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Analysis of the Circored Iron Ore Reduction Plant

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Analysis of the Circored Iron Ore Reduction Plant
A06-­‐G04 Q2 System capacity = capacity of the weakest link (bottleneck)

POM -­‐ case 2

7 staged process 1. Pre Heater -­‐ 2. Lock Hoppers -­‐ 3. 1-­‐Reactor -­‐ 4. 2-­‐Reactor -­‐ 5. Flash Heater -­‐ 6. Discharge -­‐ 7. Briquetting The 2-­‐Reactor (Fluidized Bed Stage II) is the bottleneck Input-­‐Output for 7-­‐step process # 1 2 3 4 5 6 Mass reduction Loss yield Output Inflow (t/h) Input for 100 final output (multiplier) Bottleneck Comment Given in Appendix Given in Appendix Calculated as (1-­‐Mass Reduction) * (1-­‐Loss Yield) If the 2-­‐Reactor is used at 100% (maximum), 4h reaction time Process Inflow / Final Output

Pre Heater Lock Hoppers 1-­‐Reactor 2-­‐Reactor Flash Heater Discharge Briquetting Final Output 7,60% 0,00% 15,00% 10,00% 0,00% 0,00% 0,00% 5,00% 0,00% 7,00% 1,00% 7,00% 0,00% 3,00% 87,78% 100,00% 79,05% 89,10% 93,00% 100,00% 97,00% 144,11 126,50 126,50 100,00 89,10 82,86 82,86 80,38 1,79 1,57 1,57 1,24 1,11 1,03 1,03 100,00

7 Run-­‐rate (1-­‐down time) 8 Material used

0,9 Iron Ore, Natural Gas 37,36 66,98 Magnesium oxide

1

0,99 Hydrogen

0,99

1 Nitrogen

0,97 n/a

0,99

0,8471

Process running 84.71% of total time

9 Net VC/t 10 Gross VC/t output 11 Total time running p.a. 12 Total output per hour 13 Total output p.a. 14 Total VC p.a. 15 Total FC p.a. 16 Total cost p.a. 17 Unit cost

1,5 2,36

Electricity, n/a water/ sewer & op. costs 8,08 8,6 12,72 10,70

3,51 3,62 24h per day 365 days p.a.

59,05 96,38

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