Beruflich Dokumente
Kultur Dokumente
Project Advisor Engr. Zia -ul-Haq Session: 2009-2013 Group members: Waseem-ur-Rehman 09-CH-02 M.Faiq Ilyas 09-CH-10 Muddsir Munir 09-CH-38 M.Yasar Zia 09-CH-98 M. Kamran Hyder 09-CH-104
Presentation Sequence
Introduction Comprehensive Flow Sheet Overall Material Balance Overall Energy Balance Designing
Introduction
Direct-reduced iron (DRI) also called sponge iron is produced from direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas produced from natural gas. The reducing gas is a mixture majority of hydrogen (H2) and carbon monoxide (CO) which acts as reducing agent. Fe2O3 + CO > 2Fe + CO2 Fe2O3 + H2 > 2FeO + H2O
Process Description
The direct reduction of the oxide is carried out on a continuous basis. The iron oxide, fed to the top of the shaft furnace, flows downward under gravity and is discharged from the bottom in the form of direct reduced iron. Reduced Gases having major components of Hydrogen and Carbon monoxide is fed into the Shaft Furnace. Reaction between Iron Oxide and Reduced Gases occurs at 950oC and Reduced iron in form of Pellets is achieved at the bottom of the Furnace. At the top of the Furnace, Spent gases are exists.
Cont.
Spent gases are recompressed and mixed with Natural gas and transported to the Reformer. Hence a Continuous process occurs.
Flowsheet
Flue Flue Gas Gas Natural Natural Gas Gas
Shaft Furnace
Reformer Reformer
Main Main Air Air Blower Blower Reducing Reducing Gas Gas Cooling Cooling Gas Gas Scrubber Scrubber
MIDREX
Technology Benefits
Highly Competitive Operating Costs Process Reliability / Proven Processes Low Capital Costs / Quick Payback Predictable Operating Costs Hot Steelmaking Options Environmentally Friendly Feed Material Flexibility Waste Process Options
MIDREX Direct
Reduction Plants
1. Acindar 2. American Iron Reduction 3. Amsteel Mills 4. ANSDK 5. Caribbean Ispat Ltd. 6. COMSIGUA
7. Delta Steel 8. Essar Steel 9. Georgetown Steel 10. Hadeed 11. Hanbo Steel 12. IMEXSA 13. Ispat HSW 14. Ispat Industries 15. Khouzestan Steel 16. LISCO
17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
OPCO NISCO OEMK QASCO Saldanha Steel Ispat Sidbec SIDERCA SIDOR CORUS Mobile VENPRECAR
27. TSML(Pak)
Furnace
Reformed Gases + Iron Oxide= DRI + Top gases 344553.343 + 331006.3 = 241718.2 + 433804.6 675559.64 = 675522.8
Streams out(Kg/hr)
Flue Gases=286307.4 DRI= 241718.2 Top gases= 433804.6
Total=961830.2
Reformer
Feed Gases=801.53
Heat Exchanger
Feed Gases= 278993 Air Supplied= 62027.39
Types of Reforming
Reformer is classified into 3 types, which are as follows
1- Thermal Reforming 2- Steam Reforming
Thermal Reforming
Thermal Reforming is the oldest and the first form of reforming that was developed in the late 1920s. As its name indicates, this process is carried out under a lot of temperature and pressure. Mostly used in Petroleum industries. Most of the problems occur in this type of reforming Such as the impurity of Product and the By products.
Cont..
We have used Steam Reformer because: The burning value of the fuel is increased, because steam reforming is an endothermic process, resulting in a more efficient fuel. Steam reforming produces less exhaust emissions than burning the feedstock fuel.
