Steel Dynamics Expands Amid Improving Aluminum, Steel Market

Researched by Industrial Info Resources (Sugar Land, Texas)--Steel Dynamics Incorporated (Fort Wayne, Indiana) enjoyed a solid third quarter, amid reviving demand for its aluminum and biocarbon products. The steelmaker is adding capacity in two of its strongest-performing segments, with several related projects set to come online this year. Industrial Info is tracking about 50 active and proposed projects across the U.S. from Steel Dynamics, with more than half of the potential investment attributed to a proposed aluminum-recycling plant and the expansion of an existing facility.

Steel Dynamics' third-quarter net sales totaled $4.8 billion, an 11.2% increase over third-quarter 2024, while net income stood at $404 million, a 27% increase. Mark D. Millett, the chief executive officer of Steel Dynamics, pointed to success in the company's aluminum and biocarbon segments: "We have produced finished aluminum flat rolled products for the industrial and beverage can sectors and hot band for the automotive sector, which have been qualified by several customers much sooner than anticipated."

Millett added: "The SDI Biocarbon Solutions team produced their first biocarbon [during the third quarter], which was successfully used as a carbon replacement at our Columbus Flat Roll Steel Division, providing a significantly lower-carbon supply chain for our steel customers. The team plans to continue to refine operations and increase production throughout the rest of the year."

Not coincidentally, Steel Dynamics began construction this summer on a $100 million expansion of the biocarbon production facility at its steel mill in Columbus, Mississippi, following the completion of a $150 million initial phase in March. The facility currently produces 160,000 tons per year of biochar, a carbon-rich, biomass-based charcoal that is a renewable alternative to fossil-fuel carbon. The product is used to fuel electric-arc furnaces at the company's steel mills. The expansion, which is expected to wrap up toward the end of next year, will raise production to 480,000 tons per year.

The biocarbon facility is a joint venture between Steel Dynamics and Aymium Incorporated (Gwinn, Minnesota), using the latter's patented technology. Steel Dynamics says the initial phase reduced its Scope 1 greenhouse gas emissions intensity between 20% and 25%. Subscribers to Industrial Info's Global Market Intelligence (GMI) Metals & Minerals Plant and Project databases can learn more from a plant profile and read detailed project reports on the completed Phase I and the ongoing Phase II.

Millett also pointed to record quarterly steel shipments, as imports declined from levels seen earlier in 2025 and performance improved at the company's flat-rolled steel mill in Sinton, Texas. The company started work on a series of refractory rebuilds on its electric-arc furnaces at Sinton earlier this year, which it expects to complete in December. Subscribers can learn more from a detailed plant profile and project report.

Earlier this year, Steel Dynamics completed construction on its aluminum flat-rolled mill in Columbus, Mississippi, which is designed to produce 650,000 tons per year to serve the beverage-packaging, automotive and common alloy sectors. The company also is seeking permits and regulatory approval for an aluminum-recycling plant in Benson, Arizona, which, if approved, could begin construction as early as next year. But the project remains in its early phase, where plenty of factors could delay or alter projected investments.

Subscribers can read profiles of the Columbus and Benson plants, and detailed reports on the Columbus and Benson construction projects.

"We anticipate that improving market conditions, including increased trade stability and a more favorable interest rate environment, will contribute to strong domestic demand for steel and aluminum products," Millett said in the earnings release. "Additionally, discussions with our customers reinforce the increasing importance of low-carbon, U.S.-made steel and aluminum--positioning our businesses for a long-term competitive advantage."

Subscribers to Industrial Info's GMI Project and Plant databases can click here for a full list of detailed reports for projects mentioned in this article, and click here for a full list of related plant profiles.

Subscribers can click here for a full list of reports for active and proposed projects from Steel Dynamics.

Industrial Info Resources (IIR) is the leading provider of industrial market intelligence. Since 1983, IIR has provided comprehensive research, news and analysis on the industrial process, manufacturing and energy related industries. IIR's Global Market Intelligence (GMI) platform helps companies identify and pursue trends across multiple markets with access to real, qualified and validated plant and project opportunities. Across the world, IIR is tracking more than 200,000 current and future projects worth $17.8 trillion (USD).