MIDREX® and DRI in the MENA Region:

Plant Availability
Production Reliability
Process Flexibility

4 TH W O R L D D R I A N D P E L L E T
CONGRESS
APRIL26, 2016

PRESENTED BY:
ROBERT MONTGOMERY
SALES MANAGER - MENA REGION

© 2016 Midrex Technologies, Inc. All rights reserved.

 2014 World DRI Production by region (MT)

MENA IS
KING!!
32.81 2012 2013 2014

Middle East/ North Africa 27.19 32.61 32.81

Asia/ Oceania 22.58 19.99 18.76
Latin America (including Mexico & Caribbean) 15.16 13.83 12.66
18.76
CIS/Eastern Europe 5.24 5.33 5.35
North America (US & Canada) 0.84 1.25 2.85
12.66 Sub-Saharan Africa 1.57 1.41 1.55
Western Europe 0.56 0.50 0.57

5.53

1.55
1.25
0.57
Middle East/
North Africa Latin America
(including Sub-Saharan
Mexico & Africa Western
Caribbean) Europe

© 2016 Midrex Technologies, Inc. All rights reserved.

 MENA Steelmakers - What’s Most
Important
 Plant Availability
 Production Reliability
 Process Flexibility

Production Reliability is always on the top of the list for

MENA steelmaking clients!!!

© 2016 Midrex Technologies, Inc. All rights reserved.

 DRI is the preferred EAF charge material in the
Middle East – 60% of all steel produced in the
region is made using DRI

© 2016 Midrex Technologies, Inc. All rights reserved.

 Long Term Performance Reliability

• In the MENA Region - Liquid steel via the

Gas based DR route is 50-80 $/ton cheaper
than prime scrap based LS production

• DRI production shortfalls can only be offset

by scrap

• The long term benefit of DRI supply

reliability is significant

© 2016 Midrex Technologies, Inc. All rights reserved. 5

 2014 Total World DRI Production by
Shaft Furnaces: 59.2 Mt
MIDREX =
 Plant Availability HYL Energiron
20.4%
 Production Reliability
MIDREX®
 Process Flexibility 79.6%

Midrex Plants have consistently outperformed other

technologies for the last 30 years

© 2016 Midrex Technologies, Inc. All rights reserved.

 DRI Products 
Versatile Ore‐based Metallics 

 CDRI: Cold Direct Reduced Iron

 HDRI: Hot Direct Reduced Iron charged 
directly into a melter without cooling

 HBI: Hot Briquetted Iron is direct 
reduced iron discharged from the shaft 
furnace at ≥650°C and compacted to a 
density ≥ 5 gm/cc

© 2016 Midrex Technologies, Inc. All rights reserved.

 The Value of HDRI for EAF Steelmaking
 Temperature dominates.
 HDRI → Higher Produc vity + Lower Power Consump on

© 2016 Midrex Technologies, Inc. All rights reserved.

 Options for Hot Transport

HOTLINK® – direct gravity feed (DR plant close to EAF)
HOT TRANSPORT CONVEYOR – moderate distance to EAF
HOT TRANSPORT VESSELS – longer distance to EAF

© 2014 Midrex Technologies, Inc. All rights reserved.

 Midrex Plants in MENA

 Qatar Steel – 2 Midrex Modules

 Hadeed – 4 Midrex Modules
 Jindal Shadeed – 1 Midrex Module
 SULB – 1 Midrex Module
 DRIC – 2 Midrex Modules
 Tuwairqi Steel Mills – 1 Midrex Module
 Esisco – 1 Midrex Module
 EZDK – 3 Midrex Modules
 Lisco – 3 Midrex Modules
© 2016 Midrex Technologies, Inc. All rights reserved.
 Qatar Steel DR module #1 Performance 2014/2015
o Design annual production - 400,000 tpy
o 2015 actual annual production - 827,000 tons
o 427,000 extra tons
o Plant Availability - 99.0%
o Module #1 operated 8,181 hours in 2015

© 2016 Midrex Technologies, Inc. All rights reserved.

 Hadeed Modules A, B, C
o Design annual production - 1,450,000 tpy
o 2014 actual annual production - 2,480,000+ tons
o 1,032,444 extra tons
o In 2015, Hadeed Exceeded rated capacities for the 31st
consecutive year at Modules A & B, and for the 23rd consecutive
year in Module C.

© 2016 Midrex Technologies, Inc. All rights reserved.

 Qatar Steel DR1 Module Production (MT) 1978-2014
900,000
835,317

800,000
717,640
700,000
Annunal Production (MT)

600,000

500,000

400,000

300,000 Annual Production (MT)

Rating
200,000 35 yr-Avg

3 per. Mov. Avg. (Annual

100,000 Production (MT))

-
1978
1979
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
No. of Years
 Qatar Steel DR Mod#2 Performance in 2014/2015
o Design annual production - 1,500,000 tpy
o 2015 Actual annual production - 1,887,000 tons
o 387,000 extra tons – 25% Above Rated Capacity!
o Plant Availability - 99.6%
o Module #2 set new annual production record: 1,887,000 tons
o Module # 2 operated 8,487 hours in 2015

© 2016 Midrex Technologies, Inc. All rights reserved.

 1,800,000.00
Qatar Steel DR2 Module Production (MT) 2007‐2014
1,782,893
1,667,854.00 
1,627,315.00 
 1,600,000.00
1,500,000.00  1,415,473.00 
1,355,047.00  1,342,836.00 
 1,400,000.00

 1,200,000.00
1,045,064.00 
 1,000,000.00

 800,000.00

 600,000.00

431,081.00 
 400,000.00

 200,000.00

 ‐ This image cannot currently be display ed.