High Flux Steam Reforming by Thomas Rostrup-Nielsen Haldor Topsoe A/S, Lyngby, Denmark
Reformer
Reducing Gas Flue Gas
Gas-tight refractory-lined furnace with catalyst tubes through which gas flows upward NG plus recycled top gas (feed gas) is catalytically reformed
Fuel Gas and Combustion Air
Feed Gas
Reformer Detail
(Side View)
Feed Gas
Design Approach
Minimize Gibbs Free energy of the system Area required Volume & Weight of catalyst Volume of reactors
Space time
Weight of catalyst
Design Specifications
Beggs and If Temperature Then Bourden reaction and Heat Flux occurs, where carbon changes deposit occur on catalyst
Designing Calculations
Heat Load(Heat Duty)=286941333 KJ/hr
Average heat flux= 113556.49 KJ/hr.m2 Heated Length=ZH=L=11.27m Diameter of Tube=D=0.13m Area for Single tube=A1=DL =4.600414 m2 Area required for Heat Load= Heat Load(Q) Heat Flux
(from Process Heat Transfer by DQ.KernChap#19& Chemical Reactor Design for Process Plants Case Study 111 by Howard F.Rase) (Rule of Thumb, Chapter#19 Process Heat Transfer by DQ.Kern pg#603)
Cont
Area required for Heat Load=At= 286941333 KJ/hr 113556.49 KJ/hr.m2 = 2526.8598 m2 No of Tubes= At A1 = 2526.8598 m2 = 549.26791 4.600414 m2 By Giving 30% Corrosion allowance Extra Tubes= 0.3(549.26791)= 164.7804
Cont.
Total no of tubes= 549.26791+ 164.7804 = 714.0483 714 Volume of 1 tube=V= D2L = 0.1495135 m3 4 Volume of Total tubes= 714* 0.1495135 m3 = 106.75261 m3 Volume of Total tubes=Volume of Catalyst So, Volume of Catalyst= 106.75261 m3
Cont.
Bundle diameter Db= do(Nt/k1)1/n1 Here, n1= 2.142 k1= 0.319 do= 0.1524m Nt= 714 Db= 5.583425 m
Cont.
Pitch(Triangular) Pitch = 1.25do = 0.1905 m Clearance = Pitch outer dia = 0.1925 0.1524 = 0.03810 m Inner dia of Shell=D= 5.583425 + 0.03810= 5.6215m Area of Shell= D2/4= 24.807232 m2 Length of Shell = 12.1921m Volume of Shell = D2L/4 = 302.45m3
From RC vol 6,Chapter#12,pg# 665 Process Heat Transfer by DQ.Kern
Selection of Catalyst
Steam reforming of natural gas has been performed at high temperatures over Ni - based catalysts. Ni Oxide has been the favored because of its sufficient activity and low cost. These catalysts are shaped into an optimal form, often in the shape to have a better heat and mass transfer and to minimize the pressure drop under the industrial operating conditions. The Ni - Oxide suffer from catalyst deactivation by coke formation at high temperatures. Catalyst is in form of Rasching Rings pellets.
Calculations.
Pellet Diameter =DP=0.017 m Wall Thickness=0.005 m Length=0.017 m Bulk density=b=913.05241 Kg/m3 Porosity==0.52 Mass of Catalyst=Bulk Density*Volume = 913.05241 Kg/m3 * 106.75261 m3 = 97470.73 Kg
Cont.
Mass Flow in Each Tube=
= (114851.1 *4)/(3.14*0.132*714) = 12124.97 Kg
Cont.
By putting all values in previous equation P = 9.4 Psi
Specification Sheet
Reformer Type Equipment Id Operating Condition Operating Temperature Operating Pressure Heat Flux 950oC 2.469 bar 113556.49KJ/hr.m2 Steam Reformer RF-A40
Heat Duty
Length(tube) Inner Dia (Tube) Outer dia(tube) No of Tubes
2.86*108KJ/hr
11.27m 0.13m 0.1524m 714
Specification Sheet
Volume of Tubes
Mass of Catalyst Mass flow in each tube(G) Db(bundle diameter) Pitch Clearance
106.7526m3
97470.73Kg 12124.97Kg/hr.m2 5.583425 0.1905 m 0.03810 m
5.6215m
24.807232 m2 12.1921m 302.45m3 9.4 Psi Carbon Steel
Definition Of Blower
Types Of Blowers
Positive-displacement blower
These machines operate as gear pump because of the special design of the teeth. A single stage blower can discharge gas at 0.4 to 1 atm gauge.
Centrifugal Blower
In appearance it resembles a centrifugal pump.
They are high speed operating machines, 3600 rpm or more. High speed and large impeller diameters are required because very high heads.
Block Diagram
166286.2 kg/hr
166286.2 kg/hr
P= 105526.03 Pa
P= 119026.36 Pa
Continued.
Total Suction head = Ps/g + Vs^2/2g
Continued
PV = znRT V = znRT/P
R= 8.314 kJ/kgmol.k
T= 299 K Ps= 105526.03 Pa
Z= 0.8
Continued.
