U.S. Steel Gary Works

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U.S. Steel Gary Works, also known as U.S. Steel Gary, is a steel plant in Gary, Indiana, United States that operates blast furnace (BF) and basic oxygen furnace (BOF) technology.

Location

The map below shows the exact location of the plant in Gary, Indiana, United States:

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  • Location: Gary Works, One North Broadway, Gary, Indiana 46402, United States
  • Coordinates (WGS 84): 41.620799, -87.348266 (exact)

Background

The U.S. Steel Gary Works steel plant began operating in 1908 after beginning construction in 1906. For many years, the Gary Works was the world's largest steel mill. It is currently the largest U. S. Steel manufacturing plant; its products are used for the automotive, metal building components, home construction and appliance markets.[1]

In 2018, U.S. Steel announced it would invest a minimum of $750 million into modernizing and enhancing Gary Works.[2]

In October 2021, U.S. Steel announced plans to install more pig iron capacity at the Gary Works plant, a project which would be completed in 2023.[3]

In late 2021, the Gary Works plants announced it would be idling two of its blast furnaces for a few weeks to make improvements.[4]

Environmental Compliance

In 1998, the EPA and U.S. Steel agreed that Gary Works would clean-up its facility, as the site was contaminated with metals, volatile and semi volatile organic compounds, and PCBs. As of 2005, the EPA lists that U.S. Steel has completed several interim measures, such as excavating contaminated soil.[5]

In 2016, the EPA fined U.S. Steel $2.2 million for pollution at several of its facilities, including Gary Works. The company also committed to spending $800,000 removing contaminated transformers at its Zug Island and Gary facilities.[6][7]

Plant Details

Table 1: General Plant Details

Start date Workforce size
1908[8] 2246[9]

Table 2: Ownership and Parent Company Information

Parent company Parent company PermID Parent company GEM ID Owner Owner company PermID Owner company GEM ID
United States Steel Corp 4295903049 E100000001319 United States Steel Corp[10] 4295903049 E100000001319

Table 3: Process and Products

Steel product category Steel products Steel sector end users ISO 14001 Main production equipment
semi-finished, finished rolled[10] sheet, plate, hot rolled, cold rolled, galvanized sheet, tinplate, pig iron[10] automotive, building and infrastructure, steel packaging[10] 2022[11] BF; BOF

Table 4: Plant-level Crude Steel Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Basic oxygen furnace steelmaking capacity Nominal crude steel capacity (total)
operating 7800[12] 7800[13]

Table 5: Plant-level Crude Iron Production Capacities (thousand tonnes per annum)

1Please see our Frequently Asked Questions page for an explanation of the different capacity operating statuses.
Capacity operating status1 Blast furnace capacity Nominal iron capacity (total)
operating 6495[14][15][16] 6495[14][15][16]

Table 6: Upstream Products Production Capacities (thousand tonnes per annum)

Sinter Pellets
4400[17][18] NF

Table 7: Actual Plant-level Crude Steel Production by Year (thousand tonnes per annum)

Year BOF production Other/unknown steel production Total (all routes)
2019 unknown unknown –
2020 unknown unknown –
2021 4524[19] –[19] 4524[19]
2022 5226[19] –[19] 5226[19]
2023 5325[20] –[20] 5325[20]

Table 8: Actual Plant-level Crude Iron Production by Year (thousand tonnes per annum)

Year BF production Total (all routes)
2019 4307[21] 4307[22]
2020 3965[23] 3965[24]
2021 4980[25] 4980[26]
2022 4900[27] 4900[28]
2023 5200[29] 5200[29]

Unit Details

Table 9: Blast Furnace Details

Unit name Status Start date Furnace manufacturer and model Current size Current capacity (ttpa) Decarbonization technology Most recent relining
BF 14 operating[14] 1974[30] Saint-Gobain (parts)[31] 3244.0[29] 2540[14] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[32] 2005-12[33]
BF 4 operating[34] 1917[35] – 1496.0[36] 1360[16] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[32] 2020[37]
BF 6 operating[16] 1910[35] – 1506.0[38] 1234[16] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[32] 2018[39]
BF 8 operating[40] 1909[35] Saint-Gobain (parts)[31] 1299.0[41] 1361[15] On April 3, 2024, US Steel Corporation and CarbonFree signed an agreement to implement CarbonFree’s SkyCycle™ technology at U.S. Steel’s Gary Works Blast Furnaces. This innovative project will capture and mineralize up to 50,000 metric tons of carbon dioxide annually, marking a significant step in carbon capture efforts.[32] 2016[42]

Table 10: Basic Oxygen Furnace Details

Unit name Status Start date Current capacity (ttpa)
unknown BOF (1) operating[43] 1965[44] 1300[45]
unknown BOF (2) operating[46] 1965[44] 1300[47]
unknown BOF (3) operating[48] 1965 1300[49]
unknown BOF (4) operating[50] – 1300[51]
unknown BOF (5) operating[52] – 1300[53]
unknown BOF (6) operating[54] – 1300[55]

Articles and Resources

Additional data

To access additional data, including an interactive map of steel power plants, a downloadable dataset, and summary data, please visit the Global Iron and Steel Tracker on the Global Energy Monitor website.

