THIRD YEAR INTERNSHIP AS A METALLURGICAL ENGINEER

OFFERED BY


NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF METALLURGICAL ENGINEERING



SYED MUHAMMAD SHAHBAZ
(MY-014)
syedshaz1992@gmail.com
CONTACT #: +92 345 3250881


INTERNSHIP SUPERVISOR: Mrs. ASIFA TASNEEM
DURATION OF INTERNSHIP: June 2
nd
to June 27
th
, 2014
DATE OF SUBMISSION: June 27
th,
2014

Internship Report | 2014

1

ACKNOWLEDGEMENT

Any accomplishment requires the effort of many people and there
are no exceptions. The report being submitted today is a result of
collective effort.
Although the report has been solely prepared by me with the purpose
of fulfilling the requirements of the course of BE. Metallurgy (Bachelor
of Metallurgical Engineering), there are innumerous helping hands
behind it who have guided me on my way.
First of all I would like to thank Almighty Allah for this great
opportunity granted to me to practically understand and practice what I
have studied.
Secondly, I would like to appreciate the role of my group advisors:
Mrs. ASIFA TASNEEM
Mr. ZUBAIR
Mr. SAJJAD HUSSAIN
Mr. AMAAN ULLAH DAHI
Mr. FAZAL
Mr. MUDASSIR KHALIL
Mrs. AMMARAH MOIN

for all the directions and guidelines on every stage of work regarding
the problems and counter measures, which were arisen during the
work and most importantly the management of the team, priority
goals and critical tasks which should be dealt tactfully.

Finally, yet importantly, I would like to express my heartfelt
thanks to my
Beloved parents for their blessings, my friends/classmates for their
Wishes towards the successful completion of this internship.
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PREFACE

Over the summer of 2009, I was granted the unique
opportunity to be employed by T UWAIRQI Steel Mills as an Internee.
Under the supervision of TUWAIRQI ENGINEERING department, I was
lucky enough to undertake 26 days internship that expanded my
horizons and my way of thinking.

TUWAIRQI Steel Mills is a project of Al-TUWAIRQI Group of Saudi
Arabia. It is being set up over an area of 220 acres at Bin Qasim, Karachi
with a production capacity of one million tons. The capacity can be
expanded to three million tons. The mills will start functioning soon.

My main project was based within the TUWAIRQI ENGINEERING
discipline and primarily involved practical understanding basic theories
under the supervision of concerned Engineers.


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INDEX
S. No. Topics Page No.
01 Introduction 04
02 Internship and Objective 05
03 About TSML Engineering 05
04 Assignment
I. MIDREX Process
II. Process Flow Diagram
III. Reformer And its
Advantages
IV. Chemistry Of
Reformer
V. Consumption per ton
of DRI
VI. Backward And
Forward Integration

06
05 Study About Valve 10
06 Plant layout diagrams 11
07 Problems About pressure Drop 11
08 Spread Sheets project 11
09 AutoCAD 11
10 MIDREX Plant 12
11 Iron Oxide Storage And
Handling
14
12 DRI Products 17
13 Water Complex 18
14 Cooling Tower 19
15 Work Experience At TSML
Engineering
20

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Introduction:

The Al-TUWAIRQI Group of Companies {ATG} one of the leading
business concerns in the Kingdom of Saudi Arabia and the largest
private sector steel producer, is in the process of setting up a steel
making plant in Karachi Pakistan.
The project namely TUWAIRQI Steel Mills Limited (TSML), Whose
foundation stone was laid by the president of Pakistan General Pervez
Musharraf on the30thof March, 2006, spreads over 220 acres and has a
strategic location at Port Qasim Karachi.
TSML shall be a state-of the-art steel making complex becoming the
biggest steel producing project in Pakistan. The plant shall have a
capacity of 1.28million tons per annum using the worlds most
advanced DRI {direct reduced iron} technology of the MIDREX process
which uses natural gas to convert iron ore into Direct Reduced Iron. The
process uses both lump iron ore and iron pellets as the raw material
and recycles the used gas. The process lowers both energy
consumption and environmental impact, making it an environmentally
friendly process. Along with an Intermediary Phase which includes the
setting up of an Induction Furnace to produce 0.5 million tons of billets
per annum is also being executed. The Intermediary Phase will be
completed close to the completion of DRI Plant. Phase II of the project
consists of installation of an Electric Arc Furnace and continuous caster
to produce 1.28 million tons high quality billets.



