SMS group and Hybar LLC are pioneering the development of green rebar through their collaboration on the very first Continuous Minimill Technology (CMT®) in Osceola, Arkansas. With production starting in early 2026, Hybar LLC is now operating a compact low-emission, energy-efficient rebar minimill. The mill utilizes up to 100% renewable energy from an own constructed solar park, reducing its carbon footprint by 35% compared to conventional minimills. Hybar’s CMT® mill can run on solar energy for up to 12 hours daily, supported by advanced energy management for the remaining operating time.
The project
SMS group’s technologies make Hybar’s minimill one of the most modern and sustainable of its kind. The CMT® minimill is designed for small property sizes, combining efficient operation with a lower initial investment and reduced production costs. The technology allows for an energy efficient steelmaking system by supplying liquid steel to a high-speed caster that directly feeds the rolling mill in a single, highly reliable process.
Technology
Hybar’s CMT® mill is designed to create an energy-efficient steelmaking system by integrating steelmaking, casting, and rolling into a single, highly reliable process. By charging scrap metal into the electric arc furnace (EAF), where it is melted and refined into liquid steel, the mill not only reduces its carbon footprint, but also keeps material in the loop.
Demand for sustainably produced long products is driven by strong construction and infrastructure development in many regions. As a full system provider, SMS group delivers minimill solutions tailored to these market needs. The engineering behind the CMT® mills enables renewable-energy operation, provided the local energy infrastructure can ensure an efficient supply to the mill. The CMT® mill further supports closed-loop water management through a dedicated water treatment plant for cooling and cleaning, and improves environmental performance by integrating a fume treatment plant to keep emissions within air quality objectives.
With two finishing lines for straight bars and coils, Hybar achieves high product flexibility for diverse markets. Although the mill is compact, it is designed to produce 630,000 short tons of rebar per year. It can also spool rebar up to size 8 in eight-ton spools, which is expected to be world-leading.
Solutions included in the project
X-Pact® AURA: Advanced DC EAF feeding
The X-Pact® AURA (Advanced Unit Rectifier Assembly) efficiently powers DC arc furnaces across all network configurations, including weak grids. Utilizing IGBT technology, it offers exceptional current stability, efficiency, and minimal impact on electric quality, often eliminating the need for SVC or Statcom to meet IEEE 519 standards.
Elo-Long induction furnace
The Continuous Mill Technology (CMT®) uses residual heat from continuous casting with an Elo-Long inline induction heater before rolling. Only temperature equalisation is required, reducing energy use versus full reheating and lowering costs, while eliminating direct CO2, NOx and SOx emissions.
MEERdrive®
MEERdrive® is a modular finishing system for producing wire rod and high‑speed bars, designed to maximize operational flexibility and energy efficiency. Its individual‑drive architecture supports synchronized high‑speed rolling (operation above 120 m/s) while reducing roll ring inventory and enabling rapid format changeovers.
TMbaR® - Thermomechanical rolling process for rebar
TMbaR® is a thermomechanical rolling process designed for producing high-strength deformed bars. It enhances material properties by reducing manganese content, resulting in improved weldability and ductility, making it ideal for demanding construction applications.
MEERgauge®
MEERgauge® is an autonomous laser measurement system for dimensional measurement of bars, wire rod, and tubes. It is installed directly after the rolling mill to check product dimensions and utilize tolerances. It enables early detection of dimensional anomalies in both hot and cold conditions.
X-Pact® Sampler
A robotic solution for critical process control, eliminating the need for operator presence near liquid steel. Utilizing 6-axis anthropomorphic robots, it enhances safety, reliability, and repeatability, making operations faster and reducing downtime for increased productivity.
CONDOOR®: High-performance slag door
The CONDOOR® system enhances EAF melting cycles by facilitating safe slag removal and improving performance. It automates cleaning in the slag-door area, allowing closed-door operation and reliable access for sampling and temperature management, boosting quality and yield.
