat Transfer by DQ.Kern pg#603)

Cont
Area required for Heat Load=At= 286941333 KJ/hr 113556.49 KJ/hr.m2 = 2526.8598 m2 No of Tubes= At A1 = 2526.8598 m2 = 549.26791 4.600414 m2 By Giving 30% Corrosion allowance Extra Tubes= 0.3(549.26791)= 164.7804

Cont.
Total no of tubes= 549.26791+ 164.7804 = 714.0483 714 Volume of 1 tube=V= D2L = 0.1495135 m3 4 Volume of Total tubes= 714* 0.1495135 m3 = 106.75261 m3 Volume of Total tubes=Volume of Catalyst So, Volume of Catalyst= 106.75261 m3

Cont.
Bundle diameter Db= do(Nt/k1)1/n1 Here, n1= 2.142 k1= 0.319 do= 0.1524m Nt= 714 Db= 5.583425 m

(for one pass)

Cont.
Pitch(Triangular) Pitch = 1.25do = 0.1905 m Clearance = Pitch outer dia = 0.1925 0.1524 = 0.03810 m Inner dia of Shell=D= 5.583425 + 0.03810= 5.6215m Area of Shell= D2/4= 24.807232 m2 Length of Shell = 12.1921m Volume of Shell = D2L/4 = 302.45m3
From RC vol 6,Chapter#12,pg# 665 Process Heat Transfer by DQ.Kern

Selection of Catalyst
Steam reforming of natural gas has been performed at high temperatures over Ni - based catalysts. Ni Oxide has been the favored because of its sufficient activity and low cost. These catalysts are shaped into an optimal form, often in the shape to have a better heat and mass transfer and to minimize the pressure drop under the industrial operating conditions. The Ni - Oxide suffer from catalyst deactivation by coke formation at high temperatures. Catalyst is in form of Rasching Rings pellets.

Calculations.
Pellet Diameter =DP=0.017 m Wall Thickness=0.005 m Length=0.017 m Bulk density=b=913.05241 Kg/m3 Porosity==0.52 Mass of Catalyst=Bulk Density*Volume = 913.05241 Kg/m3 * 106.75261 m3 = 97470.73 Kg

Cont.
Mass Flow in Each Tube=
= (114851.1 *4)/(3.14*0.132*714) = 12124.97 Kg

Pressure Drop Calculations

By Ergun Equation P = 150 G(1-)2 + 1.75 G2(1-) L kgD23 kgD3 Here,
P = pressure drop, lb./in2, or psi L = Heated length, ft= 37 G =Mass velocity, lb./hr.-ft2 = 2478.242 = fluid density, lb/ft3 = 0.044 = fluid viscosity, lb/hr.ft = 3.13*10-5 D = effective particle diameter,ft = 0.055774 = interparticle void fraction, dimensionless =0.52 g = gravitational constant, 4.17 x 108 lb.-ft./lb.-hr2 k = conversion factor, 144 in2/ft2

Cont.
By putting all values in previous equation P = 9.4 Psi

Specification Sheet
Reformer Type Equipment Id Operating Condition Operating Temperature Operating Pressure Heat Flux 950oC 2.469 bar 113556.49KJ/hr.m2 Steam Reformer RF-A40

Heat Duty
Length(tube) Inner Dia (Tube) Outer dia(tube) No of Tubes

2.86*108KJ/hr
11.27m 0.13m 0.1524m 714

Specification Sheet
Volume of Tubes
Mass of Catalyst Mass flow in each tube(G) Db(bundle diameter) Pitch Clearance

106.7526m3
97470.73Kg 12124.97Kg/hr.m2 5.583425 0.1905 m 0.03810 m

Inner dia of Shell(D)

Area of Shell Length of Shell(L) Volume of Shell Pressure Drop(P) Material of Construction

5.6215m
24.807232 m2 12.1921m 302.45m3 9.4 Psi Carbon Steel

Designing of Blower by Yasar Zia

Definition Of Blower

These are machines that move and compress gases .

