[SMM Analysis] 33% Overproduction: Oman’s DRI Plant Rewriting Global DRI Standard

As of July 11, 2026, the direct reduced iron (DRI) plant of Jindal Steel Oman in Sohar operated continuously for 188 days without any unplanned shutdowns. The 6.5-meter shaft furnace set a record for the highest monthly production of 185,710 mt in May 2026, with an average operating rate of 249.6 mt per hour. The facility’s production exceeded its original designed capacity of 1.5 million mt by 33%, establishing a new global benchmark for operational efficiency.

The Sohar plant integrates gas-based direct reduction (using reformed natural gas to reduce iron ore) with a 220-mt Danieli electric furnace, where hot DRI is charged directly into the furnace by gravity. Billed as the world’s first gravity-fed hot DRI charging system, it achieves significant energy savings. In early 2026, the EAF side also set records: monthly production of 235,112 mt of liquid steel at a rate of 324 mt/hour, with a charge mix of 61% hot DRI, 37% cold DRI, and 2% hot briquetted iron (HBI), and electricity consumption of 493 kWh per mt of steel. In other words, from reduction to melting, this is a fully integrated DRI-EAF process, and the high stability of the shaft furnace serves as the foundation for the entire chain’s efficiency.

Jindal’s record carries weight because it falls within a strengthening megatrend. According to data from Midrex and the World Steel Association, global DRI production reached 140.8 million mt in 2024, setting a new record high, up 3.8% YoY (the previous record was 135.7 million mt in 2023). The cumulative increase since 2019 is approximately 32.7 million mt, an increase of over 30%. More notably, this growth outpaced the mild 1% growth in global crude steel production over the same period. The DRI route is steadily expanding its share in the overall steel landscape. Midrex technology accounted for 54.1% of total production and approximately 80.1% of shaft-furnace DRI output.

However, this growth is highly concentrated. In 2024, India ranked first globally with 54.7 million mt, accounting for over one-third of the total. Iran followed with 34.7 million mt, and together the two countries accounted for about 63% of the global total. Next came Russia (8.0 million mt), Saudi Arabia (6.6 million mt), and Egypt (6.4 million mt). The landscape broadly splits into two segments: one is India’s vast domestic demand-driven system based on coal-based rotary kiln sponge iron, and the other is the gas-based DRI cluster in the Middle East and North Africa (MENA) built on cheap natural gas. Jindal Steel Oman’s Sohar plant falls into the latter category. This concentration also means that any disruption in natural gas supply, energy policy, or geopolitical turbulence in one location will be magnified to affect global DRI supply.

To grasp the strategic value of such plants, one must place them within the carbon intensity framework. According to the representative route values from the World Steel Association, the blast furnace–converter integrated route emits approximately 2.3 mt CO₂ per mt of steel, while the scrap-based electric furnace route records the lowest at around 0.7 mt. The gas-based direct reduction–electric furnace route falls in between, at roughly 1.43 mt. This means that before green hydrogen direct reduction achieves true scale, gas-based DRI represents the most viable low-carbon iron source pathway beyond the blast furnace. It is not zero-carbon, but it can already reduce the carbon footprint to around 60% of the blast furnace route. A gas-based DRI plant like Jindal Shuhar—efficient, low-cost, and running stably—sits right at the sweet spot of this transitional pathway.

Placed back into the trade dimension of the ferrous metal industry chain, the Middle East’s gas-based DRI and HBI have long played the role of supplying green iron to Europe, Turkey, and the US. The top five global DRI importers in 2024 were the US (1.5 million mt), Turkey (1.2 million mt), India (900,000 mt), Mexico (800,000 mt), and Italy (700,000 mt). As the EU Carbon Border Adjustment Mechanism (CBAM) enters the actual payment phase and embedded carbon costs increase year by year, the premium window for exporting low-carbon iron sources to Europe is opening up. Plants that can spread fixed unit costs thinner and push annualized output to 133% of designed capacity are precisely the most resilient marginal suppliers along this trade flow. Viewed from this angle, Jindal’s 188-day record is not merely a straightforward milestone.