Tosyalı Algérie MIDREX plant sets new world DRI production record

Tosyalı Algérie A.Ş. has established a new world record for direct reduced iron (DRI) produced in one year using a single direct reduction module. In 2025, Tosyalı Algérie’s module 2 achieved an output of 2.43 million tons, representing an exceptional achievement and setting a new global benchmark during its first year of operation.
In addition to this exceptional result, Tosyalı Algérie’s first DR module also delivered outstanding performance levels in 2025, ranking third globally in annual DRI production, which further underlines Tosyalı’s leadership and scale in direct reduction ironmaking.
Supplied by Midrex Technologies, Inc. and its consortium partner Paul Wurth, part of SMS group, the record-breaking module 2 is a MIDREX® plant capable of producing both hot direct reduced iron (HDRI) and cold direct reduced iron (CDRI), providing exceptional operational flexibility and efficiency.
Commenting on this record, Tosyalı Holding Board Chairman Fuat Tosyalı said, “As one of the world’s leading green steel producers, we continue our DRI (Direct Reduced Iron) investments at our facility in Algeria, delivering lower carbon emissions. Since 2020, our Tosyalı Algérie plant has broken the world DRI production record every year. In 2025, beyond the record achieved by our second module, our first DRI module also delivered a strong performance, ranking third globally in annual DRI production further confirming the scale and consistency of our twin-DRI strategy. With the commissioning of our second DRI last year, Tosyalı Algérie has reached the position of being the facility with one of the world’s largest twin DRI plants. Thanks to the advanced technology it uses, the second DRI facility became the first plant in the world to start commercial production with the capability of operating on both natural gas and—through a minor modification—100 percent hydrogen. Around the same time, other companies in Europe also announced flexible DRI investment decisions. However, we were the first company to make this decision, complete the investment, and commence production. The production record we achieved with the new DRI not only confirms the success of our investment strategy focused on sustainability, efficiency, and scale, but also further strengthened Tosyalı’s position as a global green steel producer.
This achievement further strengthens Algeria’s position in the global steel industry, supporting the country’s transition from a net importer to a major producer and exporter of high-quality steel. The record-setting DRI production output enhances domestic steel supply while enabling increased exports to international markets.
Tosyalı’s second DRI plant is integrated with a new electric arc furnace (EAF) by means of a hot transport conveyor, allowing HDRI to be continuously charged into the EAF. This configuration increases melt shop productivity while delivering significant energy savings and reduced emissions. During EAF maintenance or outage periods, the plant can seamlessly switch to producing CDRI at full capacity, maximizing overall operational availability.
“We congratulate Tosyalı Algérie on this tremendous accomplishment during its first year of operation,” said KC Woody, Midrex Technologies President and CEO. “Reaching a new global benchmark so quickly is a powerful demonstration of Tosyalı’s world-class operational excellence and the best-in-class productivity, reliability, and flexibility of MIDREX Technology. We are confident that Tosyali will be exceeding their rated capacity very soon.”
Tosyalı’s continued investments in DRI-based ironmaking reflect its long-term commitment to producing higher-quality steel with lower carbon emissions. By reducing dependence on scrap and increasing the use of DRI, Tosyali is able to achieve greater production flexibility while supporting sustainability objectives. These investments also align with global efforts to decarbonize steel production.
“On behalf of SMS group, I congratulate Tosyalı Algérie on achieving this outstanding result, and we are proud that our engineering expertise supported this milestone and contributed to a project that enhances Algeria’s steelmaking capabilities and supports the industry’s ongoing decarbonization efforts,” said Thomas Hansmann, Chief Technology Officer at SMS.