Algeria’s DRI based integrated steel producer Tosyali Algerie produced more than 2.23 million tonnes of direct reduced iron in 2020, which is a world record for a single direct reduction module, utilizing MIDREX Technology supplied by US-based Midrex Technologies.
The 2.5 million tonens per year DRI plant began using hot DRI at the electric arc furnace melt shop in February 2019. Hot DRI made up almost 72% of total production in 2020 of 1.6 million tonnes, with average metallization of about 94% and carbon averaging around 2.2%. Iron ore pellets feeding the DRI plant were supplied predominately by Tosyali Algérie’s own 4.0 million tonnes per year pellet plant on site.
Algeria was a net importer of long steel products when Tosyali started production in 2013. The initial production capacity was 1.2 million tonnes per year of reinforcing bar and represented 28% of demand at the time. A 500,000 tonnes per year wire rod facility was added in 2015, which accounts for 60% of the national demand. In 2018, Tosyali added 2.2 million tonnes of liquid steel for the production of billets, two rolling mills, and a 4 million tonnes per year pelletizing plant. In addition, the first DR plant to Algeria, a 2.5 million tonnes per year MIDREX Direct Reduction Plant, was supplied by Midrex Technologies, Inc and its consortium partner Paul Wurth. Reinforcing bar exports began in 2018, with a target of increasing exports to 600,000 tonnes in the coming years following the opening of a new port and materials handling system. Hot DRI from the DRI plant is expected to help increase billet production and boost rebar output to more than 3 million tonnes per year. Tosyali intends to add 2 million tonnes per year of flat steel capacity in the future to meet Algeria’s rising demand.
The Tosyali Algérie Iron and Steel complex is located in industrial zone of Bethioua, 40 km east of Oran, the second largest city in Algeria. It has a close access to the Mediterranean Sea and covers 4 million square meters.