PERED Presentation Turkey 04032010

MME
DIN EN GmbH Mines and Metals EngineeringISO 9001:2000
CERTIFICATE: 01 100 052057
MME
MME
DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057
MME
Company with Global Presence

Head Quater Germany, Dsseldorf
Affilations in following continents
EUROPE Geramny,Slovakia & Poland ASIA Iran,India & China NORTH AMERICA - Canada
Quality management system
MME Quality management system (QMS) is oriented on basis of the companys 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
MME
Feasibility Studies
Mines
Engineering
MME Provides Services for Steel Plants and Other Industries
Projects Execution Start Up & Comm . Maint. & Spare parts Systems & Automation Projects Financing
Iron Making Plants Steel Making Plants Rolling Mills Non Ferrous Industries
Turn Key
Mines and Metals Engineering GmbH
Train. & Tech. Assist.
MME Organization Chart
Projects Managers Projects Managers Projects (1300) Managers (1300) (1300)
Persian Direct Reduction Technology
PERED TRADE MARK CERTIFICATE
PERED PATENT CERTIFICATE
PERED PROCESS DESCRIPTION

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 FURNACE The shaft type metallizing furnace utilizes a continuous process flow at highest known efficiencies. Within the furnace, the pellets descend 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 and the lower zone for cooling. The iron oxide material descends from the reduction furnace charge hopper by gravity through a dynamic gas seal into specially designed 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 the upper part. The reducing gas is introduced around the circumference of the reduction zone in two level with different composition and temperatures through specially designed ports. If O2 injection is not there, the temp and composition of the reducing gas will be the same. Material flowing thro the reduction zone passes into a transition zone prior to entering the cooling zone. This transition zone has sufficient height 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 zone on 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

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 + CO2 3Fe2O3 + H2 2Fe3O4 + H2O Magnetite reduced to iron Wustite Fe3O4 + CO 3FeO + CO2 Fe3O4 + H2 3FeO + H2O Wustite reduced to metallic iron and Cementite Fe O + CO Fe + CO2 Fe O + H2 Fe + H2O 3Fe + CH4 Fe3C + 2H2

REFORMING In 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 + 2H2 CH4 + 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 doesnt anticipate any venting of fuel during normal operation. MATERIAL HANDLING SYSTEM For 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 MODULE For 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 SYSTEM Three 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. ----------------------------------------------------------------------
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 NIERIZ (IRAN)
NIERIZ (IRAN)
CURRENT PROJECT ACTIVITIES MIYANEH (IRAN)
MIYANEH (IRAN)
CURRENT PROJECT ACTIVITIES BAFT (IRAN)
BAFT (IRAN)
PROJECTS COMPLETED
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
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) INSIG , Automation system for new steelmaking plant (2005) Gol-E-Gohar Polycom Project Engineering (2005) (2003)
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
Furnace 3D stress analysis
PERED & OTHER TECHNOLOGY
Parameter Capacity Option Metallization Carbon % Pellet / DRI Gas Power Water Efficiency Maintenance Costs Man-Hour
Unit
Ton per Year % % Ton / Ton DRI Gcal / Ton DRI Kwh / Ton DRI M3 / Ton DRI Ton / Day M3 Euro / Ton DRI Man-Hour / Ton DRI
PERED (Estimated) 400000-1800000

DRI/HBI/HDRI/COMBO
Midrex 400000-1800000
DRI/HBI/HDRI/COMBO
HYL 400000-1800000
DRI/HBI/HDRI/COMBO
92-95 1.5 3.0 ~ 1.42 less dust 2.4 2.6 100 - 120 0.9 1.4 10-11 3.0 0.30
92-95 1.5 2.5 1.45 2.5 2.8 100 - 130 1.0 1.5 9.5-10 4.3 0.45
92-95 1.5 3.0 1.40 2.5 3.0 60 70(with O2) 1.2 1.6 4.7 0.50
Conclusion
PERED technology brings the following advantages
Latest technology Lower capital investment Lower energy & operation costs Environment friendly technology Jumbo module for more than 1.76 MTPY Option for Hot DRI / COMBO Flexibility to use local ore

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MME

DIN EN GmbH Mines and Metals EngineeringISO 9001:2000

CERTIFICATE: 01 100 052057

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

Company with Global Presence

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

Quality management system

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

MME Provides Services for Steel Plants and Other Industries

Mines and Metals Engineering GmbH

Train. & Tech. Assist.

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

MME Organization Chart

Projects Managers Projects Managers Projects (1300) Managers (1300) (1300)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

Persian Direct Reduction Technology

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

PERED TRADE MARK CERTIFICATE

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

PERED PATENT CERTIFICATE

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

PERED PROCESS DESCRIPTION

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

PERED PROCESS DESCRIPTION

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

PERED PROCESS DESCRIPTION

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES - SHADEGAN (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)

DIN EN ISO 9001:2000 CERTIFICATE: 01 100 052057

CURRENT PROJECT ACTIVITIES NIERIZ (IRAN)