2014
WORLD
DIRECT REDUCTION
STATISTICS
www.midrex.com
CONTENTS
2 World DRI Production
6 World DRI Production
by Region/Year
7 World DRI Production
Tables
9 Major Trade Routes
for DRI Products 10 World DRI Shipments
11 World Direct Reduction
Plants
Audited by
6.23.15
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TABLE OF CONTENTS
2014 World DRI Production by Process
Other Gas
0.0%
Coal-based
20.6%
Total World Production: 74.6 Mt
HYL/Energiron
16.2%
MIDREX®
63.2%
20122013
2014
MIDREX®
61.2%
63.5%
63.2%
HYL/Energiron 14.8%
15.1%
16.2%
Other Gas
0.7%
0.2%
0.0%
Coal-based
23.3%
21.3%
20.6%
Source: Midrex Technologies, Inc.
2014 World DRI Production
Tops 74.5 Million Tons:
New technology and
expansion continues despite
difficult conditions
The world’s direct reduction industry produced 74.55
million tons of DRI Products in 2014 according to data
compiled by Midrex Technologies, Inc. and audited by
World Steel Dynamics. Production fell slightly from 2013
due to natural gas shortages and curtailments in India,
and operational disruptions in other DRI producing regions, as well general downturns in steel market conditions. DRI growth was evident in a number of nations
including the USA and Bahrain. Plants based on MIDREX®
Direct Reduction Technology accounted for 47.12 million
tons, which once again led all technologies with 63.2 percent
of the market total.
Output in 2014 was more than 70 percent greater than in
2000. Factors mentioned previously that have limited growth
for the last decade persist but have been somewhat offset by
demand for DRI products in “non-traditional” applications
(i.e., blast furnaces and basic oxygen furnaces) and by the
2014 World Direct Reduction Statistics
Page 2
introduction of new reductant sources (i.e., gasified coal and
coke oven gas).
The concentration of growth in the Gulf area is a result of
the many plants which have been started-up in the past few
years. In Bahrain, production increased rapidly as the SULB
plant, which had been commissioned the prior year, was
ramped up toward full capacity. Nearby, the Gulf nations of
Saudi Arabia and Qatar also saw significantly greater DRI
production due to strong internal demand by their national
economies.
New national records for DRI output were established
in six nations; Russia, Canada and four countries in the Gulf
region, Bahrain, Iran, Qatar and Saudi Arabia. Although, it did
not set a new record, it bears note that the South African DRI
industry accomplished an increase of 10 percent over the previous year while national steel production dropped by more
than eight percent.
In the USA, the DRI plant owned by Nucor Steel began
production, which marked the first time in five years that DRI
was made in the US.
FORCES AFFECTING THE INDUSTRY
Growth in North America and the Middle East can be attributed to both product demand and availability of low cost natural gas, which is the primary fuel used for direct reduction.
Various economic and political stresses did, however, stunt
DRI production in other locations. Libya continued to suffer
as rival groups struggled for control of the country and its
© 2015 Midrex Technologies, Inc.
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3
resources. Egypt has yet to fully recover from political disruptions and Iran was restricted by international sanctions.
Venezuela continued to experience production difficulties
due to infrastructure issues caused by the nationalization of
the industry and other political and economic factors. Only
12 years ago, Venezuela was the world’s pre-eminent manufacturer of direct reduced iron. Venezuelan output in 2014
was down to 1.7 million tons, less than 20 percent of the peak
of nearly 9 million tons achieved in 2005. The decline in HBI
exports was even more pronounced. ISSB reported only 212
thousand tons of DRI/HBI exports from Venezuela, a bit more
than five percent of the 4 million tons shipped in 2006. Much
of the problem derives from inability to sustain operation of
the iron ore pellet supply chain, beginning with the mines and
continuing through the pellet plants.
India, too, experienced an insufficient supply of pellets,
but there the problem was compounded by a lack of natural
gas at a favorable price. Steps have been taken to alleviate
this problem. Jindal Steel and Power’s MIDREX® Direct Reduction Plant (JSPL-Angul) commenced operation using only
syngas produced by a dedicated coal gasification plant. This
NEW CAPACITY AND PLANTS
UNDER CONSTRUCTION
MIDREX®
New modules begin operations
Five new MIDREX® Plants began operation in 2014. In India, the
1.8 million tons per year JSPL facility, which operates using syngas from coal gasification, was started in Angul, Orissa. It produces both HDRI and CDRI for use in the adjacent JSPL meltshop.
Also in India, the 1.2 million tons per year JSW Projects plant,
which is designed to use COREX® offgas, was commissioned in
Toranagallu, Karnataka. The plant produces HDRI and CDRI. In
Esfahan, Iran, a 1.5 million tons per year plant began operations.
Kharazi A, as the plant is known, is owned by Mobarakeh Steel
Co. Another MIDREX® Plant owned by Mobarakeh Steel and
known as Saba was started at Bandar Abbas. It has a capacity of
1.5 million tons per year of CDRI. Finally, also in Iran, a MIDREX®
Plant owned by Sirjan Iranian Steel was started at Bardsir in
Kerman Province. It makes 800 thousand tons per year of CDRI.
Under Construction
The LGOK III MIDREX® Plant continued construction in Gubkin,
2014 World Direct Reduction Statistics
Page 3
TABLE OF CONTENTS
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is a first of a kind project that demonstrates that gas-short
regions also can produce DRI. Also in India, the MIDREX®
Plant at the JSW Dolvi Works in Raigad, Maharashtra, began
using coke oven gas to augment its gas supply. This is another
example of a means to produce DRI when a nearby integrated
steel works is generating coke.
Top Producing Nations
Million Tons
India17.31
Iran14.55
Saudi Arabia
6.46
Mexico
5.98
Russia
5.35
Source: Midrex Technologies, Inc.
It should be noted that a large quantity of the DRI made in India is
produced in rotary kilns using coal; therefore, Iran had the largest
production by plants using natural gas as the fuel/reductant.
