1. 1 Direct Reduction Iron Plant Group Golf Selimos, Blake A. Arrington, Deisy C. Sink, Brandon Ciarlette, Dominic F. (Scribe) Advisor : Orest Romaniuk

2. Table of Contents » 3-4 Design Basis / Block Flow Diagram » 5 – Process Flow Diagram » 6 – Initial Control Scheme » 7-8 – Plant Layout » 9-11 – Calculations » 12-14 – Convection Section » 15-20 – Economics » 21-22 – Report » 23 - Summary 2

3. Block Flow/Design Basis 3

4. Design Basis 4

5. Process Flow Diagram 5

6. Initial Control Scheme 6

7. Plant Layout (1) 7 1 2 3 4 5 6 1.Ejector 2.HX -1 3.HX -2 4.Reformer 5.Oxy booster 6.Furnace 7.Storage 8.Tankage 9.Building Road Railroad Wind 7 7 9 7

8. 8 Plant Layout (2)

9. Energy Balance Data and Equations 9

10. Calculation Summary 10

11. Heat Exchanger Calculations 11

12. Convection Section Issues 12

13. Convection Section Recommendations 13

14. Convection Section Recommendations 14

15. Equipment 15

16. Catalysts 16

17. Personnel EmployeesMan hours per day worked 7 Operators56 5 Engineers (shared with 3 plants)40/3 1 Complex manager (shared with whole plant)8/9 20 Administration (shared with whole plant)160/9 3 Safety (shared with whole plant)24/9 4 Medical staff (shared with plant)32/9 1 Maintenance (shared with plant)8/9 3 Supervisor24 Total120 17

18. Expenses 18

19. Revenue 19

20. Profit 20

21. Payback Period 21

22. Report 22

23. Report

24. Summary 24

25. 25

26. References 26

27. Flow Diagram (1) 27

28. Flow Diagram (2) 28

29. Flow Diagram (3) 29

30. Flow Diagram (4) 30

31. 31 Steam System