Based on more complete data, 2009 world DRI production reached 64.4 million tonnes, higher than first reported earlier in the year. Last year's production was not a record but remained remarkably healthy in light of economic conditions.
India, once again, led all nations in DRI production with over 22 million tonnes, more than one third of the world total. Of this, 16.2 million tonne s were made in rotary kilns. The rotary kiln, coal based method for direct reduction again set records. There are approximately 350 of these furnaces operating within India.
Iran was the second largest producer of direct reduced iron, accounting for 8.2 million tonnes. Iran led the world in natural gas based DRI production, and Venezuela and Saudi Arabia each also produced in excess of 5 million tonnes. Russia was close behind with 4.7 million tonnes. Rounding out the top ten were Mexico, Egypt, Malaysia, Qatar and Trinidad with 4.2 million, 2.9 million, 2.3 million, 2.1 million and 2 million tonnes respectively.
Difficult economic conditions caused a large share of the world’s DR capacity to be shuttered. Of the 58 MIDREX® Modules installed at the beginning of 2009, 54 remained in operation but four were idled, two in Nigeria, one in Canada and one in Trinidad. Of the 26 installed HYL Energiron Modules, 16 remained in operation while 10 were idled, three in Iran, two in Indonesia, two in Mexico, two in Venezuela and one in India.
Beginning the year reeling from the effects of the world financial crisis, the direct reduction industry made a remarkably rapid recovery in 2009. Starting in January, with approximately one fourth of capacity going unused, world direct reduced iron output gradually increased throughout the year so that by December it was back up to 96% of the all time maximum monthly production rate. This contrasted sharply with the non Chinese world’s blast furnace ironmaking industry, which fell to below 60% of capacity at the beginning of the year and had only returned to 85% by December.
Particular strength was exhibited in the CIS, in the Middle East and in South Asia where a number of nations with significant histories of DRI production broke the records of their prior best years; namely, Russia, Iran, Qatar, Saudi Arabia and India. Peru and the United Arab Emirates also set new records but each of these produces less than one million tons per year. Contrasting with the growth mentioned above, the crisis combined with other factors caused output by some nations to shrink, notably Mexico and Venezuela, each of which made less than two-thirds of its previous maximum.