Belgorod Oblast, Russia. It will produce 1.8 million tons per year
of HBI and is scheduled for start-up in 2016. Also, the voestalpine Texas MIDREX® Plant is being built in Corpus Christi, Texas,
USA. Upon completion in 2016, it will be the world’s largest HBI
plant.
HYL/Energiron
New module begins operation
The 2.5 million tons per year Nucor Louisiana plant was commissioned at the end of 2013 and contributed production in 2014,
returning the US to the ranks of DRI producing nations.
Under Construction
Work continued on the three modules previously announced
by HYL/Energiron in Egypt, India and Venezuela, totaling 5.2
million tons per year.
Rotary Kiln Coal-based
Production by rotary kiln modules fell to 15.4 million tons as
a continuation of the gradual decline since the rotary kilns
peaked in 2010 at 18.1 million tons. Nearly all of these modules
are in India.
© 2015 Midrex Technologies, Inc.
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TABLE OF CONTENTS
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DRI Production Forecast
T
he outlook continues to be positive as demand
increases in traditional and new markets, and as
new and low cost energy sources become available for
DRI production. Production numbers should bounce
back next year as new, recently commissioned, capacity ramps up toward full production. Within the past
two years, plants have begun operation in Bahrain,
Egypt, India, Iran, Pakistan and the USA. These facilities are steadily increasing production and are expected
to make more in each of the ensuing years. A large
amount of additional capacity is under construction in
Egypt, India, Russia, the USA and Venezuela, which
also will contribute to growth.
DRI Products are a key factor in modern EAF steelmaking. DRI is not an alternative to scrap, but a supplement that can enable EAFs to better utilize scrap. DRI products are high in iron
content and low in copper and other undesirable metals, tramp
elements, and nitrogen content. DRI’s true value is as a scrap
supplement that dilutes undesirable contaminants in the charge
when the EAF is called upon to make high quality flat products
and low nitrogen steels. DRI provides EAF operators the flexibility to tailor their furnace charges to achieve the desired product
quality at the lowest cost per ton of liquid steel. Thus, demand
for DRI will continue to expand as world EAF steel production
continues to grow. In addition, a new market for the BF/BOF industry is beginning to grow. The voestalpine Texas 2.0 million tons per year HBI
facility being constructed in Corpus Christi, Texas, USA, will be in
operation in early 2016. voestalpine plans to send at least one
million tons of HBI per year to their BF/BOF operations in Austria
to increase steelmaking efficiency and significantly lower CO2
emissions. The operation practice of charging HBI to the BF is
significantly lower and less costly than any other technological
solution for helping BF/BOF facilities to lower their CO2 footprint. Many see the necessity of limiting CO2 generation in Europe and
other areas will become an extremely strong incentive for building more capacity over the next decade. 2014 World Direct Reduction Statistics
Page 4
As the primary fuel for DRI processes, natural gas will continue to be a driving force for the industry. Natural gas production
is proceeding in North America at rates that were unimaginable
only 10 years due to shale gas exploration. This extraordinary
addition to gas availability has driven prices down to only a
fraction of what they were. The outlook is that this era of low
pricing will continue for decades. Simultaneously, it is becoming more and more difficult to bring new sources of metallurgical grade coal to market. So, met coal and coke prices are likely
to remain higher than long-term historical prices (1980s-early
2000s). The result of rising coke costs and relatively lower gas
costs will be growth in the DRI industry.
Another promising aspect for the future of the industry is
the broadening of DRI fuel sources. Difficulty sourcing natural
gas has been a limiting factor for production of DRI in many
locations; therefore, the ability to use other types of fuel will help
alleviate this limitation. For example, in India, three MIDREX®
Plants are operating with COREX® off gas, while one large-scale
MIDREX® facility already has begun operation using coal gas
and at least one more plant has begun supplementing its natural
gas usage with coke oven gas. This is a part of a long term strategy that will boost India’s production back to previous highs.
With these forces in place, Midrex looks forward to strong
growth for the DR industry in the years and decades to come. As
stated in last year’s World Direct Reduction Statistics booklet, we
envision DRI production to surpass 200 million tons per year by
approximately the year 2030.
© 2015 Midrex Technologies, Inc.
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TABLE OF CONTENTS
< >
2014 World Shaft Furnace Production by Process
Total World Production: 59.2 Mt
MIDREX®
79.6%
MIDREX®
20122013 2014
80.0%
80.8%
79.6%
HYL/Energiron 20.0%
19.2%
20.4%
Source: Midrex Technologies, Inc.
HYL/Energiron
20.4%
Shaft Furnace DRI Production by Process and by Year
Year
MIDREX®
HYL/Energiron
199010.73
199111.96
199213.26
199315.91
199417.83
199519.86
199621.03
199723.08
199824.82
199926.12
200030.12
200126.99
200230.11
200332.06
5.25
5.40
5.29
5.73
7.01
8.15
9.12
9.55
8.52
8.81
9.39
8.04
8.88
9.72
Year
MIDREX®
HYL/Energiron
200435.01 11.34
200534.96 11.00
200635.71 10.91
200739.72 11.20
200839.85 9.84
200938.62 7.88
201042.01 9.81
201144.38 11.03
201244.76 10.79
201347.56 11.29
201447.12 12.04
59.2 Mt
16.0 Mt
MIDREX®
‘90
HYL/Energiron
2014 World Direct Reduction Statistics
Page 5
© 2015 Midrex Technologies, Inc.
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TABLE OF CONTENTS
2014 World DRI Production by Region (Mt)
32.81
20122013 2014
Middle East/North Africa 27.19
32.61
32.81
Asia/Oceania
22.58
19.99
18.76
Latin America
15.16
13.83
12.66
CIS/Eastern Europe 5.24
5.33
5.35
North America
0.84
1.25
2.85
Sub-Saharan Africa 1.57
1.41
1.55
Western Europe
0.56
0.50
0.57
(including Mexico and Carribbean)
18.76
12.66
(US & Canada)
5.35
Source: Midrex Technologies, Inc.
