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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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DRI Plant Flowsheet Options
By:
Gerard B. Hawkins Managing Director, CEO
DRI Processes – Types using Steam Reforming
HYL type flowsheets Midrex type flowsheets Lookalikes exist in each category
DRI Processes - HYL III Process Flowsheet
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
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
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