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INTERNSHIP:
An internship is a work-related learning experience for individuals who
wish to develop hands on work experience in a certain occupational
field. Most internships are temporary assignments that last
approximately few weeks to an year.

OBJECTIVE:
To develop skills and techniques which are directly applicable to my
career.

ABOUT TSML ENGINEERING:
TSML Engineering Services is a wholly owned subsidiary of TUWAIRQI
Steel Mills Limited, which is an affiliate of Al-TUWAIRQI Holding, a
prestigious Saudi Arabian Group of Companies, globally involved in a
number of technology intensive businesses including steel
manufacturing, fabrication services and engineering design services to
the industrial sector.
To provide competitive engineering solutions and technical services to
its business users at the lowest consistent rates with fair compensation
to the Team Members, safety for public, reasonable protection of
environment and development of technology to provide remarkable
services for customers.


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ASSIGNMENT

MIDREX PROCESS OVERVIEW:

IRON ORE REDUCTION:

Iron ore consist primarily of iron oxide (Fe
3
O
4
), a combination of iron
and oxygen. The basic function of all iron ore reduction technologies is
to economically remove the oxygen from the iron ore and leave only
the iron. If the iron ore reduction technology operates entirely in the
solid state, then the product is called DIRECT REDUCED IRON, or DRI.

To produce DRI, the oxygen in the iron oxide is chemically removed by
reacting with CO and H
2
at very high temperatures of about 900c.

Within the MIDREX plant, the main unit operation is the MIDREX shaft
furnace. Inside the MIDREX Shaft furnace, the iron ore is converted to
DRI. The spent reducing gases exit the top of the shaft furnace where
they are cleaned and cooled. The recycled process gas contain a mix of
CO
2
and H
2
O unreacted H
2
and CO, and inert N
2
circulating in the
system. To obtain a high enough gas quality to reuse in the shaft
furnace, most of the CO
2
is removed from the recycled process gas via a
vacuum pressure swing absorption (VPSA) unit. After this step, the
process gas is mix with the fresh synthesis gas. St this point, the gas is
near ambient temperature.
Therefore, the gas must be heated to about 900 C prior to entering the
shaft furnace, to ensure maximize reduction efficiency.
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PROCESS FLOW DIAGRAM








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REFORMER:
The primary raw material source to produce the reducing gas for the
reactor is natural gas . Natural gas is reacted with CO
2
and water vapors
across a proprietary catalyst to produce a reducing gas rich in CO and
H
2.



ADVANTAGES OF MIDREX REFORMER:
Environmental advantages such as producing less dust
particles & generating less noise pollution.
Technical advantages such as Higher quality products in
terms of carbon content flexibility and high degree of
metallization
Much more energy efficient


CHEMISTRY OF REFORMER:

REACTION:
CH
4
+ H
2
O CO + 3H
2

CH
4
+ (3/2) O
2
CO + 2H
2
O
CO + H
2
O CO2 + H
2



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CONSUMPTION PER TONN OF DRI:

Electricity 400 kWh/TLs
Electrodes 1.2 kg/TLS
Oxygen 35 Nm3/TLS
Gas 5 Nm3/TLS
Charge Coal 10 kg/TLS
Coal Powder (Foamy Slag) 7 kg/TLS
Lime 40 kg/TLS

BACKWARD INTEGRATION:





Iron Ore
Fines
Pellets Stock Yard
Screening Day Bin
Oxide
Coating
Furnace
Feed
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FORWARD INTEGRATION:



STUDY ABOUT VALVE:
Two Types of Valves
ON/OFF
Flow Control
Gate Valve
Ball Valve
Globe Valve
Butterfly Valve
Check Valve
Pinch Valve
DRI Scrap EAF Ladle furnace
Continous
Casting
Billets /
Blloms/ Re -
Bars
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PLANT LAYOUT DIAGRAMS:
Process Flow Diagram
Piping & Instrumentation Diagram


PROBLEMS ABOUT PRESSURE DROPS:
Line Sizing Criteria For Liquid Lines
Line Sizing Criteria For Gas Lines


SPREAD SHEETS PROJECTS:
Unit Conversions


AUTOCAD:
Basic concept of AutoCAD about 2-D and 3-D.



