Apendex for the Bidding Process - What will be doneA piece of the tender application document. The outline given does not make it clear that gas reduction is part of the objective - It is
Nice find
The PDF if you want it all
https://buyandsell.gc.ca/cds/public/2017/09/12/e4ee193b106debe181c3da38e6bf0c4d/en_-_nrcan-5000033215_-_final.pdf
ANNEX “A” – STATEMENTS OF WORK SW1 Title Scaling-up processes on direct reduction of chromite and CFD modelling of relevant furnaces SW2 Background In recent years, a steady, reliable, and secure supply of critical metals has become increasingly important to major industrialized economies that seek to sustain their industrial base and develop advanced technologies, such as clean energy. In light of this, Canada, with its significant critical metal reserves, has an opportunity to supply some of the global demand for critical metals. However, to transition from promising mineral deposits to marketable products, investment in fundamental R&D and expertise is needed to address the complex technological challenges around the production, separation and processing of critical metals, and to better understand the global market for these key commodities. Chromium represents an opportunity for Canada to enter an emerging and globally strategic market. The main application of chromium is in the stainless steel industry, which is a vital to modern industry. The Ring of Fire chromite resources in northern Ontario would form the only potentially commercial quantities of chromite in North America and the fourth largest deposits in the world. However, the location of these deposits makes mining of this deposits quite challenging. Moreover, processing of chromite ore to marketable ferrochromium alloy is the other challenge for this development in Ontario due to the expensive local electricity. Natural Resources Canada (NRCan) has been directed through Budget 2015 to undertake a significant effort to support the development of Rare Earth Elements and chromite in order to maximize Canadian value and benefits from these deposits. As such, NRCan has undertaken experimental studies to enhance the knowledge on processing of chromite ores, ferrochrome production technologies and related environmental issues. SW3 Objectives To design and carry out large-scale furnace tests at the kilogram-scale, and perform a critical review of furnaces used in the direct reduction of iron and simulations of two relevant furnaces for assessing their applicability and use on direct reduction of chromite. The outcomes of this project will be (1) providing knowledge for assessing potential applicability of the flux-aided direct reduction processes at industrial scales, (2) providing products from flux-aided direct reduction tests for use in comminution and beneficiation tests, and (3) serve the broader needs of NRCan’s Chromite/Ferrochrome Project in identifying innovative and clean technology options for producing marketable ferrochrome alloys from the Ring of Fire chromite ores. SW4 Project Requirements SW4.1 Tasks, Deliverables, Milestones and Schedule The proposed scope of work will involve the following tasks. Task 1 – Scaling-up: The large-scale reduction tests at the kilogram scale will be performed on six (6) samples. The samples are mixtures of ore/concentrate, reductant (charcoal, graphite or other carbon sources) and flux/catalyst in the approximate proportions as per the table below. The table is provisional and the sample types, mass proportions and particle sizes will be defined during project kick-off meeting. RFP/DDP # NRCan-5000033215 Page 27 of 30 Type Flux MP(O/R/F) Particle size range (µm) Sample 1 Pelletized NaOH 100/22/11 -106+75 Sample 2 Pelletized Proprietary 100/22/11 -106+75 Sample 3 Powder Proprietary 100/22/11 -106+75 Sample 4 Pelletized CaCl2 100/22/30 -106+75 Sample 5 Briquetted CaCl2 100/22/30 -106+75 Sample 6 Powder CaCl2 100/22/30 -106+75 MP: mass proportion; O: ore; R: reductant; F: flux/catalyst Charcoal or graphite reductant and fluxes/catalysts will be supplied by the contractor. The ore samples and the proprietary flux/catalyst will be provided to the successful bidder. The identity and composition of the proprietary material will be kept confidential. The samples will be prepared by the contractor including grinding, sieving, mixing, pelletizing and briquetting as per the table above. The furnace design should include a heating zone large enough to accommodate a minimum of 1 kg sample preferably placed in a refractory tray with the dimensions of 17-25x17-25x3-5 cm (Length/Width/Height) to provide a maximum bed thickness of 5 cm; include a power supply capable of delivering uniform heat to the sample bed for ensuring a uniform temperature distribution across the bed maintained within ±20 °C (i.e. T=1300±20 °C) throughout the reduction experiments; allow multi-point temperature measurements (a minimum of three measuring points: immediately above the sample bed, near the bottom and near the edge of the sample bed); allow atmosphere control; allow analyses of evolved gases during reduction. The experiments will be performed for a minimum of two (2) hours