Speaking during the annual Steel Market Update Steel Summit conference, which was held virtually this year, Stickler said the company is targeting an 18 November start-up and expects to produce commercial-quality coils that same day. 

“Our expansion … is moving right along,” said Stickler. 

Through the project, Big River is doubling the plant’s capacity, taking it to approximately 2.6 million tons annually, Stickler said.

The company is adding a second electric arc furnace (EAF), a second casting strand and a second tunnel furnace, among other things.  

This new capacity comes amidst a widening divide in market share between EAF-based mills and the integrated mills. Stickler said he believes the trend will continue and predicted that integrated mills will account for less than 15% of flat-rolled production by 2025. 

“There’s no stopping the evolution that is going on. High-quality steel can, in fact, be produced starting with scrap metal in an electric arc furnace and (by forming) a slab that is 2 ½ to 3 ½ inches thick.” 

He also said there is no reason that mini-mills cannot produce exposed automotive steel, long considered to be something only integrated facilities could produce. In fact, he said Big River’s proposed second mill in Brownsville, Texas, will do just that. 

Stickler said development of that mill is continuing. An economic incentive package is starting to take shape, attractive electricity rate proposals have been received, and the company is preparing the environmental permit application, which should be filed by early next year, he said.   

Stickler said financing hasn’t yet been secured, but he remains confident that it will be.  

He said the mill is being developed as an off-balance sheet project separate from Big River Steel, which would have the option to acquire after it gets up and running. 

The mill would produce 3.5 million to 4 million tons annually, he said.