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MIDREX PLANT:
Within the MIDREX plant, the main unit operation is the MIDREX
shaft furnace. Inside the MIDREX Shaft furnace, the iron ore is
converted to DRI. The spent reducing gases exit the top of the shaft
furnace where they are cleaned and cooled. The recycled process gas
contain a mix of CO
2
and H
2
O unreacted H
2
and CO, and inert N
2

circulating in the system. To obtain a high enough gas quality to reuse
in the shaft furnace, most of the CO
2
is removed from the recycled
process gas via a vacuum pressure swing absorption (VPSA) unit. After
this step, the process gas is mix with the fresh synthesis gas. St this
point, the gas is near ambient temperature.
Therefore, the gas must be heated to about 900 C prior to entering the
shaft furnace, to ensure maximize reduction efficiency.

MIDREX PROCESS OVERVIEW

IRON ORE REDUCTION:

Iron ore consist primarily of iron oxide (Fe
3
O
4
), a combination of iron
and oxygen. The basic function of all iron ore reduction technologies is
to economically remove the oxygen from the iron ore and leave only
the iron. If the iron ore reduction technology operates entirely in the
solid state, then the product is called DIRECT REDUCED IRON, or DRI.

To produce DRI, the oxygen in the iron oxide is chemically removed by
reacting with CO and H
2
at very high temperatures of about 900c.

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REACTION:
Fe
2
O
3
+ 3CO 2Fe + 3CO
2

Fe
2
O
3
+ 3H
2
2Fe + 3H
2
O


REFORMER:
The primary raw material source to produce the reducing gas for the
reactor is natural gas . Natural gas is reacted with CO
2
and water vapors
across a proprietary catalyst to produce a reducing gas rich in CO and
H
2.


REACTION:
CH
4
+ 2O
2
CO
2
+ 2H
2
O

BLOCK DIAGRAM:





Blower Air Heat Recovery
Burners
Combustion
Zone
Heat Recovery
Zone
Stack
Top Gas Fuel
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IRON OXIDE STORAGE AND HANDLING:
Pellets are delivered in the surge bin at the port. After weighing, a
conveyor transports the pallets to the pallet pile. The pallet pile is
equipped with a stacker and will maintain a sufficient supply operation.
The pallets are weighed and transferred to the oxide day bins. The day
bin acts as a buffer of prepared oxide that is fed to the shaft furnace.
The day bin then discharge to a screening operation to separate the off
specification fractions from the desired 6-20 mm oxide fractions. The
desired oxide fractions are discharge on the oxide transfer conveyor.
Unusable material is discarded.

The material on the oxide transfer conveyor is weighed and discharged
onto the furnace feed conveyor.


PRODUCT MATERIAL HANDLING:
The material is transferred from the briquette cooling conveyors to the
HBI conveyors, which are equipped with product scales. The HBI
product is transported to the product screening station 1 where it is
separated into product fines (0-6.35 mm) and HBI (6.35-120 mm). The
fines are fed into the ground floor product fine bunker, while the HBI is
weighted and transported on the product collection conveyor to the
stacker conveyor for storage. The HBI product storage has a capacity of
100,000 tons per pile.
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The HBI is reclaimed from the HBI product storage and transported via
conveyor to the product screening station 2, where it is screened. The
HBI is transported via conveyor to the port.
All process operation within the product material handling system are
routed to various bag houses for the control of particulate emissions.
The storage pile and associated operations are controlled with fugitive
suppressants.
Process Gas System:
Spent reducing gas (top gas) exits the reduction zone of the reactor
through the refractory lined top gas duct and enters the top gas
scrubber to be cleaned and cooled. Inside the top gas scrubber, the gas
passes through two distinct processing zones.

First the gas flows through the venturi portion of the scrubber where it
is rapidly cooled and the particulate matter is wetted and removed.
Then the warm gas is split into two streams that pass through two
parallel packed beds (for additional cooling) and two sets of spin vanes
(to remove water droplets) within the scrubber. After scrubbing and
cooling, approximately two-thirds of the clean top gas (now called
process gas) flows through a second set of mist eliminators and then to
the inlet of the first stage process gas compressor, followed by a second
compressor. These compressors are centrifugal type machines
designated as first stage and second stage process gas compressors.
After compression, the process gas is mixed with natural gas and
preheated to form the feed gas for the reformer. The other one-third of
the cleaned top gas (now called top gas fuel) is mixed with a small
amount of natural gas and then passed through a mist eliminator to
remove water droplets before fueling the reformer main burners. It is
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16

important to note that the Top Gas Scrubber is not a control device but
a process device. The process gas system does not vent directly to the
atmosphere during regular operation.