2.85
Middle
East/
N. Africa
Asia/
Oceania
Latin
America
(including Mexico
& Carribbean)
CIS/
Eastern
Europe
1.55
North
America
(US & Canada)
SubSaharan
Africa
World DRI Production by Year (Mt)
Year Total
Year Total
1970 0.79
’710.95
’721.39
’731.90
’742.72
’752.81
‘763.02
‘773.52
’785.00
’796.64
’807.14
’817.92
’827.28
’837.90
’849.34
’8511.17
’8612.53
’8713.52
’8814.09
’8915.63
’9017.68
’9119.32
’9220.51
’9323.65
’9427.37
’9530.67
’9633.30
’9736.19
‘9836.96
‘9938.60
‘0043.78
‘0140.32
‘0245.08
‘03
49.45
’0454.60
’0556.87
Y
ear CDRI
0.57
Western
Europe
Source: Midrex Technologies, Inc.
HBI
HDRI
Total
‘0648.41 8.60 2.69 59.70
‘0755.79 8.34 2.99 67.12
‘0856.52 8.19 4.24 67.95
‘0952.54 6.93 4.86 64.33
‘1056.60 7.21 6.47 70.28
‘11 59.41 7.60 6.20(e)73.21
‘12 59.51 7.90 5.73(e)73.14
‘13
62.50
6.17 6.25
74.92
‘1462.37 5.17 7.01 74.55
HDRI
HBI
CDRI
74.55 Mt
(e) Estimated
0.79 Mt
‘14
‘70
2014 World Direct Reduction Statistics
Page 6
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
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7
2014 World DRI Production by Region (Mt)
NAME
‘70-‘94
Latin America
ARGENTINA
BRAZIL
MEXICO
PERU
TRINIDAD & TOBAGO
VENEZUELA
Middle East/N. Africa
BAHRAIN
EGYPT
IRAN
LIBYA
OMAN
QATAR
SAUDI ARABIA
UAE
’95
‘96
‘97 < >
TABLE OF CONTENTS
Source: Midrex Technologies, Inc.
‘98
‘99
‘00
‘01
‘02
‘03
16.50
1.33
1.42 1.50
1.54
0.99
1.42
1.28
1.46
1.74
5.38
0.30
0.34 0.32
0.34
0.40
0.42
0.43
0.36
0.41
42.17
3.70
3.90 4.54
5.68
6.24
5.83
3.67
4.90
5.62
0.61
0.003
0.02 0.12
0.11
0.05
0.08
0.07
0.03
0.08
7.10
1.05
1.07 1.24
1.14
1.30
1.53
2.31
2.32
2.28
44.354.725.34 5.365.065.056.696.386.896.90
–
5.88
6.40
4.01
–
8.01
14.71
–
–
0.85
3.23
0.97
–
0.63
2.13
–
–
0.83
3.81 0.83
–
0.64
2.30
–
–
1.19
4.38
0.99 –
0.57
2.11
–
–
1.61
3.69
1.01
–
0.71
2.27
–
–
1.67
4.12
1.33
–
0.67
2.36
–
–
2.11
4.74
1.50
–
0.62
3.09
–
–
2.37
5.00
1.09
–
0.73
2.88
–
–
2.53
5.28
1.17
–
0.75
3.29
–
–
2.87
5.62
1.34
–
0.78
3.29
–
Asia/Oceania
AUSTRALIA
CHINA
INDIA
INDONESIA MALAYSIA
MYANMAR
PAKISTAN
–
–
9.66
15.92
6.36
0.22
–
–
–
4.28
1.86
1.09
0.02
–
–
–
4.84 1.80 1.48 0.04
–
–
–
5.26
1.60
1.72
0.04
–
–
–
5.26
1.64
0.91
0.04
–
0.32
0.11
5.22
1.74
0.96
0.03
–
0.56
0.05
5.44
1.82
1.26
0.04
–
1.37
0.11
5.59
1.48
1.12
0.04
–
1.02
0.22
6.59
1.50
1.08
0.04
–
1.95
0.31
7.67
1.23
1.60
0.04
–
North America
CANADA
US
13.63
9.26
1.01
0.46
1.42 0.45
1.39
0.51
1.24
1.60
0.92
1.67
1.13
1.56
–
0.12
0.18
0.47
0.50
0.21
CIS/Eastern Europe
RUSSIA
14.341.68 1.50 1.73 1.55 1.88 1.92 2.51 2.91 2.91
Sub-Saharan Africa
NIGERIA
SOUTH
AFRICA
1.49
0.02
0.02
–––––– –
9.33
0.95
0.90
1.09
1.05
1.16
1.53
1.56
1.55
1.54
Western Europe
GERMANY
6.43
Other Nations
0.47
––––––– –
0.47
WORLD TOTAL
242.23
0.41
30.67
0.37
33.30
0.47
36.19
0.45
0.40
0.46
0.21
0.54
0.59
36.90
38.59
43.78
40.32
45.08
49.45
2014 World DRI Production by Process (Mt)
NAME
‘70-‘94
’95
‘96
‘97 ‘98
‘99
‘00
‘01
‘02
‘03
MIDREX®
HYL/Energiron
141.00
77.37
0.80
5.38
17.68
–
19.86
8.15
0.04
0.45
2.17
–
21.03
9.12 0.15 0.44
2.56 –
23.08
9.55
0.10
0.48
3.01
–
24.82
8.52
0.09
0.40
2.94
–
26.12
8.81
0.07
0.66
2.94
–
30.12
9.39
0.15
0.96
3.14
–
26.99
8.04
0.14
1.93
3.18
–
30.11
8.88
0.04
1.63
4.43
–
32.06
9.72
0.04
2.57
5.04
–
30.67
33.30
36.19
36.90
38.59
43.78
40.32
45.08
49.45
Other Shaft Furnace/Retort Processes
Fluidized Bed Processes
Rotary Kiln, Coal-based
Rotary Hearth, Coal-based
WORLD TOTAL
242.23
2014 World Direct Reduction Statistics
Page 7
© 2015 Midrex Technologies, Inc.
