The document outlines the various direct reduced iron (DRI) plant flowsheet options, detailing the HYL and MIDREX types. It provides specific features and conditions for each process, such as feedstock, pressures, exit temperatures, and catalyst requirements. Key distinctions between the HYL III and MIDREX processes are also highlighted, focusing on their configurations and operational parameters.

1. DRI Plant Flowsheet
Options
By:
Gerard B. Hawkins
Managing Director, CEO

2. DRI Processes – Types using Steam
Reforming
 HYL type flowsheets
 Midrex type flowsheets
 Lookalikes exist in each category

3. DRI Processes - HYL III Process
Flowsheet

4. 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 840°C (1545°F)
• 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

5. DRI Processes - Typical Midrex Process
Iron Oxide
Direct
Reduced
Iron
Exhaust
Stack
Flue
Gas
Natural
Gas
Feed Gas
Main Air Blower
Combustion Air
Process Gas
Compressor
Reformer
Top Gas
Scrubber
Cooling Gas
Compressor
Reducing Gas
Scrubber
Top
Gas
Reduction
Zone
Shaft/
Reduction
Furnace
Cooling
Zone

6. 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 930°C (1706°F)
• methane slip 1.0 mol % (dry)
 Specialized S tolerant reformer catalysts