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Primary steel, the strongest and most durable form of the metal, is typically also the dirtiest kind. That’s because the most common way to forge it begins with producing iron in coal-fired blast furnaces.
Now, for the first time, a new report identifies who buys the lion’s share of primary steel in the United States — and how much steel they’re buying.
At least 60% of U.S. primary steel is purchased by automobile manufacturers, according to an analysis from the environmental group Mighty Earth that was shared exclusively with Canary Media. The six automakers identified in the report — Ford Motor Co., General Motors Co., Honda Motor Co., Hyundai Motor Group, Stellantis, and Toyota Motor Corp. — produce 73% of all new cars on American roads.
The finding highlights a point of leverage for customers in decarbonizing American steel production at a moment when steelmakers are largely reversing plans for greener mills and doubling down on coal-fired blast furnaces.
“The auto market drives blast furnaces in the U.S.,” said Matthew Groch, senior director of decarbonization at Mighty Earth. ​“If they really cared and wanted to, they could put pressure on these companies they’re buying steel from. But they aren’t, and they don’t.”
Only one of the six automakers, Honda, responded to emailed questions from Canary Media. But the Japanese firm declined to comment on its steel suppliers.
“Honda is actively working to reduce CO₂ emissions associated with raw material procurement and manufacturing processes,” Honda spokesperson Chris Abbruzzese said in an email. ​“We do not publicly disclose individual supplier relationships.”
Automakers have traditionally relied on primary steel to form the outer shell of their cars because it’s long been considered higher quality than steel made from recycled scrap metal in electric arc furnaces. Increasingly, though, thanks to improvements in its purity and strength, so-called secondary steel has been able to displace some of that demand. Steel recyclers like Nucor say the auto sector represents a growing share of their customer base, but primary steel made using coal still dominates the sector.
To identify the buyers of primary U.S. steel, Mighty Earth commissioned the consultancy Empower LLC to conduct ​“an exhaustive review” of supply chains, according to the report. The analysts then reviewed ​“everything from annual reports and investor presentations to new articles and company websites, looking for clues regarding links between the steel facilities of interest and their ties to the largest U.S. automakers.” The study relied on supply chain and financial data from the platforms Panjiva, Sayari Graph, S&P Capital IQ, and MarkLines, and it used OpenRailwayMap to track materials shipped by train.
Since President Donald Trump returned to office a year ago, the nascent efforts to clean up America’s primary steel production have largely collapsed.
Cleveland-Cliffs, which had been awarded a $500 million grant from the Biden administration to finance construction of new, greener equipment at one of its Ohio steelworks, abandoned the initiative and is now working with Trump’s Energy Department to develop a coal-focused scope for the project.
U.S. Steel, whose sale to Japanese rival Nippon Steel was approved by the Trump administration, finds itself at a crossroads. The company has promised some greener investments in the U.S. but has yet to announce any specifics. Its new owner, however, has a reputation as ​“a coal company that also makes steel” — and Nippon has also promised to invest in upgrading U.S. Steel’s blast furnaces to last longer.
That leaves Hyundai’s project to build a low-carbon steel factory in Louisiana as the flagship push for clean steel in the U.S.
Despite recent challenges from the Trump administration, Hyundai has signaled its commitment to bringing the facility online by 2029. The plant is designed to first use blue hydrogen, the version of the fuel made with fossil gas and carbon capture equipment, to produce the cleaner direct reduced iron. But by the mid-2030s, the facility is expected to switch to green hydrogen, made with electrolyzers powered by renewables.
The low-carbon iron will then be fed into electric arc furnaces to produce steel — making it the first integrated low-carbon steel plant in the U.S. That Louisiana plant could reduce emissions by at least 75% relative to a traditional integrated steel plant with a blast furnace and basic oxygen furnace.
In a sign of progress, Hyundai this month announced plans to test its DRI equipment at an existing steelworks in South Korea in anticipation of bringing the technology to Louisiana.
Once that Louisiana plant comes online, Groch said, it’s expected to generate enough steel to meet Hyundai’s needs and supply additional potential buyers — opening up an opportunity for other automakers. In its report, Mighty Earth calls on automakers to commit to buying more green steel in the coming years.
General Motors and Ford have committed to buying at least 10% green steel by 2030 as part of a pledge via the First Movers Coalition, led by the World Economic Forum. Other global carmakers not included in Mighty Earth’s report, such as Volvo, Mercedes-Benz, and BMW, have adopted separate targets. Honda, Stellantis, and Toyota, meanwhile, have avoided making such promises.
Holding car companies to those targets has proved challenging. While some companies have vowed to slash emissions by buying more low-carbon steel, a September 2024 report by the International Council on Clean Transportation found that carmakers’ pledges to buy fossil-free steel by 2030 cover less than 2% of their total demand for the metal.
“We’re not asking for everyone to have 100% green steel,” Groch said. ​“But these are their commitments, and the car companies are the ones driving investment in steel.”
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