V= 576.98*8.314*299/105526.03 V= 10.873 m3
To find diameter, V= /6 d3
Continued.
V= Velocity*Area 10.873= Velocity*5.814 Velocity= 1.870 m/hr
To Find Suction Head, Ps/g + Vs^2/2g 105526.03/1.225*9.5+(1.870)^2/2*1.225*9.8 = 8790.17+0.145 = hs=28790.31 Pa
Continued.
Similarly Total Discharge Head,
PD/g + VD^2/2g 119029/0.4*9.8+(2.48)^2/2*9.8* 0.4 = 30364.54+0.784 = 30365.32 Pa H = hd-hs = 30365.32- 28790.31 = 1575.01 Pa
Reference: Density of Air = 1.005 at 26 0C Density of Air 0.4 at 665 0C
Continued.
Work done by Blower, Wb= H/ = 1575.01/0.6 Wb = 2625.01 Joule
Reference: Efficiency taken as 60 % from Unit operation Mccabe Smith 7th edition.
Continued.
Power Of Blower, PB = m0Wp = 16628.62*2625.01 PB = 58512.458 1Hp = 746 Watt PB = 58512.458/746 = 5.8*103HP
Specification sheet
Blower Equipment Code Equipment Name Operating Conditions CP-B01 Main Air Blower
Inlet temperature
Outlet temperature Inlet Pressure Outlet Pressure Flow rate Work done by Blower
26 0C
665 0C 105526.03 Pa 119026.36 Pa 166286.2 kg/hr 2625.01 J
Power of Blower
Total suction pressure
5.8*10^3 HP
hst=28790.31 Pa
Hst=30365.32 Pa
steel cooling.
Continue.
Waste heat found in the exhaust gas of various processes
or even from the exhaust stream of a conditioning unit can be used to preheat the incoming gas. This is one of the basic methods for recovery of waste heat. Many steel making plants use this process as an economic method to
Continue..
Economizer
In case of process boilers, waste heat in the
exhaust gas is passed along a recuperator that carries the inlet fluid for the boiler and thus decreases thermal energy intake of the inlet fluid.
Cold Stream
Air 26 0C
665 0C
Flue Gases
368 0C
Hot Stream
1125 0c
286307.4*1.557*(1125-T) = 344553.3*1.7310*580-131
445780.621 * (1125-T) = 267793371.3 1125-T = 600.721 T = 524.27 0C
Continue..
Q= UA Tm
A= Q/UTm A = 267793371.3/4000*465.65 A = 143.77 m2
Continue
To find Number of Tubes, Nt = ? We know that Area = 2rl Area = 795.31 m2 r= 0.0508 m l= 4 m l= A/2r l= 395.31/2*3.14*0.0508 l= 2492.94 m
Continue
Now to find Number of Tubes,
Nt = 2492.94/4 Nt = 623.23 tubes
286307.4*1.557*(524-T) = 166286.2*2.01*(500-26)
445780.62*(524-T) = 158427514.2 524 T = 355.393 0C
T = 168.60 0C
Continue
To find Area,
Q= UA Tm
A= Q/UTm
Tm = 1- 2/ln(1/2)
= 142-24/ln(142/24) Tm = 66.4 0C Area = 158427514.2/3000*66.4 A = 795.31 m2
Continue..
To Find Number of tubes, Area = 2rl Area = 795.31 m2 r=0.0508 m l= 4 m l= A/2r l= 795.31/2*3.14*0.0508 l= 450.65 m Nt = 113 tubes Dia of each tube, Outer dia of tube d0 = 2 Inner dia of Tube di = 1.6
Specification Sheet
Equipment Code Equipment Name Operating Conditions Inlet temperature Outlet temperature Inlet pressure 1125 0C of flue gases 368 0C of flue gases 100724.85 Pa of flue gases HE-B05, HE-A65 Heat Recovery Unit
Outlet pressure
Inlet temperature outlet temperature Inlet pressure Outlet pressure Inlet temperature Outlet temperature
100524.8 pa 119029.36 Pa
795.31 m2
143.77 m2 2667793371.3 watt/m2.k
Heat transfer coefficient of flue gas and air 158482751.42 watt/m2.k system Material of Construction Corrosion Allowance Thickness of Material Outer dia Inner dia Carbon steel 0.1 0.2 2 1.6