Mesabi Nugget Delaware, LLC (Mesabi Nugget) is an iron nugget production facility in northeastern Minnesota. Mesabi Nugget is the first of its kind facility that has developed a direct-reduction process to make 97% pure, metallic iron nuggets suited for direct use in electric arc furnaces from iron ore concentrate. Production of nuggets at the Mesabi Nugget plant located near Hoyt Lakes, Minnesota, began in late 2009 with first shipments to Steel Dynamic's Flat Roll division in February 2010. The facility is not currently operating due to market conditions.
Mesabi Nugget was permitted to conduct initial performance tests after a designated production level of iron nuggets was achieved. The production level was reached in January 2012, after years of challenges developing this new technology. The results of the initial performance testing showed numerous failed stack tests for several pollutants, including mercury.
The consent decree includes the following injunctive relief: (1) use of mercury sorbent trap monitoring unit for continuous emission monitoring; (2) development and use of Preventative Maintenance and Operation Plans for multiple process units; (3) Best Available Control Technology Analysis for multiple pollutants and permit amendment requirements; (4) performance testing requirements for various emission units; and ceasing the operation of a coal pulverizing unit.
Mesabi Nugget has agreed to pay a civil penalty of $150,000 for its violations of the CAA