FROM RUST TO IRONDeisy C. Arrington, Dominic Ciarlette, Blake Selimos & Brandon Sink

Mentor: Orest J. Romaniuk of Ambitech University of Illinois at Chicago

Abstract

Oxi Fuel Booster

Process Flow Diagram

Economics

Midrex Reformer

Oxy Fuel Boost Reformer

Removal

GuardBed

Heaters

Top GasScrubber

Midrex Reformer

Main Air Blower Shaft Furnace

Iron Ore

Iron Briquettes

Compressor

Fuel Gas

Recycle

Ejector Stack

Environmental Effects

Design Basis

As environmental regulation become more restrictive, iron refining processes will need to produce less emissions. The process of Direct Reduction can utilize natural gas to refine iron and produce less carbon dioxide than traditional methods such as smelting. By taking advantage of an emerging natural gas abundance due to advances in hydraulic fracturing, we believe a DRI plant can be profitable in North Dakota.

Natural Gas will be sent to the plant from the Gas Processing Plant. That gas will then be heated and sent to the reformer where it will be reformed into H2, CO, CO2, and inert N2. That gas will then be sent to an Oxy Fuel Boost Reformer, which will require O2 from the syngas plant. From there the gas will enter the shaft furnace where Fe2O3 will be reduced by the reformed gas to create DRI. Also exiting the furnace will be a top gas of which, CO2 will be separated and sent to the Gas and Water Treatment plant. Some of the top gas will also be compressed and recycled into the incoming natural gas stream. Also, the CO2 free portion of the stream will be sent to the combustion chamber of the reformer along with air and some natural gas. The heat of this combustion process will then go through a heater to preheat the incoming air into the combustion chamber as well as the natural gas going into the reformer before exiting the plant through an ejector stack as CO2 H2O and N2.

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.

1 Year (USD) 10 Year (USD) 17 Year (USD)

Total Expenses 529,000,000 613,000,000 660,000,000

Total Revenue 790,000,000 860,000,000 1,000,000,000

Income Before Taxes 300,000,000 350,000,000 400,000,000

Taxes (40%) 104,000,000 99,000,000 150,000,000

Income After Taxes 120,000,000 140,000,000 160,000,000

Total Cumulative Income 178,000,000 2,000,000,000 3,500,000,000

ProductThe final product of this process is directly reduced iron pellets. These pellets can be refined to be up to 95% pure iron. The DRI can then be shipped by rail to steel mills in the American Midwest, or to the great lakes where it can be shipped to international markets. This plant will also create excess carbon dioxide which will be delivered to the resource recovery plant where it will be processed into a sellable product.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17$0.00

$500,000,000.00

$1,000,000,000.00

$1,500,000,000.00

$2,000,000,000.00

$2,500,000,000.00

$3,000,000,000.00

$3,500,000,000.00

$4,000,000,000.00

Payback Period

Capitol costTotal Profit

Year

USD $

NPV 1,254,000,000

IRR 38.57%

Payback Period 2.5 Years

The Midrex Reformer is unique in that it is considered a dry reformer. No steam is directly input to the reformer. Instead the recycled is the driving force in the reformation. All of the required comes from the recycled top gasses and a reverse water gas shift reaction that occurs at hightemperatures. The water is required in order to maintain the catalyst.

Compound Ton / Year

406 - 1014

1,000,000

50

Midrex plants are designed with the goal of minimizing water, air, and noise pollution. In comparison to traditional blast furnaces, Midrex plants have much lower emissions due to using natural gas instead of coal, as well as having a reformer that can handle larger amounts of recycled than the average steam-methane reformer