Australia hasn't built a new steel mill in more than 30 years. Greensteel Australia is about to — a $500 million all-electric plant on the old BHP site at Mayfield, producing 600,000 tonnes of rebar a year from the first quarter of 2028. Patrick Buchan, Greensteel's Head of Government Relations, joins James MacDonald on the Danieli technology being built in Italy right now, the policy shift that made onshore steel viable again, why Newcastle beat the rest of the country for the site, and what 200 jobs means for the Hunter.

In this episode:

• The $500 million investment and what it buys — an all-electric mill on Industrial Drive at Mayfield North, the site BHP ran until 1999.
• Why the technology is the story: an electric arc furnace running at around 1,000 degrees, supplied by Danieli of Italy. "No gas, no flame, no chimneys."
• 600,000 tonnes of rebar a year — the critical input to Australian construction and housing — with a growth path into other steel products.
• The policy shift: faster approvals, Future Made in Australia incentives, and why both the federal and NSW governments moved.
• Sovereignty as the argument — oil, steel and microprocessors as the three inputs a country of 28 million can't afford to import.
• How Greensteel started: owners Meena and Romana Ibrahim couldn't get rebar for their own construction businesses through COVID, so they built a steel company.
• Why Mayfield — buildings long enough for a 400-metre rolling line, rail, power and roads, and an intergenerational steel skill base.
• The jobs: 200 direct roles, recruitment opening early 2027, Danieli training included, and no formal-qualification barrier.
• What's next — a stage two in advanced discussions for another New South Wales site, and a ground-breaking with "a very notable political figure."

Patrick Buchan is Head of Government Relations at Greensteel Australia, the company building a $500 million all-electric steel mill at Mayfield in Newcastle — Australia's first new steel plant in more than three decades. Before Greensteel he spent four years on the policy staff of the US Office of the Secretary of Defense at the Pentagon, across the Obama and first Trump administrations.

Greensteel opens recruitment for the Newcastle mill in early 2027. Patrick Buchan on LinkedIn: linkedin.com/in/patrick-buchan-56830b124

Chapters

0:00 Cold open

1:03 Welcome to Engineering in the Hunter

1:56 Patrick's path from Canberra to Greensteel

3:24 Four years inside the Pentagon

6:01 How Australian policy made this possible

9:21 The 600,000-tonne rebar plan

10:27 Inside the new steelmaking technology

14:01 The politics behind the comeback

18:43 How Greensteel Australia got started

20:29 Greensteel signs the deal

21:05 Why Mayfield, Newcastle won the site

21:56 Balancing tradition and renewables

23:34 The road to 2028

24:06 200 jobs and an open call for workers

26:38 The $500 million investment, by the numbers

27:19 How Newcastle is already talking about it

28:22 Sovereign manufacturing and sustainability

29:48 Australia's first steel plant in 30 years

31:39 The trend back to trades

32:40 What's next: stage two

35:35 On founders and entrepreneurship

36:57 On risk, reward, and having a crack

38:16 A story about his dad and the cricket

39:45 Wrapping up

Engineering in the Hunter is hosted by Melinda Sietsma with NTP Talent founder James MacDonald. James hosts this episode. Learn more at ntptalent.com.au.

Engineering in the Hunter is produced by Day One®, trusted partners in the technology space and the team that helped build Blackbird Ventures' Wild Hearts. Sister shows include First Cheque, Oversubscribed and In The Blink of AI. Episodes are cross-promoted across the network.