High speed rotating devices that develop a maximum

pressure of 2 atm.

Types Of Blowers
Positive-displacement blower
These machines operate as gear pump because of the special design of the teeth. A single stage blower can discharge gas at 0.4 to 1 atm gauge.

Two stage blower can discharge gas at 2 atm.

Centrifugal Blower
In appearance it resembles a centrifugal pump.
They are high speed operating machines, 3600 rpm or more. High speed and large impeller diameters are required because very high heads.

Block Diagram

166286.2 kg/hr

Main Air Blower

166286.2 kg/hr

P= 105526.03 Pa

P= 119026.36 Pa

Calculations--Work done by Blower Wb= H/ Power of the Blower

PB = m0Wp hs = Ps/g ; hD = PD/g Vs = Vs^2/2g ; VD = VD^2/2g
Reference: From Mc-cabe Smith unit operation 7th edition

Continued.
Total Suction head = Ps/g + Vs^2/2g

Total Discharge head = PD/g + VD^2/2g To Find, H = hD hs P = PD Ps

Reference: From Mccabe Smith unit operation 7th edition

Continued
PV = znRT V = znRT/P

n= 16628.62/28.8 n= 576.98 kgmol

R= 8.314 kJ/kgmol.k
T= 299 K Ps= 105526.03 Pa

Z= 0.8

Continued.
V= 576.98*8.314*299/105526.03 V= 10.873 m3

To find diameter, V= /6 d3

10873 = 3.14/6*d3 d= 2.721 m

To find Area, A= /4d2 A= 3.14/4*(2.721)^2 A= 5.814 m2

Continued.
V= Velocity*Area 10.873= Velocity*5.814 Velocity= 1.870 m/hr
To Find Suction Head, Ps/g + Vs^2/2g 105526.03/1.225*9.5+(1.870)^2/2*1.225*9.8 = 8790.17+0.145 = hs=28790.31 Pa

Continued.
Similarly Total Discharge Head,
PD/g + VD^2/2g 119029/0.4*9.8+(2.48)^2/2*9.8* 0.4 = 30364.54+0.784 = 30365.32 Pa H = hd-hs = 30365.32- 28790.31 = 1575.01 Pa
Reference: Density of Air = 1.005 at 26 0C Density of Air 0.4 at 665 0C

Continued.
Work done by Blower, Wb= H/ = 1575.01/0.6 Wb = 2625.01 Joule

Reference: Efficiency taken as 60 % from Unit operation Mccabe Smith 7th edition.

Continued.
Power Of Blower, PB = m0Wp = 16628.62*2625.01 PB = 58512.458 1Hp = 746 Watt PB = 58512.458/746 = 5.8*103HP

Specification sheet
Blower Equipment Code Equipment Name Operating Conditions CP-B01 Main Air Blower

Inlet temperature
Outlet temperature Inlet Pressure Outlet Pressure Flow rate Work done by Blower

26 0C
665 0C 105526.03 Pa 119026.36 Pa 166286.2 kg/hr 2625.01 J

Power of Blower
Total suction pressure

5.8*10^3 HP
hst=28790.31 Pa

Total Discharge Pressure

Hst=30365.32 Pa

Designing Of Heat Recovery Unit

BY Muhammad Yasar Zia 09-CH-98

Heat recovery unit

A heat recovery unit (HRU) is an energy recovery heat
exchanger that recovers heat from hot streams with potential high energy content, such as hot flue gases from a diesel generator or steam from cooling towers or even waste water from different cooling processes such as in

steel cooling.

Continue.
Waste heat found in the exhaust gas of various processes
or even from the exhaust stream of a conditioning unit can be used to preheat the incoming gas. This is one of the basic methods for recovery of waste heat. Many steel making plants use this process as an economic method to

increase the production of the plant with lower fuel

demand.