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TABLE OF CONTENTS
2014 World DRI Production by Region (Mt)
‘04
Latin America
ARGENTINA
BRAZIL
MEXICO
PERU
TRINIDAD & TOBAGO
VENEZUELA
1.74
1.83
1.95 1.81
1.86
0.81
1.57
1.68
1.61
1.54
1.67
0.44
0.43
0.38 0.36
0.30
0.01– ––––
6.54
5.98
6.17 6.26
6.01
4.15
5.37
5.85
5.59
6.13
5.98
0.08
0.09
0.14 0.09
0.07
0.10
0.10
0.09
0.10
0.10
0.09
2.36
2.25
2.08 3.47
2.78
1.99
3.08
3.03
3.25
3.29
3.24
7.83
8.95
8.61 7.71
6.87
5.61
3.79
4.47
4.61
2.77
1.68
Middle East/N. Africa
BAHRAIN
EGYPT
IRAN
LIBYA
OMAN
QATAR SAUDI ARABIA
UAE
– –––––– ––
0.78
1.44
3.02
2.90
3.10
2.79
2.64
2.91
2.86
2.97
2.84
3.43 (r) 2.88
6.41
6.85
6.85 7.44
7.46
8.20
9.35
10.37
11.58
14.46 14.55
1.58
1.65
1.63
1.64 1.57
1.11
1.27
0.30
0.51
0.95
1.00
– –––––– 1.11
1.46
1.47
1.45
0.83
0.82
0.88
1.30
1.68
2.10
2.16
2.23
2.42
2.39
2.64
3.41
3.63
3.58
4.34
4.97
5.03
5.51
5.81
5.66
6.07
6.46
–
–
–
–
–
–
1.18
2.25
2.72
3.07
2.41
Asia/Oceania
AUSTRALIA
CHINA
INDIA
INDONESIA
MALAYSIA
MYANMAR
PAKISTAN
0.69
–
–
–
–
–
–
–
–
–
–
0.43
0.41
0.41
0.60
0.18
0.08– ––––
9.37
12.04
14.74 19.06
21.20
22.03
23.42
21.97
20.05
17.77
17.31
1.47
1.27
1.20 1.32
1.21
1.12
1.27
1.23
0.52
0.76 (r) 0.12
1.68
1.38
1.54 1.84
1.94
2.30
2.39
2.16
2.01
1.40 (r) 1.33
0.04
–––––––––
–
– ––––––––
0.06
–
North America
CANADA
US
1.09 0.59 0.45 0.91 0.69 0.34 0.60 0.700.84 1.251.55
0.18
0.22
0.24
0.25
0.26– – –––
1.30
CIS/Eastern Europe
RUSSIA
3.14
Sub-Saharan Africa
NIGERIA
SOUTH AFRICA
–
–
–
0.15
0.20
–
–
–
–
–
–
1.63 1.78 1.75 1.74 1.18 1.39 1.12 1.411.571.411.55
Western Europe
GERMANY
0.61 0.440.580.590.520.380.450.38.560.50
0.57
WORLD TOTAL
‘06
‘07 Source: Midrex Technologies, Inc.
NAME
Other Nations
’05
< >
‘08
‘09
‘10
‘11
‘12
‘13
‘14
3.34 3.28 3.41 4.56 4.67 4.79 5.20 5.24 5.335.35
– –––––– –––
–
54.60
56.87
59.70
67.12
67.95
64.33
70.28
73.21
73.14
‘08
‘09
‘10
‘11
‘12
74.92 (r) 74.55
2014 World DRI Production by Process (Mt)
NAME
MIDREX®
HYL/Energiron
‘04
WORLD TOTAL
54.60
’05
‘06
‘07 ‘13
‘14
35.01
34.96
35.71
39.72
39.85
38.62
42.01
44.38
44.76 47.56
47.12
11.34
11.00
10.91
11.20
9.84
7.88
9.81
11.03
10.79 11.29 (r) 12.04
Other Shaft Furnace/Retort Processes 0.04
– – ––––––
–
–
Fluidized Bed Processes
1.62
1.52
1.31 1.05
1.08
0.50
0.34
0.48
0.53
0.14
–
Rotary Kiln, Coal-based
6.41
9.17
11.53 14.90
16.92
17.33
18.12
17.32
17.06
15.93 15.39
Rotary Hearth, Coal-based*
–
0.18
0.22
0.24
0.25
0.26
–
–
–
–
56.87
59.70
(r) Revised
2014 World Direct Reduction Statistics
67.12
67.95
64.33
70.28
73.21
73.14
74.92 (r) 74.55
* Beginning in early 2009, the plant began feeding recovered wastes in addition to iron ore,
therefore it no longer fits within the definition of DRI used by this report.
Page 8
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
9
TABLE OF CONTENTS
< >
Major Trade Routes For International Trade of DRI (HBI and CDRI)
NOTE: Domestic and smaller trade routes are not shown.
The map shows the major routes of international transport of DRI in 2014. The width of the lines indicates the amount
of DRI that traveled over the individual routes.
Data for the map was taken from three sources: the Iron
and Steel Statistics Association (ISSB) in London, The International Iron Metallics Association (IIMA) in Rotherham, UK,
and reports from individual operating DR plants. Data from
the ISSB originates with national export and import records;
for instance, from the US Customs Bureau. IIMA information
derives from a variety of sources. It should be stressed that
a significant portion of the export data does not match the
import data. In specific, reports from individual plants show
over two million tons of shipments for which the destination is
unknown.
