International Journal of Iron & Steel Society of Iran

International Journal of Iron & Steel Society of Iran

Aspen HYSYS Simulation of Reformer and Heat Recovery System

Document Type : Research Paper

Authors
F. M. Mohsenzadeh 1
A. Payab 2
G. Monazami Tehrani 1
H. Payab 3
1 Department of Health, Safety and Environment, School of Public Health and Safety, Shahid Beheshti University of Medical Sciences, Tehran, Iran
2 Food science industry, UNSW University of Sydney, Sydney, Australia
3 Iran National Iranian Steel Company, Tehran, Iran
10.22034/ijissi.2025.2006686.1268
Abstract
 This research develops a simulation model for new design of reformer and heat recovery system (HRS) in the direct reduced of Khuzestan steel company in Iran. The endothermic reforming reactions in the reformer tubes, the natural gas, and fuel gas combustion in the burners were considered. A part of the combustion energy in the reformer box is absorbed by the reformer tubes while the rest of the energy enters the HRS at 1100 °C. The outlet fuel gas from HRS enters the stack at 325 °C. Equations of energy, mass, and momentum were together solved in the Aspen HYSYS software. The profiles of temperature, pressure, and components percentage are obtained in the reform and fuel gas. According to the results, an improved HRS can increase the reformer efficiency and reduce the temperature of the exhaust gas of the stack, as well as the refractory improvement. HRS reduced its energy loss from the body by half in spite of a two-fold increase in its heat transfer surface. The fuel gas temperature rose from 48 to 200 °C by raising tube bundle at the end of the HRS. The exhaust gas temperature from the stack also showed a decline from 311.5 to 261.3 °C. The flow rate of natural gas can be increased by 20% due to increased energy input to the reformer combustion chamber, enhancing the production of reduced gas by 7%. This increase in the amount of reducing gas can increase the tonnage production from the average 103 Ton/hr to 110 Ton/hr. However, the amount of stack flue gas carbon dioxide decreased by 7.29%. 
Keywords
MIDREX Plant
Reformer
Energy Saving
Heat Recovery System
HYSYS Software

Subjects

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