References

  1. ↑ Gary Works, U.S. Steel, Retrieved on: Aug. 18, 2020
  2. ↑ "United States Steel Announces Major Modernization and Asset Revitalization at Gary Works - www.ussteel.com". www.ussteel.com. 2018-08-20. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  3. ↑ "US Steel to install pig iron capacity in Indiana | Argus Media". www.argusmedia.com. 2021-10-29. Retrieved 2021-11-02.
  4. ↑ Oktay, Ali (2021-08-18). "US Steel to shut another two blast furnaces for work in fourth quarter: spokeswoman". www.spglobal.com. Retrieved 2021-11-02.
  5. ↑ "Hazardous Waste Cleanup: U.S. Steel, Gary Works Facility - Gary, Indiana". EPA. 2005. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  6. ↑ Matheny, Keith (2016-11-23). "U.S. Steel fined $2.2M, required to make repairs for Midwest pollution". Detroit Free Press. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  7. ↑ "U. S. Steel Corporation Agrees to End Litigation, Improve Environmental Compliance at Its Three Midwest Facilities, Pay Civil Penalty of $2.2 Million and Perform Projects to Aid Communities Affected by U. S. Steel's Pollution". Department of Justice. 2016-11-22. Retrieved 2021-11-02.{{cite web}}: CS1 maint: url-status (link)
  8. ↑ https://web.archive.org/web/20210418104540/https://www.nwitimes.com/business/steel/u-s-steel-starts-layoffs-of-up-to-workers-at/article_a2368734-c52f-5ee2-8761-2b9f03734c30.html. Archived from the original on 2021-04-18. {{cite web}}: Missing or empty |title= (help)
  9. ↑ https://www.nwitimes.com/business/local/u-s-steel-to-lay-off-244-workers-when-it-idles-tin-operations-at-gary/article_697b1039-c566-5cd4-b2f8-e07800784625.html. {{cite web}}: Missing or empty |title= (help)
  10. ↑ 10.0 10.1 10.2 10.3 https://web.archive.org/web/20240125024713/https://www.ussteel.com/about-us/locations. Archived from the original on 2024-01-25. {{cite web}}: Missing or empty |title= (help)
  11. ↑ https://web.archive.org/web/20220214142646/https://www.ussteel.com/sustainability/certifications. Archived from the original on 2022-02-14. {{cite web}}: Missing or empty |title= (help)
  12. ↑ AIST_BOF_2023
  13. ↑ AIST_BOF_2023
  14. ↑ 14.0 14.1 14.2 14.3 https://web.archive.org/web/20220710052907/https://www.spglobal.com/commodityinsights/en/market-insights/latest-news/metals/081821-us-steel-to-shut-another-two-blast-furnaces-for-work-in-fourth-quarter-spokeswoman. Archived from the original on 2022-07-10. {{cite web}}: Missing or empty |title= (help)
  15. ↑ 15.0 15.1 15.2 https://web.archive.org/web/20220926184517/https://www.insideindianabusiness.com/articles/u-s-steel-idling-blast-furnace-at-gary-works. Archived from the original on 2022-09-26. {{cite web}}: Missing or empty |title= (help)
  16. ↑ 16.0 16.1 16.2 16.3 16.4 https://web.archive.org/web/20211027060812/https://www.argusmedia.com/en/news/2165052-us-steel-to-restart-gary-works-blast-furnace. Archived from the original on 2021-10-27. {{cite web}}: Missing or empty |title= (help)
  17. ↑ https://web.archive.org/web/20191002155639/https://www.nwitimes.com/business/gary-works-sinter-plant-suffering-operational-difficulties/article_253b7e21-3a36-5d14-bf61-7150a436daaa.html. Archived from the original on 2019-10-02. {{cite web}}: Missing or empty |title= (help)
  18. ↑ (PDF) https://web.archive.org/web/20221130215256/https://www.epa.gov/sites/default/files/2015-12/documents/ironsteel.pdf. Archived from the original (PDF) on 2022-11-30. {{cite web}}: Missing or empty |title= (help)
