MIDREX® Plants with 3rd Quarter Anniversaries

Midrex is known for designing, engineering, and servicing reliable direct reduction plants, as well as for making certain that these plants have long and successful operating lives. This issue of Direct From Midrex recognizes the start-up of Antara Steel Mills HBI on Labuan Island, FT, Sabah, Malaysia – 40 years; Libyan Iron and Steel Company (LISCO), Module I in Misurata, Libya – 35 years; JSW Steel (Dolvi Works) in Dolvi, Maharashta, India – 30 years; ArcelorMittal/Nippon Steel India, Module IV, in Hazira, Gujarat, India – 20 years; JSPL (Angul Works) in Angul, Odisha, India – 10 years; and JSW (Toranagallu Works) in Toranagallu, Karnataka, India – 10 years.

STARTED 40 YEARS AGO IN THE 3RD QUARTER

Location: Labuan Island, FT, Sabah, Malaysia

• Start-up: August 1984
• Product: HBI
• Rated Capacity: 0.65 million tons/year

The first MIDREX HBI Module was started up in August 1984 for Sabah Gas Industries, which later became part of the Lion Group as Antara Steel Mills HBI. Esteel Enterprise of Singapore completed acquisition of the HBI plant in 2022.

Antara Steel Mills HBI operated 9% over its annual rated capacity in 2023, following a record-setting year in 2022 of 20% over rated capacity. Total iron content averaged 92.63% for the year. All production was shipped by water to third parties. Cumulative HBI production through 2022 is more than 23.3 million tons.

STARTED 35 YEARS AGO IN THE 3RD QUARTER

Location: Misurata, Libya

• Start-up: July 1989
• Product: CDRI
• Capacities: 0.55 million tons/year

Production by LISCO’s three modules increased significantly in 2023 compared to previous years. Modules 1 & 2 produce CDRI for the LISCO steel mill, while Module 3 produces HBI for export.

The three modules combined to set a multimodule production record that was last set in 2005 and eclipsed the 35 million tons milestone for cumulative production.

Read more about Libya Iron and Steel Company (LISCO) at: https://libyansteel.com

STARTED 30 YEARS AGO IN THE 3RD QUARTER

Location: Raigad, Maharashtra, India

• Start-up: September 1994
• Product: CDRI
• Rated Capacity: 1.0 million tons/year

JSW Steel’s MIDREX Module easily exceeded its rated capacity in 2023 and operated 8198 hours. Approximately 10% of the module’s energy input is COG injected to the shaft furnace to reduce natural gas consumption.

JSW Steel (Dolvi) has averaged 8044 hours of operation per year since its initial start-up in 1994, and 8149 hours per year in the last 8 years. Its cumulative production through 2022 is almost 33.2 million tons.

Read more about JSW Steel and its Dolvi Works at: https://www.jswsteel.in

STARTED 20 YEARS AGO IN THE 3RD QUARTER

Location: Hazira, Gujurat, India

• Start-up: July 2004
• Product: HBI/HDRI
• Capacity: 1.0 million tons/year

Module IV established new annual productivity & electricity consumption records in 2023, as well as a new monthly production record in May.

All six modules combined have produced over 91 Mt of HDRI, HBI, and CDRI since start-up of the first two modules in 1990. Approximately 96% of the output from the four HDRI/HBI modules was in the form of HDRI, while Modules I and VI produce CDRI exclusively.

Read more about ArcelorMittal/Nippon Steel India at: https://www.amns.in

STARTED 10 YEARS AGO IN THE 3RD QUARTER

Location: Angul, Odisha, India

• Start-up: July 2014
• Product: HDRI/CDRI
• Capacity: 1.8 million tons/year

This is the first MxCol Plant using synthesis gas from coal gasifiers to produce both HDRI and CDRI for the adjacent steel shop. Through 2022, the plant had produced more than 5.3 million tons of DRI.

A hot DRI conveying system is installed from the MIDREX Plant to the melt shop. HDRI production was 54% of total production in 2023. COG was used in the DR plant throughout the year, averaging ~15% of the plant’s energy requirements.

Read more about JSPL and its Angul Works at: https://jindalshadeed.com/odisha

STARTED 10 YEARS AGO IN THE 3RD QUARTER

Location: Toranagallu, Karnataka, India

• Start-up: August 2014
• Product: HDRI/CDRI
• Capacity: 1.2 million tons/year

JSW Steel (Toranagallu) using COREX export gas as energy input, operated over 8000 hours in 2023. Through 2022, the plant had produced almost 6.9 million tons of DRI.

A hot DRI conveying system is installed from the MIDREX Plant to the melt shop. 55% of production went to the steel shop as HDRI.

Read more about JSPL and its Toranagallu Works at: https://www.jswsteel.in