Installed alongside the existing SMS “CMT 550” mill, the new facility will create the world’s first twin “CMT” system and increase Hybar’s annual reinforcing bar production capacity by 630,000 short tons. Groundbreaking for the project is expected to take place in late 2026 with start-up scheduled twenty-four months later.

By integrating an additional “CMT 550” mill at the Osceola site in Arkansas, the twin mill solution enables optimal use of transport logistics and a shared connection to the same renewable power source. Utilizing the site’s 105-megawatt solar park, supported by a 160-megawatt-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%.

The new “CMT 550” mill is engineered to create an energy-efficient steelmaking system by integrating steelmaking, casting, and rolling into a single, exceptionally reliable process. SMS will supply the complete “CMT” mill from a single source. The new mill expands Hybar’s reinforcing bar production by an additional 630,000 short tons per year, producing bars from 12.4mm to 35mm 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 the proven “Edge DC” design platform and a twin ladle furnace station, providing high electrical efficiency, operational flexibility, and consistent steel quality. The “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 unprecedent level of availability. A comprehensive 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 the 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 fourteen housing-less stands and a six-pass “MeerDrive” high-speed finishing block. Thanks to its flexible gear ratio selection, “MeerDrive” technology reduces roll ring inventory by 60% compared to conventional finishing blocks. Directly after rolling, a “TBK MeerGauge” autonomous laser measurement system provides dimensional verification, process optimization, and improved tolerance utilization. The integrated “HSD” (High Speed Delivery) system enhances material yield and bundle shape by comparison with multistrand 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 embedded at the Osceola site to coordinate tailored solutions. With early engagement starting 14 months before commissioning, SMS has forecasted consumables demand, optimized spares inventories, and customized 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.

www.sms-group.com