  19. ↑ 19.0 19.1 19.2 19.3 19.4 19.5 (PDF) https://web.archive.org/web/20230311144635/https://s26.q4cdn.com/153509673/files/doc_financials/2022/ar/2022-Annual-Report.pdf. Archived from the original (PDF) on 2023-03-11. {{cite web}}: Missing or empty |title= (help)
  20. ↑ 20.0 20.1 20.2 (PDF) https://investors.ussteel.com/sec-filings/all-sec-filings/content/0001104659-24-035004/tm2332710d5_ars.pdf. {{cite web}}: Missing or empty |title= (help)
  21. ↑ AIST_BF_2020
  22. ↑ AIST_BF_2020
  23. ↑ AIST_BF_2021
  24. ↑ AIST_BF_2021
  25. ↑ AIST_BF_2022
  26. ↑ AIST_BF_2022
  27. ↑ AIST_BF_2023
  28. ↑ AIST_BF_2023
  29. ↑ 29.0 29.1 29.2 https://imis.aist.org/store/detail.aspx?id=PR-RU2024-5. {{cite web}}: Missing or empty |title= (help)
  30. ↑ https://www.nwitimes.com/business/local/the-return-of-no-13/article_e89302c5-f9dd-558e-8116-56fc31752449.html. {{cite web}}: Missing or empty |title= (help)
  31. ↑ 31.0 31.1 (PDF) https://web.archive.org/web/20221128015619/https://www.ceramicsrefractories.saint-gobain.com/sites/hps-mac3-cma-pcr/files/assetbank_media/Iron---Steel-Blast-Furnace-brochure-2022-web-2274441.pdf. Archived from the original (PDF) on 2022-11-28. {{cite web}}: Missing or empty |title= (help)
  32. ↑ 32.0 32.1 32.2 32.3 https://investors.ussteel.com/news-events/news-releases/detail/672/u-s-steel-and-carbonfree-sign-definitive-agreement-to. {{cite web}}: Missing or empty |title= (help)
  33. ↑ https://www.theautochannel.com/news/2005/09/20/143441.html https://12ft.io/proxy?q=https%3A%2F%2Fwww.nwitimes.com%2Fbusiness%2Flocal%2Fthe-return-of-no-13%2Farticle_e89302c5-f9dd-558e-8116-56fc31752449.html, https://www.theautochannel.com/news/2005/09/20/143441.html. {{cite web}}: Check |url= value (help); Missing or empty |title= (help)
  34. ↑ https://web.archive.org/web/20221209072603/http://www.nwitimes.com/business/local/u-s-steel-restarts-blast-furnace-4-at-gary-works-as-conditions-recover/article_61b32de8-143e-5cf7-9eef-0d9a7cada5dd.html. Archived from the original on 2022-12-09. {{cite web}}: Missing or empty |title= (help)
  35. ↑ 35.0 35.1 35.2 (PDF) https://web.archive.org/web/20170202182154/http://permits.air.idem.in.gov/37377d.pdf. Archived from the original (PDF) on 2017-02-02. {{cite web}}: Missing or empty |title= (help)
  36. ↑ AIST_BF_2023
  37. ↑ https://songerservices.com/projects/rolling-pandemic-punches. {{cite web}}: Missing or empty |title= (help)
  38. ↑ AIST_BF_2023
  39. ↑ (PDF) https://investors.ussteel.com/sec-filings/all-sec-filings/content/0001163302-18-000042/0001163302-18-000042.pdf. {{cite web}}: Missing or empty |title= (help)
  40. ↑ https://web.archive.org/web/20230327102405/https://www.aist.org/news/steel-news/2023/march/20-24-march-2023/u-s-steel-returns-idled-blast-furnace-to-service. Archived from the original on 2023-03-27. {{cite web}}: Missing or empty |title= (help)
  41. ↑ AIST_BF_2023
  42. ↑ https://web.archive.org/web/20230202175103/https://www.matrixnac.com/project/uss-gary-works/. Archived from the original on 2023-02-02. {{cite web}}: Missing or empty |title= (help)
  43. ↑ AIST_BOF_2023
  44. ↑ 44.0 44.1 https://imis.aist.org/store/detail.aspx?id=PR-RU2024-1. {{cite web}}: Missing or empty |title= (help)
  45. ↑ AIST_BOF_2023
  46. ↑ AIST_BOF_2023
  47. ↑ AIST_BOF_2023
  48. ↑ AIST_BOF_2023
  49. ↑ AIST_BOF_2023
  50. ↑ AIST_BOF_2023
  51. ↑ AIST_BOF_2023
  52. ↑ AIST_BOF_2023
  53. ↑ AIST_BOF_2023
  54. ↑ AIST_BOF_2023
  55. ↑ AIST_BOF_2023

Resources

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