A new direct reduced iron (DRI) facility planned for U.S. Steel’s Arkansas-based steelmaking facility, Big River Steel Works, in Osceola, Arkansas, is expected to strengthen domestic steelmaking capabilities by linking iron ore production, ironmaking, and electric arc furnace (EAF) steel production within a single U.S.-based supply chain. The facility will produce hot direct reduced iron (HDRI) and hot briquetted iron (HBI) for use in downstream steel melting operations, supporting domestic steel production with a U.S.-based source of metallic feedstock.
The project is part of a $1.9 billion investment by U.S. Steel to construct a DRI facility adjacent to its Big River Steel Works operation. Once in service, the facility is expected to produce approximately 2.5 million metric tons of HDRI annually to support steel production at the site.
The DRI facility will process iron ore pellets sourced from U.S. Steel’s Minnesota Ore Operations, creating a domestic production pathway from iron ore mining through ironmaking and steel melting. The HDRI produced at the facility will be fed directly into the steelworks’ EAF operations, while HBI can be used as a metallic feedstock for steel production and transportation.
To support the project, Midrex Technologies was selected to provide its MIDREX Flex® technology, which is designed to operate on natural gas while allowing for increased hydrogen use as supporting infrastructure and supply become available. The facility plans to be the first U.S.-based DRI plant designed to produce both HDRI and HBI.
Construction is expected to begin in 2027, with startup anticipated in 2029. The project is part of U.S. Steel’s strategy to expand steelmaking capacity and strengthen a domestic “mine-to-melt” steel supply chain. It is expected to support production of steel grades for automotive, electrical, and industrial applications.
Press release is available in its original form here.
Main image shows the Big River Steel MIDREX plant model. Image Credit: Midrex Technologies
