Figure 3.1.: Photo of the Circored Plant

~ 160 m Iron Ore Fines CFB Preheater Inclined Bucket Elevator 1st Stage CFB Reactor 2nd Stage FB Reactor Briquetting Plant HBI Product Process Gas Heat Exchanger Process Gas Compressor Fired Gas Heaters ~ 110 m Electrical Substation& Control Room Figure 3.2.: Engineering drawing

Inventory / Buffers Do NOT have a capacity; however, there might be a limited number of flow units that can be put in this inventory space at any moment of time Multiple flow unit types possible Arrows Indicate the flow of the flow unit Multiple flow unit types possible (see Section 3.5) Activities Carried out by resources Add value and are required for completion of the flow unit May or may not carry inventory Have a capacity (maximum number of flow units that can flow through the activity within a unit of time) Figure 3.3: Elements of a Process

Pre-Heater Pile of Iron ore fines Figure 3.4.: Process flow diagram, first step

Lock Hoppers 1 st Reactor2 nd Reactor Figure 3.5: Process Flow diagram (to be continued) Pre-Heater Pile of Iron ore fines

Figure 3.6. : Completed process flow diagram for the Circored process Flash Heater DischargeBriquetting Lock Hoppers 1 st Reactor2 nd ReactorPre-Heater Pile of Iron ore fines Finished Goods

Figure 3.7. : Completed process flow diagram for the Circored process Pile of Iron ore fines Pre-Heater Briquet- ting Flash heater Dis- charge Finished goods Lock Hoppers 1 st Reactor 2 nd Reactor

Compute the Capacity for each of the Resources Use demand to compute the implied utilization levels Identify the Bottleneck Prepare a Process Flow Diagram Compute various Performance measures Use different Colors to mark Flow units Note that capacity levels may differ depending on product type Compute the work- load across all product types Step with highest implied utilization Extensions required for working with multiple flow units Extensions required for working with multiple flow units Compute the Capacity for each of the Resources Use demand to compute the implied utilization levels Identify the Bottleneck Prepare a Process Flow Diagram Compute various Performance measures Compute the Capacity for each of the Resources Use demand to compute the implied utilization levels Identify the Bottleneck Prepare a Process Flow Diagram Compute various Performance measures Use different Colors to mark Flow units Note that capacity levels may differ depending on product type Compute the work- load across all product types Step with highest implied utilization Figure 3.11: Summary of process analysis