at 1300 °C under an inert atmosphere until achieving a reasonable degree of reduction. The evolved gases will be monitored throughout the experiments. The contractor will propose a detailed methodology and apparatus including the furnace design to accommodate the above requirements. Task 2 – Review of Technologies on Direct Reduction of Iron or other Ferrous Alloys: The review will include those that are relevant or potentially applicable to direct reduction of chromite. The list would include technologies with reactors of vertical shaft, rotary hearth, rotary kiln and fluid bed or any other possible design. The review will consider reactor sizes, unit capacity, throughput, material handling (both feed and products), heat sources, furnace liner, types of reductants (i.e. solid vs. reformed natural gas), material types and sizes (e.g. pellet, lumpy, fines), material flow, and metalslag segregations with respect to their relevancy and applicability to direct reduction of chromite, and their potential limitations for metal recoveries. In addition, other aspects such as off-gasses, particulates and wastes will be part of the review. Following the review, two furnace designs will be selected in consultation with CanmetMINING technical team for CFD modelling (Task 3). Task 3 – Computational Fluid Dynamics (CFD) Modelling and Design of Furnaces: This task involves CFD modelling of two furnace types identified as per Task 2 to determine the effects of furnace design elements and requirements on unit capacity, feed rate, material flow, residence time, temperature profiles, heat transfer, carbothermic reactions and degrees of metallization. The work encompasses setting up operating and boundary conditions for the simulations, and defining limitations on mass transfer, heat transfer and furnace performance with respect to chemical reactions taking place inside the furnace and achieving reasonable degrees of reduction and metallization. The CFD models should incorporate (1) the carbothermic reduction reactions that take place in the material bed and (2) the combustion of fuels, into the simulation/modelling of both heat transport and material flow. Much higher thermal energy is required for the direct reduction of chromite in comparison to the direct reduction of iron. Therefore, special efforts should be made to address this requirement. The carbothermic reactions can consider an average composition of the additives, and the kinetic factors RFP/DDP # NRCan-5000033215 Page 28 of 30 needed for the simulations will be determined in consultation with CanmetMINING technical team. Based on the CFD modelling, potential advantages or limitations/challenges from using this specific type of furnace for industrial chromite direct reduction practice should be discussed. The bidder can use the CFD case study reported in the following journal publication as an example. G.K. Gaurav and S. Khanam, Computational fluid dynamics analysis of sponge iron rotary kiln, Case Studies in Thermal Engineering, 9 (2017) 14-27. Deliverables: Deliverable 1: An initial meeting within five (5) working days of signing the contract. The date, type (telephone, videoconference, WebEx, in person) and place of the meeting (if in person) will be decided jointly between NRCan and the supplier. The objective of the meeting is to discuss the proposal, to clarify the schedule and refine/finalize the work plan. Deliverable 2: Revised work plan within 3 working days of Deliverable 1. Deliverable 3: Progress Report - The Contractor must provide a progress report that provides a summary of tests completed, results and issues encountered to date. This is to be decided upon Deliverable 2. Deliverable 4: Sub-samples (about 10g) of the feed to the furnace (i.e. green pellets, briquettes, or powders) for each reduction test. Deliverable 5: Products from the furnace experiments and data tables of evolved gas compositions and temperature profiles of different locations at the end of each test. Deliverable 6: Draft report summarizing the findings of Task 2. Natural Resources Canada will review and set up a meeting date for Deliverable 6 within five (5) working days after receiving the draft report. Deliverable 7: Meeting at the end of Task 2 to decide on the furnace types selected for simulation and providing the inputs for the simulation stage. Deliverable 8: Draft report summarizing the simulation and proposed design of furnaces (including the assumptions made, the operating and boundary conditions, size, type of heat and location of heat sources, effect of parameters that are evaluated) as per Task 3. Deliverable 9: Final Report: Submission of a report (in English) at the end of the project which must address all changes/comments provided by NRCan. SW4.2 Reporting Requirements Contractor will provide regular updates and reports as per deliverables listed above. SW4.3 Method and Source of Acceptance All deliverables are subject to inspection by the Project Authority. The Project Authority shall have the right to reject any deliverables that are not considered satisfactory, or require their correction before payment will be authorize