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

2 Design Basis Comercial Scale Production Enviromental Review Specifications to meet Industry Standards Clear statement of Feedstock Engineering Design Standards

3 Design Basis Comercial Scale Production The plant will produce around 2.05 ton/yr Reactions – Fe2O3 + 3CO → 2Fe + 3CO2 – Fe2O3 + 3H2 → 2Fe + 3H2O

4 Design Basis Environmental Review * The Midrex have been trying to reduce the emissions. One approach is to use natural gas as a reluctant 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) (2)

5 Design Basis Specifications to meet Industry Standards

6 Design Basis Clear statement of Feedstock The feedstock will be any blend of pellets and lump ores. (3) (3)

7 Design Basis Engineering Design Standards

8 Competing Process Blast Furnace DRI – Midrex process variations We chose the DRI Midrex process with one reformer because it is more cost efficient than using two reformers and it’s more energy efficient than a Blast Furnace.

9 Competing Process (whithin Midrex) (4) 1)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); 2) Basic Oxygen Furnace (BOF) It can be loaded in the charging box and charged and melted like crap. (HBI is a preferred charge material) 3)Blast Furnace Increase hot metal production and lower coke consumption (can be increased by 20%). 4)Secondary Oxygen Reformer (4))

10 Conceptual Process Blok Flow

11 Questions?? Any questions???

12 THANK YOU!!!