pered presentation turkey 04032010

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057MME Mines and Metals Engineering GmbH

M M

E

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

MME


MME

Head Quater – Germany, Düsseldorf

Affilations in following continents

• EUROPE – Geramny,Slovakia & Poland

• ASIA – Iran,India & China

• NORTH AMERICA - Canada

Company with Global Presence


Quality management system

MME Quality management system (QMS) is oriented on basis of the company’s processes.

It is distinguished between value adding activities (core processes), which convert the demands of the customers directly and

supporting and managing processes, which support the core-processes or are necessary for the maintenance of the management system.


MME

Maint. & Spare parts

Start Up & Comm .

Systems & Automation

Projects Financing

Train. & Tech. Assist.

Projects Execution

Feasibility Studies

Engineering

MME

MME Provides Services

for Steel Plantsand

Other Industries

Mines and Metals Engineering GmbH

Mines

Iron MakingPlants

Steel MakingPlants

Rolling Mills

Non FerrousIndustries

Turn Key


MME Organization Chart

Projects Managers(1300)Projects Managers

(1300)Projects Managers(1300)


Persian Direct Reduction Technology

®


PERED TRADE MARK CERTIFICATE


PERED PATENT CERTIFICATE


The PERED® Direct Reduction Process converts iron oxide pellets into highly metallized Iron either in the form of direct reduced iron(DRI), which are ideal feed materials for high quality steelmaking.

METALLIZING FURNACEThe shaft type metallizing furnace utilizes a continuous process flow at highest known efficiencies. Within the furnace, the pelletsdescend by gravity and will be metallized by direct counter current contact with reducing gasses in the reduction zone.The shaft furnace is divided in three zones with separate gas system, the upper zone for reduction, transition zone for carburizing andthe lower zone for cooling.The iron oxide material descends from the reduction furnace charge hopper by gravity through a dynamic gas seal into speciallydesigned feed pipes into the reduction furnace.The actual reduction zone in which the oxide is heated up to required temperature and the same time being reduced, is located at theupper part. The reducing gas is introduced around the circumference of the reduction zone in two level with different composition andtemperatures through specially designed ports. If O2 injection is not there, the temp and composition of the reducing gas will be thesame.Material flowing thro the reduction zone passes into a transition zone prior to entering the cooling zone. This transition zone has sufficientheight to isolate the reduction zone and cooling zone gas circuits from each other and to allow independent control.In-situ reforming can be achieved by injecting NG into the Transition zone or allowing cooling gas to flow upward from the cooling zoneon a controlled basis. In –situ reforming has several beneficial functions:•It carburizes the metallic iron•It cools the metallic iron•It uses sensible heat in the metallic iron to heat and reform the natural gas into additional reducing gas•It increases plant productivity•It decreases overall energy consumption

PERED PROCESS DESCRIPTION


Cooling of the hot metalized DRI will be effected in the cooling zone beneath the transition zone. The DRI is cooled by counter current flow of recycled cooling gas. The cooling gas is introduced through a specially designed nozzles in the lower part of the metallizing furnace.

At the top of the cooling zone, hot cooling gas is sucked through four off take channels & scrubbed, compressed and recycled after conditioning with NG.

The reduction furnace operates at fairly higher pressure with the reduction and cooling gases remaining within the furnace system by means of dynamic seal at both top and bottom of the reduction furnace.

The raw material entering and product discharged through the seal legs provide resistance to the furnace gas escape. The additional sealing gas given in the top and bottom seal legs prevents completely the gas escape from the furnace.Under optimized chemical and thermal utilization of the gas reduction of the pellets will take place according to the following reactions:

Hematite reduced to magnetite 3Fe2O3 + CO 2Fe3O4 + CO23Fe2O3 + H2 2Fe3O4 + H2O

Magnetite reduced to iron WustiteFe3O4 + CO 3FeO + CO2Fe3O4 + H2 3FeO + H2O

Wustite reduced to metallic iron and CementiteFe O + CO Fe + CO2Fe O + H2 Fe + H2O 3Fe + CH4 Fe3C + 2H2



REFORMINGIn the reformer, natural gas is reacted with CO2 and H2O to produce a reducing gas rich in CO and H2 in presence of specially designed catalyst. The important reforming reactions are:CH4 + CO2 2CO + 2H2CH4 + H2O CO + 3H2

These reactions are endothermic and thus require heat input. The reducing gas quality and the temperature of the reformer are automatically controlled based on the set operating guidelines..

The feed gas for the reformer will be a mixture of natural gas and recycled top gas with adequate steam for stochioimetric reaction. Approx. 70% of the top gas is used as process gas and flows through the process gas compressor, which will be conditioned with steam and NG to feed to reformer, while the remaining gas will be utilized as fuel to the reformer. The top gas fuel surplus if any will be vented to atmosphere at appropriate height. But the process doesn’t anticipate any venting of fuel during normal operation.MATERIAL HANDLING SYSTEMFor unloading, stacking, reclaiming of oxide and feeding to direct reduction plant and also storage and supply DRI to battery limit is designed as per the requirement .Product material handling also designed to handle cold DRI with adequate amount of storage facilities.INERT GAS FOR DR MODULEFor direct reduction plant, Seal gas is provided for sealing and purging purposes. The DR module will produce enough seal gas for that purpose with exhaust flue gas. In addition an Inert gas generator will be provided to start on the generator power for plant emergencies.WATER SYSTEMThree circuits with corresponding cooling system provide the water requirement of the plant.The Machinery cooling water system essentially serves to cool the machinery and equipment.The Process water system has two circuits namely contaminated water system & clean water system which provides for cooling and cleaning of the gas circuits.Cleaning and recycling of the water is provided in order to minimize the requirement of fresh makeup water.