This image cannot currently be display ed. This image cannot currently be display ed. This image cannot currently be display ed. This image cannot currently be display ed. This image cannot currently be display ed. This image cannot currently be display ed. This image cannot currently be display ed. This image cannot currently be display ed.

2007 2008 2009 2010 2011 2012 2013 2014

 Hadeed Module E
o Design annual production -
1,760,000 tpy
o 2014 actual annual production -
1,770,154 tpy
o Still the world record holder for
DRI produced in a single year –
2,000,458 tons in 2013.
o Plant Availability - 95.89%
o Hadeed’s 4 Midrex® Modules
have produced more than 74
Million tons of DRI to date

© 2016 Midrex Technologies, Inc. All rights reserved.

 Jindal Shadeed Performance 2015
o Design annual production - 1.500,000 tpy
o 2015 actual annual production - 1,509,130 tons Despite
being NG Limited
o Plant Availability - 99.0%
o Plant operated 8,219 hours in 2015
o Only 6.5 total hours of unscheduled downtime!

© 2016 Midrex Technologies, Inc. All rights reserved.

 SULB Plant performance in 2014
o 2014 Plant Availability: 98.40%
Unique natural gas conditions
o 8,247 hours in 2014
 11 % N2
o 2014 Monthly production record: 
 700 ppm H2S
135,275 tons
o 2016 : New Monthly production 
record 146,182 tons in March, 2016!

© 2016 Midrex Technologies, Inc. All rights reserved.

 MIDREX® Innovation/Results
 40 years of technology improvement
 MIDREX® Plants built 30 years ago are producing at double capacity.
 MIDREX® Plants hold the yearly  production records for shaft furnace‐based  
production of HDRI, HBI and CDRI.

© 2016 Midrex Technologies, Inc. All rights reserved.

 What Makes this Performance
Possible?
 World class leadership, training and operational
standards
 World class preventive maintenance program
 Process / Product development
 Robust processes and equipment
 Long term - joint collaboration between client and
technology supplier

© 2016 Midrex Technologies, Inc. All rights reserved.

 New DRI Plant Projects since 2010
Tuwairqi Steel Mills – 1.28 Mtpy
SULB – 1.5 Mtpy
JSW Toranagallu – 1.20 Mtpy
JSPL Angul – 1.8 Mtpy
Lebedinsky GOK III – 1.8 Mtpy
voestalpine Texas – 2.0 Mtpy
Tosyali Algerie – 2.5 Mtpy

© 2016 Midrex Technologies, Inc. All rights reserved.

voestalpine Texas -World’s Largest HBI
Plant Built for the Blast Furnace
Overview
• Capacity: 2,000,000 tons/year
• Location: Corpus Christi, Texas
• Product: HBI
• Start-up: 2016
Driving Forces
• 1 million tons of HBI will be shipped to
voestalpine’s integrated mills
• Increase blast furnace productivity in
the Linz and Donawitz (Austria)
• Decrease specific CO2 emissions
• Provide additional HBI for merchant
market
• Leverage low cost NG in USA

© 2016 Midrex Technologies, Inc. All rights reserved.

voestalpine Texas -
World’s Largest HBI
Plant

© 2016 Midrex Technologies, Inc. All rights reserved.

LGOK 3 - 1.8 MTPY merchant
HBI Plant
Overview
• Capacity: 1,800,000 tons/year
• Location: Gubkin, Russia
• Product: HBI
• Second MIDREX® HBI Plant and 3rd
HBI plant on site

PROJECT STATUS:
Engineering nearly complete
Equipment delivery ongoing
Construction started
Startup by April. 2017

24 © 2016 Midrex Technologies, Inc. All rights reserved.

LGOK 3 - 1.8 MTPY merchant
HBI Plant

© 2016 Midrex Technologies, Inc. All rights reserved.

 Tosyali Algerie

© 2016 Midrex Technologies, Inc. All rights reserved.

 TOSYALI ALGERIA
Capacity: 2.5 million tpy HDRI/CDRI
Furnace Type: MIDREX MEGAMOD®
7.65 m Hot Discharge Furnace
Reformer: 8 Row x 18 Bays
Products: 100% CDRI or HDRI/CDRI
Location: Oran, Algeria
PROJECT STATUS:
 Contract effective May 1, 2015

© 2016 Midrex Technologies, Inc. All rights reserved.

 World’s Largest DRI Combo
Plant
Tosyali Holding awarded World’s Largest 2.5 MTPY DRI Combo
Plant Order to Midrex and its partner Paul Wurth in Algeria

Customer: Tosyali Holding  

Plant Capacity:‐ 2.5 MTPY
Product::‐ HDRI/CDRI‐Combo Discharge
Fuel:‐ Natural Gas
Hot DRI Transport: Mech Conveyor  (Aumund)
Location:‐ Algeria 

• Largest single DRI plant to produce multiple

DRI products (HDRI/CDRI) in combination.

• HDRI will be fed via an Aumund hot Signing for ceremony in Istanbul
transport conveyor to a new EAF allowing for Turkey, June 2015
greater EAF productivity and energy savings

© 2016 Midrex Technologies, Inc. All rights reserved.

 Tosyali Algerie

© 2016 Midrex Technologies, Inc. All rights reserved.

 Designed for Today,
Engineered for Tomorrow™

THANK YOU
Visit www.midrex.com for more technical 
presentations and the 2015 World Direct Reduction 
Statistics Booklet

© 2016 Midrex Technologies, Inc. All rights reserved.