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DRI Plant Flowsheet Options By: Gerard B. Hawkins Managing Director, CEO

(DRI) Direct Reduction Iron Plant Flowsheet Options

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DRI Processes – Types using Steam Reforming HYL type flowsheets Midrex type flowsheets Lookalikes exist in each category

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Page 1: (DRI) Direct Reduction Iron Plant Flowsheet Options

DRI Plant Flowsheet Options

By:

Gerard B. Hawkins Managing Director, CEO

Page 2: (DRI) Direct Reduction Iron Plant Flowsheet Options

DRI Processes – Types using Steam Reforming

HYL type flowsheets Midrex type flowsheets Lookalikes exist in each category

Page 3: (DRI) Direct Reduction Iron Plant Flowsheet Options

DRI Processes - HYL III Process Flowsheet

Page 4: (DRI) Direct Reduction Iron Plant Flowsheet Options

DRI Processs - Features of HYL III Steam Reformer

Natural gas feedstock Downflow + down-fired Typical conditions

• S/C ratio 1.9 - 2.5 • pressure 6 - 7 barg • exit temperature 840°C (1545°F) • methane slip 2.0 - 2.5 mol % (dry)

Steam reformer catalysts • same types as HyCO (+H2/NH3/MeOH)

plants • feed purity to < 0.1 ppm S required

Page 5: (DRI) Direct Reduction Iron Plant Flowsheet Options

DRI Processes - Typical Midrex Process Iron Oxide

Direct Reduced

Iron

Exhaust Stack

Flue Gas

Natural Gas

Feed Gas

Main Air Blower

Combustion Air

Process Gas Compressor

Reformer

Top Gas Scrubber

Cooling Gas Compressor

Reducing Gas

Scrubber

Top Gas

Reduction Zone

Shaft/ Reduction Furnace

Cooling Zone

Page 6: (DRI) Direct Reduction Iron Plant Flowsheet Options

DRI Processes - Features of Midrex Type Reformer

Natural gas feedstock Upflow + up-fired Typical conditions

• From recycle gas CO2 ~15 mol %; CO ~15 mol %; H2O gives S/C

~0.6 S required against metal dusting (up to 10

ppm) • pressure 1 - 2 bara • exit temperature 930°C (1706°F) • methane slip 1.0 mol % (dry)

Specialized S tolerant reformer catalysts

Page 7: (DRI) Direct Reduction Iron Plant Flowsheet Options