DRI Plant Flowsheet

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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 840C (1545F)
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

Flue
Gas

Natural
Gas

Shaft/
Reduction
Furnace
Process Gas
Compressor
Main Air Blower

Top Gas
Scrubber
Reduction
Zone

Top
Gas

Reducing Gas
Reformer
Scrubber
Cooling
Zone
Cooling Gas
Compressor
Exhaust
Stack

Feed Gas
Combustion Air

Direct
Reduced
Iron

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 930C (1706F)
methane slip 1.0 mol % (dry)
Specialized S tolerant reformer catalysts