Gas-based direct reduction

Construction of world’s largest HDRI/CDRI Plant

TOSYALI ALGERIA

TOSYALI ALGERIA

Main plant features

World’s largest DRI Combo Plant

Capacity: 2.5 Mio t/year HDRI/CDRI

Furnace Type: Midrex Megamod® 7.65 m dia.

Reformer: 8 Rows x 18 Bays

Project description

In May 2015, the Turkish Steel producer

Tosyali Holding awarded Midrex Technologies,

Inc. and its partner Paul Wurth S.A. the

project to build the world’s largest multiple

product direct reduced iron plant for the

new steelworks of Tosyali Algeria located in

Bethioua (Oran), Algeria.

The new MIDREX NG™ Combo Direct Reduc-

tion Plant was designed to produce 2.5 million

tonnes of direct reduced iron per year and

has the capability to vary its production to

produce hot direct reduced iron (HDRI) and/or

cold direct reduced iron (CDRI) simultaneously

without any stoppage of production. This new

DRI plant is the largest single DRI facility to

produce multiple DRI products in combina-

tion ever built. HDRI is fed via a hot transport

conveyor to a new electric arc furnace (EAF)

located adjacent to the MIDREX® DRI plant

allowing for greater EAF productivity and

energy savings. CDRI can also be produced for

additional on-site use.

This new MIDREX® DRI Combo Plant provides

the Tosyali Algeria steelmaking facility with

greater production flexibility to produce high

quality, low impurity steels as well as to de-

crease their demand for imported scrap.

Paul Wurth’s Scope of Supply

` Engineering and supply of equipment

` Supervision of erection and commissioning

` Training

` Provider of local services

Gas-based direct reduction

Main project data

Order received: May 2015

Start of commissioning: June 2018

First production of cold DRI (CDRI): November 2018

Hot DRI (HDRI) production and

official plant start-up:

February 2019

Benefits of Hot Direct Reduced Iron

There are two main benefits of charging

hot DRI (HDRI) to the EAF: lower specific

electricity consumption and increased pro-

ductivity. Energy savings occur because less

energy is required in the EAF to heat the

DRI to melting temperature, resulting in

reduced electricity consumption of about 20

kWh/t liquid steel for each 100° C increase in

DRI charging temperature. The productivity

increase is related to the reduced tap-to-tap

time (up to 20%) compared to charging CDRI.

Additional benefits of charging hot DRI (HDRI)

to the EAF are:

yy Reduced electrode consumption

yy Lower overall emissions due to lower

electricity demand and reduced need for

charge carbon

MIDREX® process fueled by natural gas MIDREX® REFORMER

VCA**CERT

IFIED SAFETY SYSTEM

VINCOTTE

Paul Wurth S.A.32, rue d’AlsaceL-1122 LuxembourgPhone: (+352) 4970-1Fax: (+352) 4970-2209paulwurth@paulwurth.comwww.paulwurth.com

International presence:Brazil, Chile, Czech Republic, Germany, India, Italy, Japan, Korea, Mexico, P.R. China, Russia, South Africa, Taiwan, Ukraine, U.S.A., Vietnam

© Copyright 2019 Paul Wurth S.A. – all rights reserved

Non Contractual Data: Paul Wurth believes that the data contained in this folder are correct and accurate, but cannot guarantee same or better performances for any specific site without a detailed quote. Patents and Patents pending. — Paul Wurth equipment and processes are protected in many countries by patents.

Paul Wurth and the Paul Wurth Logo are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction. Midrex is a registered trademark of Kobe Steel, Ltd and used under licence.

The MIDREX® DRI combination

plant provides Tosyali Algeria

greater flexibility in producing

high quality steel products,

and eliminates the need to

purchase imported scrap.”

Dr. Suhat Korkmaz, CEO of Tosyali Holding

Tosyali Algerie makes

world record with daily

production of 7,700 tons

of direct reduced iron.”

10 July 2019