1. FROM RUST TO IRON Deisy C. Arrington, Dominic Ciarlette, Blake Selimos & Brandon Sink Mentor: Orest J. Romaniuk of Ambitech University of Illinois at Chicago FROM RUST TO IRON Deisy 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 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 Expenses529,000,000613,000,000660,000,000 Total Revenue790,000,000860,000,0001,000,000,000 Income Before Taxes300,000,000350,000,000400,000,000 Taxes (40%)104,000,00099,000,000150,000,000 Income After Taxes120,000,000140,000,000160,000,000 Total Cumulative Income 178,000,0002,000,000,0003,500,000,000 Product The 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. NPV1,254,000,000 IRR38.57% Payback Period2.5 Years temperatures. The water is required in order to maintain the catalyst. CompoundTon / Year 406 - 1014 1,000,000 50