A proposed merchant pig iron plant in North Dakota could transform dormant iron-rich mine waste from Minnesota into a key raw material for American steel manufacturing. If approved, the $2 billion project would become the first large-scale operation in the United States to produce merchant pig iron from previously processed mine waste, helping strengthen the country’s domestic steel supply.
Project to Recycle Minnesota Mine Waste
North American Iron and its sister company, Calumet Reclamation Co., plan to develop a 2,400-acre processing facility near Minot, North Dakota. The proposed merchant pig iron plant is designed to produce up to 2 million metric tonnes of merchant pig iron each year, a high-purity material widely used in steelmaking.
Rather than relying on conventional mining, the project will use pre-processed iron-rich mine waste from a former mine in Calumet, Minnesota. The material will be transported nearly 500 miles by rail to the Minot facility, which is located near North Dakota’s largest rail yard.
According to Jim Bougalis, CEO and founder of North American Iron, the project would establish the first large-scale domestic supply of merchant pig iron in the United States. At present, the country depends heavily on imports, while tariffs and international conflicts have placed additional pressure on global supply chains.
Project Expected to Support Regional Economy
In addition to supporting domestic steel production, the proposed merchant pig iron plant is expected to generate significant economic activity in North Dakota. The development is projected to create up to 1,000 construction jobs and approximately 650 permanent positions once operational.
Regional economic development officials have also highlighted the project as an opportunity to diversify the local economy by introducing a new industrial sector to the Minot area.
Regulatory Review Remains Underway
The project remains in the approval stage and must secure several regulatory clearances before construction can begin. North Dakota regulators are currently reviewing the facility’s air quality permit application, as the proposed complex would be classified as a major potential source of air emissions. Public comment periods are expected as part of the review process.
In addition, a proposed natural gas pipeline that would supply the facility is awaiting federal approval. If the required permits are granted, construction of the merchant pig iron plant is expected to begin in 2027, with commercial operations scheduled to commence in 2029. The project would mark a significant milestone for domestic steel production by introducing a new source of merchant pig iron manufactured from recycled mine waste in the United States