Different types of heat recovery units

Recuperators: This name is given to different types of heat exchanger that the exhaust gases are passed through, consisting of metal tubes that carry the inlet gas and thus preheating the gas before entering the process Heat pipe exchanger: Heat pipes are one of the best thermal conductors. They have the ability to transfer heat hundred times more than copper. The heat pipe is mainly used in space, process or air heating.

Continue..
Economizer
In case of process boilers, waste heat in the
exhaust gas is passed along a recuperator that carries the inlet fluid for the boiler and thus decreases thermal energy intake of the inlet fluid.

Three Streams In Heat Recovery Unit

Cold Stream
Feed Gas 131 0C 580 0c

Cold Stream
Air 26 0C

665 0C

Flue Gases
368 0C

Hot Stream

1125 0c

Flue Gas and Feed Gas System

Q=m1Cp1T1= m2Cp2T2
Q= m1Cp1(1125-T) = m2Cp2(T2-T1)

286307.4*1.557*(1125-T) = 344553.3*1.7310*580-131
445780.621 * (1125-T) = 267793371.3 1125-T = 600.721 T = 524.27 0C

To Find Area Of the tubes

We Know that
Q= UA T To Find Tm, = (2- 1)/ln(2/1) = 545-393/ln(545/393) Tm = 465.65 0C

Continue..
Q= UA Tm
A= Q/UTm A = 267793371.3/4000*465.65 A = 143.77 m2

Reference: U = 4000 Watt/m2 .K from Aspen plus

Continue
To find Number of Tubes, Nt = ? We know that Area = 2rl Area = 795.31 m2 r= 0.0508 m l= 4 m l= A/2r l= 395.31/2*3.14*0.0508 l= 2492.94 m

Continue
Now to find Number of Tubes,
Nt = 2492.94/4 Nt = 623.23 tubes

Dia of each tube,

Outer dia of tube d0 = 2 Inner dia of Tube di = 1.6
Reference;. Unit operation by Mccab smith 7th edition

Flue Gas and Air System

Similarly,
m1Cp1T1= m2Cp2T2 m1Cp1(524-T) = m2Cp2(500-26)

286307.4*1.557*(524-T) = 166286.2*2.01*(500-26)
445780.62*(524-T) = 158427514.2 524 T = 355.393 0C

T = 168.60 0C

Continue
To find Area,

Q= UA Tm
A= Q/UTm

Tm = 1- 2/ln(1/2)
= 142-24/ln(142/24) Tm = 66.4 0C Area = 158427514.2/3000*66.4 A = 795.31 m2

Continue..
To Find Number of tubes, Area = 2rl Area = 795.31 m2 r=0.0508 m l= 4 m l= A/2r l= 795.31/2*3.14*0.0508 l= 450.65 m Nt = 113 tubes Dia of each tube, Outer dia of tube d0 = 2 Inner dia of Tube di = 1.6

Specification Sheet
Equipment Code Equipment Name Operating Conditions Inlet temperature Outlet temperature Inlet pressure 1125 0C of flue gases 368 0C of flue gases 100724.85 Pa of flue gases HE-B05, HE-A65 Heat Recovery Unit

Outlet pressure
Inlet temperature outlet temperature Inlet pressure Outlet pressure Inlet temperature Outlet temperature

100324.7 Pa of flue gases

580 0C 131 0C of feed gases of feed gases

148336.59 Pa of feed gases 153137.7 Pa of feed gases 26 0C of air 500 0C of air

Inlet pressure Outlet pressure

100524.8 pa 119029.36 Pa

Heat Transfer area of flue gas and air system

Heat transfer area of flue gas and feed gas Heat transfer coefficient of flue gas and feed gas

795.31 m2
143.77 m2 2667793371.3 watt/m2.k

Heat transfer coefficient of flue gas and air 158482751.42 watt/m2.k system Material of Construction Corrosion Allowance Thickness of Material Outer dia Inner dia Carbon steel 0.1 0.2 2 1.6