Design and process simulation for the production of hydrogen gas for applications in reduction of iron ore

Abstract

This project was centered on the design and process simulation for hydrogen gas production, with a specific application in iron ore reduction. The primary objective was to devise an efficient and sustainable method for hydrogen production, a crucial component in the iron ore reduction process. The project commenced with an exhaustive study of various hydrogen production methods, including steam methane reforming, water electrolysis, and thermochemical cycles. The selection of the most suitable method was based on efficiency, cost and mostly, environmental impact considerations. Following the selection, the chosen method was simulated using Aspen plus process simulation software. The produced hydrogen gas was to be utilized in the reduction of iron ore, a critical phase in the steel making process. The project demonstrated that alkaline water electrolysis is a viable and efficient method for hydrogen production. The simulation using Aspen plus revealed that optimizing parameters such as current density, electrolyte concentration, and operating temperature, significantly enhance the electrolyzer’s performance. The process flow diagram developed provided a clear visualization of the system’s components and their interactions, ensuring efficient hydrogen production the mathematical model underscored the importance of balancing the various over voltages to achieve higher energy efficiency. Overall, the project confirmed that with proper design and optimization, alkaline electrolysis can meet the industrial requirements for high purity hydrogen production.