Heat Recovery System:
The reformer flue gas exits on both sides of the reformer and enters
the parallel train heat recovery system. Each parallel system contains
combustion pre heaters and feed gas pre-heaters, all of which consist
of alloy bundle type heat exchangers suspended in the refractory lined
heat recovery ducts.
The combustion air pre-heaters are designed to preheat the
combustion air to about 600 C in two stages. The feed gas pre-heaters
located downstream of the combustion air pre-heater heat the feed gas
to approximately 600 C as well.
The flue gas exits the parallel trains through a common ejector
stack which generates the required draft with a single ejector stack fan.
The ejector stack is an induced draft (venturi type) flue gas stack. It uses
the ejector stack fan to generate sufficient suction to pull the flue gases
out of the reformer and through the heat recovery system. The heat
recovery system increases the reformer capacity and reduces the net
plant energy consumption by approximately 25-30%.




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DRI Products:
The MIDREX Process can produce three different product forms, depending on
the application: cold DRI (CDRI), hot briquetted iron (HBI) and hot DRI (HDRI).

CDRI is generally stored for later use in a nearby electric arc furnace (EAF). HBI is a
briquetted product that is ideal for storage and for shipping to distant consumers.
HDRI is discharged hot from the shaft furnace and transported to an EAF for
melting.
CDRI
Most MIDREX Plants built to-date produce CDRI. After reduction, the pellets and
lump are cooled in the lower part of the MIDREX Shaft Furnace to about 50 C.
This material is temporarily stored in silos to passivate it before transportation to
an adjacent EAF or another site. CDRI is ideal for continuous charging to the EAF.
HBI and Hot Briquetting:
Hot briquetting of DRI has been practiced on an industrial scale for more than
three decades and is now the preferred method of preparing DRI for storage and
transport internationally. To make HBI, hot DRI is discharged from the
MIDREX Shaft Furnace at about 700 C and compressed into pillow-shaped
briquettes with a typical size of 30 x 50 x 110 mm. HBI is 50 percent denser than
DRI pellets and lump, which reduces the tendency for re-oxidation.

This enables HBI to be stored and handled without special precautions as
recognized by the International Maritime Organization (IMO). HBI can be moved
using typical scrap handling equipment and easily batch charged to the EAF, thus
requiring no capital investment by the steel mill. HBI can be continuously charged
with specially-designed systems.

HDRI
Charging of HDRI to an adjacent EAF at 600 C or higher provides the optimum
way for DRI users to increase productivity and reduce cost. MIDREX offers three
methods for hot transport: HOTLINK, hot transport conveyor and hot transport
vessels.
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WATER COMPLEX:

Clarifier
Hot sump
Warm sump
Machining and Cooling Water Pump
Cooling Tower
Cold Sump

Pumps:
Heat Exchanger Pumps
Cold Process Water Pumps
Hot Water Pumps
Cooling Water Recirculation Pumps

Tanks:
Hot Water Tank
Warm Water Tank
Machining and Cooling Water Tank

PROCESS WATER FLOW:
The process water is key because it is used in scrubbers and for providing
seal in case of damaging the pneumatic seal. The seal gas if fail to restrict the toxic
gases then process water will keep toxic gases intact and do not allow them to
escape into the atmosphere.


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Clarifier:
The tank is used for the collection of water after it is used by the process,
the basic function of clarifier is to separate the dust particles by the action of
centrifugal force due to which heavier particles move to center with the help of
vipers.

HOT SUMP:
The hot Sump is a tank which store water after the overflow of clarifier.
This hot water is used in dust collector and in scrubber in order to maintain the
temperature to an extent.
WARM SUMP:
The warm sump stores the water to increase the temperature of water
to limit which is also used to in some parts of the plant.
MACHINING AND COOLING SUMP (MCW):
The MCW is used for cooling. MCW is used for cooling of plant and
instrument air compressors and to avoid corrosion.

COOLING TOWER:
The water from hot tank after completing its requirements is sent to
cooling tower. There are 5 cooling towers out of which 4 are running
and 1 on standby. The water is pulled to the top of tower by high
pressure motors and introduced into the tower. The hot water flow
down and exchanging heat as a result water losses heat and air gains
heat and remove from the top by action of induced draft.


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WORK EXPERIENCE AT TSML ENGINEERING:
Being undergraduate student, it was a great opportunity for me to
work as internee with professionals in one of the reputed consulting
firm of Pakistan. The attitude, behavior, knowledge and the training
methods adopted by these professionals helped us a lot to increase my
professional and personal growth. It was a great learning experience,
my vision has enlarged drastically. My approach toward the practical
work has changed a lot. It has been a very useful experience; getting
such exposure to practical work during this phase will help us
immensely while choosing my appropriate field.