The arrows do not originate and terminate at specific countries. Rather, sums for dispatch and arrival were totaled by
region and the arrows flow from region to region. For instance, the widest arrow originating from the north coast of
South America shows DRI and HBI coming from the Caribbean (Venezuela plus Trinidad and Tobago) and being transported to North America (Canada, the United States and
Mexico). The regions for the purpose of these statistics are:
North America, Caribbean, South America, NW Europe (UK,
Scandinavia, Benelux, France, and Germany), Mediterranean
Europe (mostly Spain and Italy) and Turkey, Eastern Europe,
North Africa, the CIS nations, Arabian Gulf plus Oman, South
Asia, SE Asia, East Asia and Oceania (Indonesia and Malaysia).
2014 World Direct Reduction Statistics
Page 9
TRENDS
Russia and Trinidad continued to be the dominant sources
of merchant product. Combined, they shipped over 5 million
tons, nearly two-thirds of the total of all international trade.
Oman and Malaysia also were major sources, each exporting
over 750 thousand tons. In addition, Libya, India and Venezuela
all shipped greater than 200 thousand tons each.
The biggest market by far was the United States, which
received more than 2.25 million tons. This is due in part to the
large volume of high quality steels, especially flat products,
which is made in US EAFs. The low residual metallic content
of direct reduced iron is crucial to successfully manufacturing
these steels.
The increasing maturity and worldwide reach of the market should be noted. From publicly available customs data, it
was possible to identify 34 nations that imported more than 10
thousand tons of DRI throughout Europe and the CIS, in North
America, and East and Southeast Asia.
Over the next few years, the volume of shipments is
expected to increase markedly, as two large MIDREX® HBI
Plants will begin operation in 2016, voestalpine Texas in the
US and LGOK III in Russia. Combined they will produce nearly
4 million tons of HBI.
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
10
TABLE OF CONTENTS
World DRI Shipments (Mt)
Year
CDRI
HBI
19700.004 –
’71
0.04 –
’720.08 –
’73
0.13 –
’74
0.26 –
’750.34 –
‘760.37 –
‘770.32 –
’78 0.280.11
’79 0.660.12
’80 0.810.25
’81 0.830.25
’82 0.800.18
’83 0.590.36
’84 0.830.39
’85 0.710.61
’86 0.890.73
Year
CDRI
HBI
’87 0.850.77
’88 1.480.83
’89
1.27 0.94
’90
1.46 1.71
’91 1.292.67
‘92 1.452.71
‘93 1.453.56
’94 2.443.93
’95 3.693.98
’96 3.583.20
’97 3.993.51
’98 4.243.00
’99 4.014.41
’00 4.545.02
’01 2.836.58
’02 4.856.45
’03
4.63 7.63
Source: Midrex Technologies, Inc.
Year
CDRI
HBI
HBI
CDRI
’04 4.266.82
’05
6.76 7.12
’06
7.81 6.75
’07 10.826.24
‘08 8.015.99
‘09 8.505.38
‘10 8.425.60
‘11 7.976.06
‘12 8.176.58
‘13 8.565.62
‘14 7.705.17
12.87 Mt
0.004 Mt
‘70
Year
Water Land
1970–0.004
’71 –0.04
’72 0.010.07
’73
0.02 0.12
’74
0.03 0.23
’75 0.060.28
‘76 0.100.26
‘77 0.040.27
’78 0.120.57
’79 0.330.45
’80 0.540.52
’81 0.530.55
’82 0.650.33
’83 0.670.28
’84 0.690.53
’85 0.810.51
’86 0.990.63
< >
‘14
Year
Water Land
’87 0.950.67
’88 1.081.23
’89
1.34 0.87
’90
1.79 1.38
’91 2.251.71
‘92 2.241.93
‘93 2.902.11
’94 3.462.91
’95 3.763.92
’96 3.403.50
’97 3.813.80
’98 4.223.11
’99 5.453.00
’00 6.662.90
’01 7.591.82
’02 6.744.56
’03
8.31 3.94
Year
Water Land
’04 6.574.51
’05
7.02 6.86
’06
6.80 7.75
’07 8.198.87
‘08 6.417.59
‘09 5.398.48
‘10 6.617.42
‘11 6.497.55
‘12 8.486.27
‘13 7.796.39
‘14 7.235.64
Water
Land
0.004 Mt
‘70
12.87 Mt
‘14
Note regarding land shipments: It is estimated that one-third of the DRI produced in rotary kilns in India
is transported by truck to nearby melting furnaces. This tonnage is included in the figures given above.
2014 World Direct Reduction Statistics
Page 10
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
11
World Direct Reduction Plants
Plant
TABLE OF CONTENTS
Status as of 5/31/15
LocationCapacity (Mt/y)Modules
< >
Source: Midrex Technologies, Inc.
