We develop calibrated models of energy and material consumption patterns in the US steel industry, starting with an energy end-use model based on 1994 Manufacturing Energy Consumption Survey (MECS) data. Then process-step models of material and energy use are developed and calibrated against the energy end-use model and data from the US Commerce Department and the American Iron and Steel Institute. These models can serve as benchmarks for current steelmaking operations and as base cases for simulating changes in steelmaking energy utilization and waste streams spurred by economics, regulations, or technology innovations. (C) 2001 Elsevier Science Ltd. All rights reserved.