With a major new production line in operation at its Big River Steel facility in Arkansas, U. S. Steel has entered the market for electrical steel in a big way. Its new Indux™ steel is thin-sheet non-grain oriented electrical steel with carefully designed magnetic properties aimed particularly at serving the growing market for electric vehicle motors.
The company’s expansion into electrical steel production is rooted in its acquisition of Big River Steel in 2021 and, since then, nourished with extensive capital investment and a commitment to advanced steelmaking technology encompassing a strong dedication to environmental stewardship. Now representing the largest capital investment in the history of Arkansas, the site is becoming a centerpiece for state-of-the-art production of a full portfolio of steel products.
To learn more about the operation and the Indux product, we interviewed Daniel Brown, senior vice president of advanced technology steelmaking for U. S. Steel and chief operating officer of Big River Steel Works. In addition to Big River Steel operations, he has responsibility over the new mill and facilities in Osceola. He has been serving as the BRS Chief Integration Officer since January 2021 and a member of the BRS operations integration team since August 2020. He has been with U. S. Steel 25 years, joining the company in 1994.
- What is U. S. Steel’s current involvement in electrical steel?
“U. S. Steel has entered the electrical steel market with its InduX™ line of non-grain oriented (NGO) electrical steel, produced at its Big River Steel facility in Osceola, Arkansas. This product is designed for applications such as electric vehicle (EV) motors, generators, and transformers, offering ultra-thin, lightweight steel with favorable magnetic properties.”
- How does the acquisition of Big River Steel fit into the picture?
“The acquisition of Big River Steel has been pivotal for U. S. Steel’s expansion into advanced steel products. Big River Steel’s state-of-the-art electric arc furnace (EAF) technology and LEED-certified facilities have enabled U. S. Steel to produce high-quality NGO electrical steel domestically, aligning with the growing demand for sustainable and efficient steel solutions.
Also, U. S. Steel is the first steel company in the world to qualify to sellsteel manufactured at Big River Steel as ResponsibleSteel Certified. ResponsibleSteel is the industry’s leading global multi-stakeholder standards body. By meeting the standard for Certified Steel, the Big River Steel facility demonstrates its continued commitment to advancing industry sustainability while delivering profitable solutions for stakeholders and benefits for the planet.”
- Tell us about the status of your current expansion activity & growth plans for electrical steel including plant capacity and production volume.
“U. S. Steel has completed a $450 million investment in a new NGO electrical steel line at its Big River Steel facility. The line, approximately 2,333 feet long, has an annual production capacity of 200,000 tons, making U. S. Steel the largest domestic producer of NGO electrical steel. This expansion supports the company’s strategy to meet the increasing demand for electrical steel, particularly in the EV market.”
- What are the major applications and markets for your electrical steel?
“InduX™ electrical steel is primarily targeted at the electric vehicle sector, where its magnetic properties enhance motor efficiency and vehicle range. Additionally, it serves applications in generators and transformers, contributing to energy efficiency in various industries. “
- Please highlight the technology advancements and noteworthy technical characteristics of your electrical steel.
“InduX™ electrical steel features ultra-thin gauges ranging from 0.15 to 0.5 millimeters, which are not widely available among competitors. This thinness contributes to improved magnetic performance, essential for high-efficiency motors. The steel is produced using EAF [electric arc furnace] technology, utilizing up to 90% scrap steel, resulting in a 70-80% reduction in CO₂ emissions compared to traditional steelmaking processes. U. S. Steel’s strategic investments and technological advancements position it as a key player in the electrical steel market, supporting the transition to sustainable energy and transportation solutions.”
Background
Non-grain oriented electrical steel is a type of electrical steel characterized by having isotropic magnetic properties, meaning its magnetic properties are similar in all directions. This contrasts with grain-oriented electrical steel (GOES) which has a preferred magnetic direction due to its specific grain structure. NGOES is typically used in applications where magnetic flux changes direction frequently, such as in electric motors, generators and some small transformers.
The $3 billion steelmaking facility in Arkansas is designed to be the most advanced in North America and stands as the largest private project in the history of the state. The new optimized steel production facility will feature two electric arc furnaces with 3 million tons per year of advanced steelmaking capability, a state-of-the-art endless casting and rolling line, and advanced finishing capabilities. The NGO electrical steel line came online in late 2023. This followed completion in 2021 of U. S. Steel’s two-step acquisition of Big River Steel and beginning construction in 2022 of the NGO line, a $450 million project. For more information, see ussteel.com.
Editor’s Note: Operations at Big River Steel are ongoing amidst a high-stakes saga in which U. S. Steel has embraced an offer to be purchased by Nippon Steel of Japan for about $15 billion. Currently, however, the deal is snagged in a legal dispute with the U.S. government, steelmaker Cleveland-Cliffs and the United Steelworkers union. Cleveland-Cliffs, which is U.S. Steel’s main competitor, has made an offer to purchase U.S. Steel for about $7 billion.