Product
Start-up
Status*
SHAFT FURNACE TECHNOLOGY
MIDREX® PROCESS
ArcelorMittal Hamburg
ArcelorMittal Montreal 1
TenarisSiderca
ArcelorMittal Montreal 2
SIDOR I
Acindar
Qatar Steel I
SIDOR II
ArcelorMittal Point Lisas I & II
Global Steel Holdings
Hadeed A & B
OEMK I - IV
Antara Steel Mills
Khouzestan Steel Co. I - IV
EZDK I
LISCO 1 & 2
Essar Steel I & II
FMO
VENPRECAR
Essar Steel III
Hadeed C
Mobarakeh Steel A - E
JSW Dolvi Works
EZDK II
LISCO 3
ArcelorMittal Lázaro Cárdenas
COMSIGUA
ArcelorMittal Point Lisas III
ArcelorMittal South Africa
EZDK III
Essar Steel IV
Nu-Iron
Essar Steel V
Mobarakeh Steel F
DRIC I & II
Hadeed E
LGOK II
Qatar Steel II
Khouzestan Steel V
Lion DRI
HOSCO I & II
Essar Steel VI
Khorasan Steel I
Jindal Shadeed
Hamburg, Germany
Contrecoeur, Quebec, Canada
Campana, Argentina
Contrecoeur, Quebec, Canada
Matanzas, Venezuela
Villa Constitucion, Argentina
Mesaieed, Qatar
Matanzas, Venezuela
Point Lisas, Trinidad & Tobago
Warri, Nigeria
Al-Jubail, Saudi Arabia
Stary Oskol, Russia
Labuan Island, Malaysia
Ahwaz, Iran
El Dikheila, Egypt
Misurata, Libya
Hazira, India
Puerto Ordaz, Venezuela
Matanzas, Venezuela
Hazira, India
Al-Jubail, Saudi Arabia
Mobarakeh, Iran
Raigad, India
El Dikheila, Egypt
Misurata, Libya
Lázaro Cárdenas, Mexico
Matanzas, Venezuela
Point Lisas, Trinidad & Tobago
Saldanha Bay, South Africa
El Dikheila, Egypt
Hazira, India
Point Lisas, Trinidad & Tobago
Hazira, India
Mobarakeh, Iran
Dammam, Saudi Arabia
Al-Jubail, Saudi Arabia
Gubkin, Russia
Mesaieed, Qatar
Ahwaz, Iran
Banting, Malaysia
Bandar Abbas, Iran
Hazira, India
Khorasan (Mashad), Iran
Sohar, Oman
0.40
0.40
0.40
0.60
0.35
0.60
0.40
1.29
0.84
1.02
0.80
1.67
0.65
1.84
0.72
1.10
0.88
1.00
0.82
0.44
0.65
3.20
1.00
0.80
0.65
1.20
1.00
1.36
0.80
0.80
1.00
1.60
1.50
0.80
1.00
1.76
1.40
1.50
0.80
1.54
1.65
1.50
0.80
1.50
1
1
1
1
1
1
1
3
2
2
2
4
1
4
1
2
2
1
1
1
1
5
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
CDRI
HBI
CDRI
CDRI
CDRI
HBI/HDRI
HBI
HBI
HBI/HDRI
CDRI
CDRI
CDRI
CDRI
HBI
CDRI
HBI
CDRI
CDRI
CDRI
HBI/HDRI
CDRI
HBI/HDRI
CDRI
CDRI
HDRI/CDRI
HBI
CDRI/HBI
CDRI
HDRI/HBI
CDRI
CDRI
CDRI
HDRI/HBI
‘71
‘73
‘76
‘77
‘77
‘78
‘78
‘79
‘80/’82
‘82
‘82/’83
‘83/’85/’85/’87
‘84
‘89/’90/’92/’01
‘86
‘89/’90
‘90
‘90
‘90
‘92
‘92
‘92/’93/’94
‘94
‘97
‘97
‘97
‘98
‘99
‘99
’00
‘04
‘06
‘06
‘06
‘07
‘07
‘07
‘07
‘08
‘08
‘09/‘10
‘10
‘10
‘11
O
O
O
O
O
O
O
O
O
I
O
O
O
O
O
O
I
O
O
I
O
O
O
O
O
O
O
O
O
O
I
O
O
O
O
O
O
O
O
O
O
O
O
O
(Continued next page)
Note 1: This list does not include plants that are inoperable or that have been dismantled.
Note 2: This list only includes plants processing feed materials with total iron content of 60% or higher and producing DRI with metallization of 85% or higher.
Note 3: There are hundreds of small rotary kilns in India with annual capacities of 10,000-30,000 tons per year that are not included on this list. The total
capacity of all rotary kilns in India is estimated to be 19.5 Mt/y.
* Status Codes: O – Operating I – Idle C– Under Contract
Note 4: Only a representative sample of rotary kiln facilities larger than 50,000 tons per year are shown.
or Construction
2014 World Direct Reduction Statistics
Page 11
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
12
World Direct Reduction Plants
Plant
< >
TABLE OF CONTENTS
Status as of 5/31/15
LocationCapacity (Mt/y)Modules
Source: Midrex Technologies, Inc.
Product
Start-up
Status*
SHAFT FURNACE TECHNOLOGY
MIDREX® PROCESS (Continued)
IGISCO
Ardakan (Yazd), Iran
0.80
1
Khorasan Steel II
Khorasan (Mashad), Iran
0.80
1
South Kaveh Steel Kish, Iran
1.86
2
Tuwairqi Steel Mills
Karachi, Pakistan
1.28
1
SULB
Hidd, Bahrain
1.50
1
Arfa Steel
Ardakan (Yazd), Iran
0.80
1
Saba
Bandar Abbas, Iran
1.50
1
JSW Projects Ltd.
Toranagallu, Karnataka, India
1.20 1 Mobarakeh Steel (Kharazi A)
Esfahan, Iran
1.5
1
Sirjan Iranian Co.
