ANSDK Second Direct Reduction Plant

Owned by Alexandria National Iron & Steel Co. (ANSDK), the plant was established to be the same as the First Direct Reduction Plant established back in 1986.
This project covered the piping of the Second Direct Reduction Plant within the core area and the rack yard.
The design package included the piping route plan, steel structure arrangement plan, general foundation and anchors plan, piping arrangement drawings, piping isometrics, piping support drawings, operation support drawings, operation platform drawings, piping stress analysis, and material takeoff lists for piping, supports, insulation, and site painting and welding.
The plant includes a Midrex iron-making plant with an annual production capacity of 830,000 tons (within the Core Area), a water treatment system, and a material handling system. Based on improvements in available technology, some modifications were introduced to the
plant to improve production and maintenance activities.
The plant is divided into three areas:
• Core Area: furnace, compressor, reformer, and stack areas
• Raw Material (Iron Oxide) & Finished Product Area
• Rack Yard: overhead piping on the pipe racks within the plant battery limit Piping mainly consists of utility fluid distribution pipes (up to 2,200 mm in diameter), and weighs approximately 900 tons. The piping system also includes the pipes interconnecting the Water Treatment System and the Core Area. Piping endpoints at other areas or buildings are located in the vicinity of the pipe rack.
The plant was successfully established at a construction cost of USD 125 million, and the first production was initiated in September 1997.