Tosyali Algerie A.Ş. established a new world record in 2021 for annual direct reduced iron (DRI) production by a single module plant, producing more than 2.28 million tons. The former record was set in 2020 by Tosyali in only its second year of operation.
Full compliance with environmental principles
“Our fundamental priority is operational sustainability and full compliance with environmental, social and governance principles,” Dr. Suhat Korkmaz, CEO of Tosyali Holding, said. “Tosyali Algerie DRI Plant setting a worldwide production record two years in a row is proof of our operational excellence. As a team of nearly 3000 employees, we are very proud of being a part of this success story. This record also places Algeria in a very successful position in the DRI industry across the world.”
“In the last quarter of 2021, we started the last phase of our investment in Tosyali Algerie, which includes a new DRI facility with the latest and highest available technology. This new investment will enable a significantly lower carbon footprint, one of the best practices in the world steel industry,” Dr. Suhat said.
“This new investment in Algeria is highly important, not only because of 2.5 million tons of additional capacity but also because of the positive environmental impact. At Tosyali Algerie, we produce steel with a low carbon footprint by using the world’s most advanced DRI technology, and we will be even more competitive in terms of environmental impact with this new technology transfer to Algeria.”
Stephen C. Montague, President & CEO of Midrex Technologies, Inc., said, “We congratulate the management and staff of Tosyali Algerie for their continued excellence in plant operation. Setting the DRI production record for a second time is a real testament to the skill and know-how of the Tosyali Group.”
Contract for Second MIDREX Plant
In July 2021, Tosyali Holding awarded Midrex and its partner Paul Wurth a contract to build a second DRI plant at the Tosyali Algerie steelworks in Bethioua (Oran), Algeria. The new DRI plant will produce 2.5 million tons of cold DRI (CDRI) and hot DRI (HDRI), similar to the original plant, with the capability of all MIDREX Plants to operate with even more hydrogen in the future. HDRI will be fed via a hot transport conveyor to a new electric arc furnace (EAF), allowing for greater EAF productivity and energy savings. During melt shop outages, the plant can continue producing CDRI up to full capacity, which maximizes operational ability.
“We’re very pleased to be working with Tosyali on a second DRI plant.” Midrex Technologies President and CEO Stephen C. Montague said. “Direct reduction is the best technology to reduce the CO2 footprint of the steel industry, and this plant is designed to utilize even more hydrogen as it becomes available in the future.”
Speaking for Paul Wurth, Dr. Thomas Hansmann, Head of Metallurgy at SMS Group, said, “Being part of the new project for the second DRI module of Tosyali Algerie is a privilege for us and the recognition of the job done together over the last years. This additional production capacity will give Tosyali the opportunity to extend their presence in the international steel market with a technology leader in the industry’s decarbonization efforts and at the same time will further contribute to the economic and industrial development of Algeria, one of the leading industrial countries of North Africa.”
Converting from natural gas to hydrogen
MIDREX Plants produce high-quality DRI products (CDRI, HDRI, and HBI) from iron ore using the natural gas-based MIDREX Direct Reduction Process (MIDREX NG™) – the most environmentally friendly technology for ore-based ironmaking. MIDREX NG provides greater raw material flexibility by allowing the use of DRI-grade pellets, blast furnace-grade pellets, and lump ores. Compared to blast furnace ironmaking, a standard MIDREX NG plant can reduce CO2 emissions by more than 50% and has the flexibility to be converted from 100% natural gas to 100% hydrogen as the reducing agent. MIDREX H2™, which uses 100% hydrogen, is available for greenfield plants.
- MIDREX is a registered trademark of Kobe Steel, Ltd.
- MIDREX NG is a trademark of Midrex Technologies Inc.