Kerman, Iran
0.8
1
ESISCO
Sadat City, Egypt
1.76
1
Jindal Steel & Power
Angul, India
1.80
1
voestalpine Texas
Corpus Christi, Texas, USA
2.00
1
LGOK III
Gubkin, Russia
1.80 1 65.4378
CDRI
CDRI
CDRI
HDRI/CDRI
HDRI/CDRI
CDRI
CDRI
HDRI/CDRI
CDRI
CDRI
HDRI/CDRI
HDRI/CDRI
HBI
HBI
HYL/ENERGIRON PROCESS
Ternium 3M5 Monterrey, Mexico ArcelorMittal Lázaro Cárdenas I Lázaro Cárdenas, Mexico ArcelorMittal Lázaro Cárdenas II Lázaro Cárdenas, Mexico JSW Steel
Raigad, India PT Krakatau Steel
Cilegon, Indonesia Khouzestan Steel (ASCO) Ahwaz, Iran Perwaja Steel Kemaman, Malaysia Usiba Salvador Bahia, Brazil Ternium 2P5 Puebla, Mexico Ternium 4M Monterrey, Mexico Lebedinsky GOK Gubkin, Russia Hadeed D Al-Jubail, Saudi Arabia Briqven
Matanzas, Venezuela JSW Steel 2
Raigad, India Emirates Steel I (GHC) Abu Dhabi, UAE Gulf Sponge Iron
Abu Dhabi, UAE Emirates Steel II (GHC) Abu Dhabi, UAE Suez Steel Egypt Nucor Steel Louisiana
Convent, Louisiana, USA
Ezz Rolling Mills
Egypt JSPL
Raigarh, India
Sidor Matanzas, Venezuela 0.50
1.00
1.00
0.75
1.35
1.03
1.20
0.31
0.61
0.68
0.90
1.10
1.50
0.90
1.60
0.20
1.60
1.95
2.50
1.90
2.50
0.80
25.88
1
2
2
1
2
3
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
29
CDRI CDRI CDRI HBI/CDRI CDRI CDRI CDRI CDRI CDRI HDRI HBI CDRI HBI CDRI HDRI CDRI HDRI HDRI/CDRI CDRI CDRI HDRI CDRI 2.20
4
HBI
‘12
‘12
‘12/’13
‘13
‘13
‘13
‘14
’14 ’14
’14
‘15
‘15
‘16
’16 O
O
O
O
O
O
O
O
O
O
O
O
C
C
‘83 ‘88 ‘91 ‘93 ‘93 ‘93 ‘93 ‘94 ‘95 ‘98 ‘99 ‘99 ‘00 ‘07 ‘09 ‘10
‘11 ‘13 ‘13 ‘15 ‘16 ‘16 O
O
O
I
O
I
O
I
O
O
O
O
I
O
O
O
O
O
O
C
C
C
’00
I
FLUIDIZED BED TECHNOLOGY
FINMET PROCESS
Orinoco Iron
Matanzas, Venezuela
Note 1: This list does not include plants that are inoperable or that have been dismantled.
Note 2: This list only includes plants processing feed materials with total iron content of 60% or higher and producing DRI with metallization of 85% or higher.
Note 3: There are hundreds of small rotary kilns in India with annual capacities of 10,000-30,000 tons per year that are not included on this list. The total
capacity of all rotary kilns in India is estimated to be 19.5 Mt/y.
* Status Codes: O – Operating I – Idle C– Under Contract
Note 4: Only a representative sample of rotary kiln facilities larger than 50,000 tons per year are shown.
or Construction
2014 World Direct Reduction Statistics
Page 12
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
13
World Direct Reduction Plants
Plant
TABLE OF CONTENTS
Status as of 5/31/15
LocationCapacity (Mt/y)Modules
< >
Source: Midrex Technologies, Inc.
Product
Start-up
Status*
FLUIDIZED BED TECHNOLOGY
CIRCORED PROCESS
Mittal - ISG Trinidad
Point Lisas, Trinidad & Tobago
0.50
1
HBI
‘99
I
FIOR PROCESS
Operaciones RDI
Matanzas, Venezuela
0.40
1
HBI
‘76
I
ROTARY KILN TECHNOLOGY
SL/RN PROCESS
Piratini
Charquedas, Brazil
SIIL
Paloncha, India
Siderperu
Chimbote, Peru
ISCOR
Vanderbijlpark, South Africa
Bihar Sponge Iron, Ltd.
Chandil, India
Prakash Industries Champa, India
Nova Iron & Steel
Bilaspur, India
Sree Metallics
Keonjhar, India
Ashirwad
Jamshedpur, India
Vandana Global
Siltara, Raigarh, India
JINDAL PROCESS
Jindal Steel & Power
Raigarh, India
Monnet Ispat Raipur, India
Rexon Strips Ltd.
Via Lathikata, India
DRC PROCESS
Scaw Metals I
Germiston, South Africa
Scaw Metals II
Germiston, South Africa
Tianjin Iron & Steel
Tianjin, China
CODIR PROCESS
Dunswart
Benoni, South Africa
Sunflag
Bhandara, India
Goldstar
Mallividu, India
SHENWU RHF PROCESS
Tianjin Rockcheck
Tianjin, China
0.06
1
0.06
2
0.10
3
0.72
4
0.15
1
0.40
2
0.15
1
0.06
3
0.05
2
0.05
1
1.8020
CDRI
‘73
CDRI
‘80/’85
CDRI
‘80
CDRI
‘84
CDRI
‘89
CDRI
‘93/’96
CDRI
‘94
CDRI
‘99/’00
CDRI
‘00
CDRI
I
O
I
O
O
O
O
O
O
O
0.90
6
0.30
2
0.06
2
1.2610
CDRI
CDRI
CDRI
‘93/’94/’95/’96/’00 ‘93/’98
‘93/’00
O
O
O
0.18
2
0.15
1
0.30
2
0.635
CDRI
CDRI
CDRI
‘83/’89
‘97
‘97
O
O
I
0.15
1
0.15
1
0.22
2
0.524
CDRI
CDRI
CDRI
‘73
‘89
‘92
O
O
I
0.50
CDRI
‘14
C
1
TISCO PROCESS
Tata Sponge Iron, Ltd.
Keonjhar, Orissa, India
0.24
2
Vallabh Steels
Ludhiana, Punjab, India
0.12
1
0.363
SIIL PROCESS
Bellary Steel & Alloys
Bellary, Karnataka, India
0.06
2
HEG
Borai, India
0.09
2
Kumar Met.
Nalgonda, India
0.06
2
Aceros Arequipa
Pisco, Peru
0.08
2
0.298
CDRI
‘86/‘98
CDRI
O
O
CDRI
CDRI
CDRI
CDRI
O
O
O
O
‘92/’93
‘92
‘93
‘96
Note 1: This list does not include plants that are inoperable or that have been dismantled.
Note 2: This list only includes plants processing feed materials with total iron content of 60% or higher and producing DRI with metallization of 85% or higher.
Note 3: There are hundreds of small rotary kilns in India with annual capacities of 10,000-30,000 tons per year that are not included on this list. The total
capacity of all rotary kilns in India is estimated to be 19.5 Mt/y.
* Status Codes: O – Operating I – Idle C– Under Contract
Note 4: Only a representative sample of rotary kiln facilities larger than 50,000 tons per year are shown.
or Construction
2014 World Direct Reduction Statistics
Page 13
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
14
World Direct Reduction Plants
Plant
TABLE OF CONTENTS
Status as of 5/31/15
LocationCapacity (Mt/y)Modules
< >
Source: Midrex Technologies, Inc.