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MME ACTIVITIES


CURRENT PROJECT ACTIVITIES (IRAN)

South Kaveh DRI MIDREX ( 2 X 0.8 MTPY)

SHADEGAN DRI PERED (0.8 MTPY) Turn Key

BAFT DRI PERED (0.8 MTPY) Turn Key

MIYANEH DRI PERED (0.8 MTPY) Engineering & Procurement

NIRIZ DRI PERED (0.8 MTPY) Engineering & Procurement

Chaharmahal Steelmaking Plant – (1.2 MTPY) Turn Key


CURRENT PROJECT ACTIVITIES (IRAN)

Neiriz Steelmaking Plant Eng. &supply

Oxin Steel Wide Plate Mill Consultancy

KSC Wide Plate Mill (Turn Key)


CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

SHADEGAN (IRAN)


CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)


CURRENT PROJECT ACTIVITIES – NIERIZ (IRAN)

NIERIZ (IRAN)


CURRENT PROJECT ACTIVITIES – NIERIZ (IRAN)


CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)


CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)

MIYANEH (IRAN)


CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)


CURRENT PROJECT ACTIVITIES BAFT (IRAN)

BAFT (IRAN)


CURRENT PROJECT ACTIVITIES BAFT (IRAN)


KSC - 3 DRI (MIDREX ) Module up gradation to 1.6 MMTPY (1996 - 99)

KSC - Slab casters increase of product length from 6 to 9 and 12 meters (1997)

KSC - Master Plan for up gradation to 3.2 MMTPY with SMS-DEMAG & Techint (1999)

INSIG - Pipe rolling mill technical assistance (2000)

KSC EAF No. 1&2 upgraded to 1.25 MMTPY (2001)

KSC ZAMZAM DRI (MIDREX ) Plant 0.8 MMTPY (turn-key) (2002)

KSC Oxide coating for DRI Modules (2002)

PROJECTS COMPLETED


PROJECTS COMPLETED

KSC - Engineering - oxygen injection system for DRI modules (2002)

MSC - pelletizing plant technical assistance (2003)

Gol-E-Gohar hematite recovery, feasibility study (laboratory & pilot plant testing) (2003)

INSIG , Automation system for new steelmaking plant (2005)

Gol-E-Gohar Polycom Project Engineering (2005)

KSC - ZAMZAM II (MIDREX) DRI Plant 800,000 t/y (turn-key) (2008)


PROJECTS – BID STAGE

OXIN – COMBO HDRI JUMBO PERED 1.76 MTPY (IRAN) ISAPAT INDUS. LIMITED – MIDREX HDRI CONVERSION (INDIA)KSC, ZAM ZAM III – DRI JUMBO PERED (IRAN) GOL-E-GOHAR – HBI JUMBO PERED (IRAN)


SUPPORT SERVICES

TRAINING – OPERATORS & ENGINEERS

COMMISSIONING OF DRI AND STEEL PLANTS

FEASIBILITY STUDIES

PROCUREMENT SERVICES

SUPPLY OF TECHNICAL EXPERTS


PERED TECHNOLOGY


Major area of plant

Core area

Non Core Area


Core Area

REDUCTION SHAFT FURNACE

GAS SCRUBBERS (COOLING AND TOP GAS)

COMPRESSOR STATION

REFORMER

RECUPERATOR & WASTE FLUE GAS SYSTEM

WATER SYSTEM

SEAL GAS SYSTEM

AUTOMATION

ELECTRICAL SYSTEM (MAIN SUBSTATION/RECEVING & DISTRIBUTION STATION)


Non Core Area

INSTRUMENT / PLANT AIR SYSTEM

QUALITY CONTROL LABORATORY

WORKSHOP

MATERIAL HANDLING ( PRODUCT + IRON OXIDE)

RAW WATER TREATMENT

SHIPPING & RECEIVING


TYPICAL PERED REACTOR


TYPICAL PERED REACTOR – GAS SYSTEM


DUAL TOP GAS OFFTAKE


PERED REACTOR SUPPORT & DOUBLE GAS ENTERY


TYPICAL PERED REFORMER


TYPICAL PERED REACTOR COOLING GAS ARRANGEMENT


PERED PROCESS SIMULATIONS (CFD/FEA)


Gas pathlines based on pressure


Pellet velocity & Residence time in furnace


Effect of residence time of Pellets in Shaft Furnace


Furnace 3D stress analysis


PERED & OTHER TECHNOLOGY

Parameter Unit PERED(Estimated)

Midrex HYL

Capacity Ton per Year 400000-1800000 400000-1800000 400000-1800000

Option - DRI/HBI/HDRI/COMBO DRI/HBI/HDRI/COMBO DRI/HBI/HDRI/COMBO

Metallization % 92-95 92-95 92-95

Carbon % % 1.5 – 3.0 1.5 – 2.5 1.5 – 3.0

Pellet / DRI Ton / Ton DRI ~ 1.42 less dust 1.45 1.40

Gas Gcal / Ton DRI 2.4 – 2.6 2.5 – 2.8 2.5 – 3.0

Power Kwh / Ton DRI 100 - 120 100 - 130 60 – 70(with O2)

Water M3 / Ton DRI 0.9 – 1.4 1.0 – 1.5 1.2 – 1.6

Efficiency Ton / Day – M3 10-11 9.5-10 -

Maintenance Costs Euro / Ton DRI 3.0 4.3 4.7

Man-Hour Man-Hour / Ton DRI 0.30 0.45 0.50


Conclusion

PERED technology brings the following advantages

Latest technologyLower capital investmentLower energy & operation costsEnvironment friendly technologyJumbo module for more than 1.76 MTPYOption for Hot DRI / COMBOFlexibility to use local ore

pered presentation turkey 04032010

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