Senior Design Presentation Direct Fe Reduction Iron Plant Group Golf Selimos, Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette, Dominic F. Advisor : Orest Romaniuk Group Meeting 1 – 01/29/2013

Design Basis Commercial Scale Production 2 The plant will consume 51.6 Million SCF/Day of Methane. The plant will produce 2.05 Million M. Ton/Year of DRI. 2

Design Basis   3

Design Basis Environmental Review 4 The Midrex® have been trying to reduce the emissions. One approach is to use natural gas as a reductant fuel source, it will result in less emission than coal.(1) It produces only one third the CO2 that a traditional blast furnace produces.(2) (1)http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf (2)http://www.midrex.com/uploads/documents/MidrexCorporateBrochure1.pdf 4

Design Basis (3) (3) http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf 5

Design Basis Specifications to meet Industry Standards 6 The MIDREX® process produces significantly less pollution than traditional processes. 6

Design Basis (4) (4) http://midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf 7

Design Basis Engineering Design Standards 8 “OXY+®” Oxygen Injection Heat Recovery 8

Competing Process Midrex® Options Process Options Energy Natural Gas Coal Reformer (Natural gas option) MIDREX Steam Coal Gas (Coal option) Gasifier syngas CORREX® Shaft Furnace Size Diameter range is 4.5m – 7.5m (4)http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf Please figure out the advantages and disadvantages to each 9

Competing Process Non-Midrex® Options Electric Arc Furnace (EAF) Batch Charging: it can eliminate the need for a second or third scrap charge (lower energy and improve productivity, can be added up to 30 percent of the charge). Continuous charging: can be used to feed up to 100 percent of the required metallics (reduce back charges and allows the furnace roof to stay on, and retaining heat). Basic Oxygen Furnace (BOF) It can be loaded in the charging box and charged and melted like crap. HBI is a preferred charge material. Blast Furnace Increase hot metal production and lower coke consumption Can be increased by 20%. Please figure out how each alternative differs from the MIDREX plant 10

Conceptual Process Blok Flow 11

Questions? 12

THANK YOU 13

Supplemental Material Environmental Review extra concerns (5) (5) http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf 14

Supplemental Material (6) (6) http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf 15

(6) (6) http://www.midrex.com/uploads/documents/MIDREXShaftBrochure2.pdf 16

(7) (7) KOBELCO TECHNOLOGY REVIEW NO. 29 DEC. 2010 17