gasification and the midrex® dr process...the midrex process • converts iron ore to direct...
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GASIFICATION AND THEGASIFICATION AND THEMIDREX® DR PROCESSMIDREX® DR PROCESS
By: Rob By: Rob CheeleyCheeley
Midrex Direct Reduction CorporationMidrex Direct Reduction Corporation
Presented at the:Presented at the:
1999 1999 Gasification Gasification Technologies ConferenceTechnologies Conference
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MIDREXMIDREX
•• Technology CompanyTechnology Company
•• 80 employees80 employees
•• Located in CharlotteLocated in Charlotte
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DIRECT REDUCED IRONDIRECT REDUCED IRON
•• Known as DRIKnown as DRI
•• Elemental iron produced as solidElemental iron produced as solid
•• Feedstock for steel mini-millsFeedstock for steel mini-mills
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THE MIDREX PROCESSTHE MIDREX PROCESS
•• Converts iron ore to direct reduced ironConverts iron ore to direct reduced iron( DRI )( DRI )
•• 67% of World DRI Production of 3767% of World DRI Production of 37million tonsmillion tons
•• 47 Plants in 16 countries47 Plants in 16 countries
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IRON ORE REDUCTIONIRON ORE REDUCTION
3 CO + Fe3 CO + Fe22OO33 --> 2 Fe + 3 CO --> 2 Fe + 3 CO22
3 H3 H22 + Fe + Fe22OO33 --> 2 Fe + 3 H --> 2 Fe + 3 H22OO
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IMEXSA MIDREX PLANTIMEXSA MIDREX PLANT
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SYN GAS CHARACTERISTICSSYN GAS CHARACTERISTICS
Temperature Ambient - 2700 F
Pressure < 300 psig
H2/CO Ratio All are acceptable
Gas Quality > 2 ; > 10 preferred
Methane 0 - 5 %
Sulfur < 0.3 %
Quality = ( % H2 + % CO ) / ( % H2O + % CO2 )
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SYN GAS FLOW RATESSYN GAS FLOW RATES
FlowrateFlowrate Per t of DRIPer t of DRI
NmNm33 650 - 750650 - 750
SCFSCF 24,000 - 28,00024,000 - 28,000
MMBtuMMBtu 7.5 - 8.77.5 - 8.7
Assumes: Quality > 10 & 310 Btu/ftAssumes: Quality > 10 & 310 Btu/ft33
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ECONOMICS IN U.S.ECONOMICS IN U.S.
Direct CostsDirect Costs
Iron Ore Iron Ore $ 58 / t$ 58 / t
CoalCoal $ 17 / t$ 17 / t
OthersOthers $ 18 / t$ 18 / t
Indirect CostsIndirect Costs
Capital ChargeCapital Charge $ 32 / t$ 32 / t
OthersOthers $ 5 / t$ 5 / t
TotalTotal $ 130 / t$ 130 / t
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BEST LOCATIONSBEST LOCATIONS
•• East Asia East Asia
•• West Europe West Europe
•• Australia Australia
•• Brazil Brazil
•• India India
•• South Africa South Africa
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KEYS TO VIABILITYKEYS TO VIABILITY
•• Use Excess Synthesis GasUse Excess Synthesis Gas
•• Use Refinery By-ProductsUse Refinery By-Products
•• Minimize Capital CostsMinimize Capital Costs
•• Integrated Mini-Mill ComplexIntegrated Mini-Mill Complex
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INTEGRATED MINI-MILLINTEGRATED MINI-MILL
•• Gasification Gasification PlantPlant
•• MIDREX PlantMIDREX Plant
•• Steel MillSteel Mill
•• Power PlantPower Plant
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INTEGRATED MINI-MILL FLOWSHEETINTEGRATED MINI-MILL FLOWSHEET
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INTEGRATEDINTEGRATED MINI-MILLMINI-MILL
•• 2,700,000 t/y MIDREX Plant2,700,000 t/y MIDREX Plant
•• 2,400,000 t/y Steel Mill2,400,000 t/y Steel Mill
•• 360 MW Power Plant360 MW Power Plant
•• 16,000,000 SCF/h Synthesis Gas16,000,000 SCF/h Synthesis Gas
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SALDANHA STEELSALDANHA STEEL
•• Near Cape Town, South AfricaNear Cape Town, South Africa
•• First First Gasifier Gasifier / DRI Combination/ DRI Combination
•• Uses COREX® ProcessUses COREX® Process
•• Started-up in 1999Started-up in 1999
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COREX® Export GasCOREX® Export Gas
ItemItem Typical DesignTypical Design
HH22/CO/CO 0.50.5
Gas CompositionGas Composition
COCO 35 - 45 %35 - 45 %
HH22 15 - 20 %15 - 20 %
COCO22 35 %35 %
NN22, H, H22OO 1 - 6 %1 - 6 %
CHCH44 1 %1 %
TemperatureTemperature 100 - 140 F100 - 140 F
PressurePressure 2 - 25 2 - 25 psigpsig
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SALDANHA STEEL PLANTSALDANHA STEEL PLANT
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CONCLUSIONSCONCLUSIONS
•• GasifierGasifier / MIDREX is a viable option / MIDREX is a viable option
•• Integrated Mini-Mill has best economicsIntegrated Mini-Mill has best economics
•• Asia has best potentialAsia has best potential