Hybar Orders Second Continuous Minimill from SMS Group
(From left to right: Luca Spaziani (SMS group), Chandler Ault (Hybar LLC), Filippo Verlezza (SMS group), John Moore (Hybar LLC), Shaun Nagy (Hybar LLC), Andrea Gallina (SMS group), Brett Doolittle (Hybar LLC), Mario Fabro (SMS group), Carlo Cascino (SMS group) In front from left to right: Sam Fowler (Hybar LLC), Dave Rigby (SMS group)).
US-based scrap metal recycling and steel production company Hybar LLC has again selected SMS group to supply a second continuous minimill technology order (CMT® 550) for its steelmaking complex in Osceola, Arkansas (USA).
The company is focused on environmentally sustainable steel production and plans to install the new equipment alongside its existing SMS CMT 550 mill, creating the world's first twin CMT system.
In capacity terms, the additional continuous minimill increases Hybar's rebar production capacity by 630kt (short tons).
Groundbreaking for the project is expected to take place in late 2026 with start-up scheduled for 24 months later.
According to SMS group, by integrating an additional CMT® 550 mill at the Osceola site in Arkansas, the twin CMT® mill solution enables optimal use of transport logistics and a shared connection to the same renewable power source. Utilizing the site’s 105mW solar park, supported by a 160mW hours battery storage system, mill operation is designed to achieve one of the lowest carbon footprints in the long-product sector. Compared to a conventional minimill, carbon emissions are expected to be reduced by up to 35%.
“Building on the success of our first CMT® mill at Hybar’s Osceola site to produce long products, we see huge potential to expand our capacities here at Osceola by combining logistics and labor expertise already on-site with this CMT® twin solution. This enables us to effectively respond to the increasing demand for green long products by taking advantage of shared utility costs,”
——David Stickler, CEO Hybar.
SMS group claims that the new mill is engineered to create an energy-efficient steelmaking system by integrating steelmaking, casting, and rolling into a single process. The company will supply the complete mill from a single source. The new mill will produce bars from 12.4 to 35 millimetres in one to four-ton bundles.
The plant will also include future provision for VCC® (Vertical Compact Coiler) technology for coils up to eight tons.
The meltshop features an electric arc furnace based on SMS group's EDGE DC design platform and a twin ladle furnace station, providing high electrical efficiency, operational flexibility, and consistent steel quality, it is claimed.
X-Pact AURA, an advanced electronics system, provides the electrical power feed to the melting unit, enabling high productivity (>80 tons per hour) with low energy consumption and minimal impact on the electrical grid. The modular architecture (six equivalent AURA packages installed) allows Hybar to run the plant at an unprecedented level of availability. A digital package ensures plant-wide acquisition of real-time and production data, feeding the DataXpert platform to provide advanced logic and develop machine learning models for equipment monitoring and smart operation.
A hallmark of the CMT® concept is claimed to be 'seamless integration of casting and rolling into one continuous production process'. A high-speed single-strand endless caster with CONREX mold tube technology connects the meltshop to the rolling mill via an induction equalization furnace, reducing dependence on fossil-fuel reheating furnaces.
The rolling mill is equipped with 14 housing-less stands and a six-pass MEERdrive® high-speed finishing block. Thanks to its flexible gear ratio selection, MEERdrive® technology is claimed to reduce roll ring inventory by 60% compared to conventional finishing blocks. Directly after rolling, a TBK MEERgauge autonomous laser measurement system provides dimensional verification, process optimisation, and improved tolerance utilisation. An integrated HSD® (High Speed Delivery) system enhances material yield and bundle shape by comparison with multi-strand bar rolling using a short cooling bed.
Building on the operational success of Hybar’s first CMT® 550 mill, SMS has established a dedicated lifecycle partnership model combining on-site expertise with comprehensive support. A dedicated SMS expert is located at the Osceola site to co-ordinate tailored solutions. With early engagement starting 14 months prior to commissioning, SMS has forecasted consumables demand, optimized spares inventories, and customised rolling guide solutions. The same proven approach is now being extended to support the twin CMT® system and strengthen equipment reliability.
“Building on the success of our first CMT® mill at Hybar’s Osceola site to produce long products, we see huge potential to expand our capacities here at Osceola by combining logistics and labor expertise already on-site with this CMT® twin solution. This enables us to effectively respond to the increasing demand for green long products by taking advantage of shared utility costs,” says David Stickler, CEO Hybar.
As a single-source supplier, SMS combines process technology, plant engineering, automation and digital solutions into one integrated platform. Leveraging the experience gained from Hybar’s first CMT® 550 mill in Osceola, SMS will support project execution and commissioning to reduce startup risk and accelerate the transition to profitable production.