Remell Bryant fed steel coils into the “cold strip” as a way to support her daughter as a single mother.
Valerie Denney worked on the “pickle line,” removing impurities from hot steel, before shifting to a career in public relations.
Jack Weinberg tested metallurgical content until he was laid off, then went on to negotiate international environmental treaties.
Terry Steagall played on the banks of a polluted river near the steel mill as a child, then spent 41 years inside the mill as a machinist, repairing gearboxes, cranes, and line shafts, before retiring in 2023.
Now, the four are collaborating to demand a shift away from coal-based steelmaking and toward cleaner methods for the Northwest Indiana industry in which they once worked. They’re all members of Gary Advocates for Responsible Development (GARD), a grassroots group founded in 2021 by former steelworker Dorreen Carey.
Such a transition could save thousands of jobs, create new economic opportunities, and avoid about $75 million in healthcare costs in the region, according to a report released Thursday by the Indiana University Environmental Resilience Institute and the consultancy 5 Lakes Energy, and commissioned by Indiana Conservation Voters.
Only six integrated mills — facilities that produce both steel and the iron needed to make it — are operating in the United States, and three of them are in Northwest Indiana. With their hulking, polluting blast furnaces, these mills may soon become a thing of the past in the U.S., as steel is increasingly being produced in smaller and cleaner operations, frequently in the Southern states.
The GARD organizers echo the report’s authors and other industry experts in warning that if Indiana’s mills don’t modernize and clean up, they could go the way of the other steel mills that once proliferated in the region, but were shuttered during the steel industry crisis of the late 1970s and ’80s. The region still hasn’t recovered from that era, and further closures could mean thousands of job losses and gutted public coffers. The report notes that Northwest Indiana’s steel mills once had more than 65,000 workers but employ only about 9,000 today. Without modernization, the study estimates, Northwest Indiana steel mill jobs could fall below 5,000 by 2034.
Converting a traditional integrated mill to much-cleaner direct reduced iron (DRI) technology costs billions of dollars, and the Biden-era incentives that could have encouraged companies to make the switch were eliminated by the Trump administration. It’s a hard sell, but GARD considers global steelmaker Nippon Steel’s 2025 acquisition of U.S. Steel’s Gary Works mill, in Gary, Indiana, an opportunity.
Steagall said he “didn’t see a pathway” to green steel until the Japanese company entered the picture.
Nippon plans to allocate $3.1 billion for upgrades to Gary Works. About $300 million of that will go toward relining its largest blast furnace — which will extend its life for about another 20 years. The company could use some of the remaining money to replace the mill’s three other blast furnaces with a DRI plant, GARD proposes in a recent report.
It would cost about $3.6 billion to transition Gary Works to cleaner steelmaking, according to the Indiana University report. Modernizing the area’s other two mills, both owned by Cleveland-Cliffs, would cost $2.8 billion to $3 billion each. That’s in line with what the companies have indicated they will spend to maintain those operations.
In a February earnings call, Cleveland-Cliffs announced that it is planning to reline an Indiana blast furnace next year. The company had in fact proposed a DRI conversion at one of its Ohio mills, but backed off the plan after Trump took office in 2025.
Advocates note that the crucial technologies needed for green steel — DRI and electric furnaces — already exist at commercial scale, and efforts are gaining steam globally to combine the two. Many existing DRI plants use natural gas, which results in much lower emissions than the coal that fuels blast furnaces. But using green hydrogen — produced by splitting water atoms using renewable electricity — would slash emissions even further.
The biggest challenge may be convincing company leaders to make a major change in an industry that “has never been known to move quickly,” as Steagall put it.
An evolving steel industry
In an integrated steel mill like Gary Works, iron is added to a blast furnace, where it undergoes chemical reactions involving limestone and coke — a baked-down, concentrated form of coal. Molten iron is then converted to “primary steel” in a separate stage. This process results in the type of high-quality, flat-rolled steel suitable for automobiles and buildings.
But it is highly polluting, with about 2 million metric tons of carbon dioxide released for each ton of steel produced globally, along with high levels of particulate matter, sulfur dioxide, nitrogen oxides, and other pollutants.
The fortunes of Gary Works and other integrated steel mills declined starting in the late 1970s because of slowing demand and competition from abroad, including from “mini-mills,” which use electric arc furnaces to make steel — mostly from scrap metal — without producing any iron on-site. Integrated mills in Indiana, Illinois, Ohio, and Pennsylvania downsized their operations and then closed over several decades, transforming thriving cities into Rust Belt relics. Nationwide, steel sector employment fell from about 512,000 in 1974, according to a study by the National Bureau of Economic Research, to about 85,000 today, according to Federal Reserve Economic Data.
“Republic Steel, Bethlehem Steel, J&L Steel, they all shut down or were liquidated,” said Weinberg, who worked for eight years in Gary Works’ sheet and tin division.
Though the Gary Works mill survived, its workforce was greatly reduced – from more than 30,000 people at its peak in the 1970s to about 4,300 people today. By the 2010s, the city was notorious for its abandoned buildings and urban decay.
As GARD organizers see it, without investments in clean steel, Gary’s fortunes could fall further. The plant’s market niche — high-quality primary steel — is vulnerable to competition from the electric arc furnaces that make at least 60% of the country’s steel today.