Product
Start-up
Status*
ROTARY KILN TECHNOLOGY
OSIL PROCESS
OSIL
Keonjhar, Orissa, India
Lloyd’s Metals & Eng. Ghugus, India
DAV PROCESS
Davsteel
Cullinan, South Africa
0.10
1
0.15
1
0.252
CDRI
CDRI
‘83
‘95
O
O
0.04
1
CDRI
‘85
O
BGRIMM PROCESS
ArcelorMittal South Africa
0.30
2
CDRI
‘09
O
Vanderbijlpark, South Africa
OTHER
Mahalaxmi TMT Bars
Wardha, Maharashtra India
0.24
1
CDRI
‘11
BMM Ispat Ltd
Danapura, Hospet, Karnataka, India 0.73
CDRI
Sarda Energy and Minerals, Ltd.
Siltara, Raipur, India
0.36
CDRI
Godawari Power and Ispat
Siltara, Raipur, India
0.5
CDRI
Nalwa Steel and Power Ltd.
Raigarh, Chhattisgarh, India
0.18
CDRI
Janki Corp., Ltd.
Sidiginamola, Bellary, Karnataka
0.18
CDRI
Andhunik Metaliks, Ltd.
Chadrihariharpur, Orissa, India
0.3
CDRI
Shyam SEL Ltd.
West Bengal and Odisha, India
0.8
CDRI
Shri Bajrang Power and Ispat
Raipur, India
0.21
CDRI
Gallantt Metal, Ltd.
Kutch, Gujarat, India
0.2
CDRI
SKS Ispat, Ltd.
Raipur, Chhattisgarh, India
0.27
CDRI
Bhushan Power and Steel Ltd.
Sambalpur, Odisha, India
1.5
CDRI
11-’12
Bhushan Steel Ltd.
Angul, Odisha, India
1.5
CDRI
Electrotherm (India) Ltd.
Kutch, Gujarat, India
0.15
CDRI
Jayaswal Neco Industries Ltd.
Raipur, Chhattisgarh
0.25
CDRI
SMC Power Generation Ltd.
Jharsuguda, Odisha, India
0.2
CDRI
7.57
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
ROTARY HEARTH FURNACE TECHNOLOGY
IRON DYNAMICS PROCESS
Iron Dynamics**
Butler, IN, USA
0.50
1
CDRI
‘98
O
Note 1: This list does not include plants that are inoperable or that have been dismantled.
Note 2: This list only includes plants processing feed materials with total iron content of 60% or higher and producing DRI with metallization of 85% or higher.
Note 3: There are hundreds of small rotary kilns in India with annual capacities of 10,000-30,000 tons per year that are not included on this list. The total
capacity of all rotary kilns in India is estimated to be 19.5 Mt/y.
* Status Codes: O – Operating I – Idle C– Under Contract
Note 4: Only a representative sample of rotary kiln facilities larger than 50,000 tons per year are shown.
or Construction
** Beginning in early 2009, the plant began feeding recovered wastes in addition to iron ore,
therefore no longer fits within the definition of DRI used by this report.
2014 World Direct Reduction Statistics
Page 14
© 2015 Midrex Technologies, Inc.
SECOND QUARTER 2015
6.23.15
15
TABLE OF CONTENTS
<
2014 WORLD DIRECT REDUCTION STATISTICS is compiled by The following organizations supplied or assisted in collecting data
Midrex Technologies, Inc., Charlotte, North Carolina, USA. The
publication is posted annually on the Midrex web site.
Midrex Technologies, Inc. compiles world DRI production data on
an annual basis as a service to industry.
Direct reduced iron (DRI) is a high quality metallic product
produced from iron ore that is used as a feedstock in electric
arc furnaces, blast furnaces and other iron and steelmaking
applications. Hot briquetted iron (HBI) is a compacted form of DRI
designed for ease of shipping, handling, and storage.
Midrex Technologies, Inc. is an international process engineering
and technology company that provides global process technology solutions to various industries and is principally known for
the MIDREX® Direct Reduction Process that converts iron ore into
a high-purity DRI or HBI for use in steelmaking, ironmaking, and
foundry applications. Midrex continues to develop new technologies relating to its traditional iron and steel roots.
for this issue of 2014 WORLD DIRECT REDUCTION STATISTICS:
Sponge Iron Manufacturers Association – India
World Steel Association – Belgium
International Iron Metallics Association – UK
South East Asia Iron and Steel Association – Malaysia
Iron and Steel Statistics Bureau – UK
Kobe Steel Ltd. – Japan
All Individual MIDREX® Direct Reduction Plants
Other Direct Reduction Plants
MIDREX® is a registered trademark of Kobe Steel, Ltd.
MXCOL® is a registered trademark of Kobe Steel Ltd.
COREX® is a registered trademark of Siemens VAI
Metals Technologies GmbH, Austria
For updates check www.midrex.com
For more information or general comments,
please e-mail: [email protected]
World Steel Dynamics (WSD) has audited Midrex’s collection and preparation
process of the “2014 World Direct Reduction Statistics”, i.e. “The Booklet”. It is
our observation that at the present, Midrex receives inputs from all over the world
from practically every known direct reduction producer either directly or indirectly
through partner organizations. Midrex invites all producers to participate directly.
In instances where plant information is not available directly from producers, Midrex
deduces that information from publicly available data. WSD has reviewed the data
collection and preparation procedures and can confirm the documentation substantiates the methodology and accuracy of the data to be published in The Booklet for
the world direct reduction industry in 2014.
Audited by
Englewood Cliffs,
New Jersey, U.S.A.
June, 2015
© 2015 Midrex Technologies, Inc.
Designed for Today,
Engineered for Tomorrow™
2014 World Direct Reduction Statistics
Page 15
SECOND QUARTER 2015
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