CONDRIVE
CONDRIVE Direct Oscillation Drive is a purely electric solution for mold oscillation in continuous billet casting. It provides hydraulic-like performance while reducing cost and enabling online adjustment of amplitude, frequency, and oscillation curve. This supports optimized surface quality and high operational reliability.
VCC® Vertical Compact Coiler
The VCC® Vertical Compact Coil produces compact, torsion-free coils, enhancing storage and transport efficiency. This innovative technology optimizes production processes, significantly reducing handling costs and improving overall operational performance.
HSD®: High-Speed Delivery System
HSD® High Speed Delivery is an innovative system for producing round and deformed bars at very high speeds. It enables single‑strand rolling from 6 to 43 mm, improves material yield, reduces short bars, and delivers significant cost savings with consistent product quality.
EAFXpert™
EAFXpert™is an advanced tool designed to optimize electric arc furnace (EAF) operations by transforming data into actionable insights. It enhances safety, efficiency, and reliability through predictive and prescriptive optimization techniques.
Genius Condition Monitoring
Genius CM® provides real-time condition monitoring for metallurgical plants using sensor networks and AI-supported analysis. It delivers early alerts and supports predictive maintenance to reduce downtime and false alarms. Modular integration across equipment improves reliability, safety, and efficiency.
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X-Pact® AURA: Advanced DC EAF feeding
Learn moreThe X-Pact® AURA (Advanced Unit Rectifier Assembly) efficiently powers DC arc furnaces across all network configurations, including weak grids. Utilizing IGBT technology, it offers exceptional current stability, efficiency, and minimal impact on electric quality, often eliminating the need for SVC or Statcom to meet IEEE 519 standards.
Electric Arc Furnace with scrap basket Elo-Long induction furnace
Learn moreThe Continuous Mill Technology (CMT®) uses residual heat from continuous casting with an Elo-Long inline induction heater before rolling. Only temperature equalisation is required, reducing energy use versus full reheating and lowering costs, while eliminating direct CO2, NOx and SOx emissions.
MEERdrive®
Learn moreMEERdrive® is a modular finishing system for producing wire rod and high‑speed bars, designed to maximize operational flexibility and energy efficiency. Its individual‑drive architecture supports synchronized high‑speed rolling (operation above 120 m/s) while reducing roll ring inventory and enabling rapid format changeovers.
TMbaR® - Thermomechanical rolling process for rebar
Learn moreTMbaR® is a thermomechanical rolling process designed for producing high-strength deformed bars. It enhances material properties by reducing manganese content, resulting in improved weldability and ductility, making it ideal for demanding construction applications.
MEERgauge®
Learn moreMEERgauge® is an autonomous laser measurement system for dimensional measurement of bars, wire rod, and tubes. It is installed directly after the rolling mill to check product dimensions and utilize tolerances. It enables early detection of dimensional anomalies in both hot and cold conditions.
X-Pact® Sampler
Learn moreA robotic solution for critical process control, eliminating the need for operator presence near liquid steel. Utilizing 6-axis anthropomorphic robots, it enhances safety, reliability, and repeatability, making operations faster and reducing downtime for increased productivity.
CONDOOR®: High-performance slag door
Learn moreThe CONDOOR® system enhances EAF melting cycles by facilitating safe slag removal and improving performance. It automates cleaning in the slag-door area, allowing closed-door operation and reliable access for sampling and temperature management, boosting quality and yield.
CONDRIVE
Learn moreCONDRIVE Direct Oscillation Drive is a purely electric solution for mold oscillation in continuous billet casting. It provides hydraulic-like performance while reducing cost and enabling online adjustment of amplitude, frequency, and oscillation curve. This supports optimized surface quality and high operational reliability.
VCC® Vertical Compact Coiler
Learn moreThe VCC® Vertical Compact Coil produces compact, torsion-free coils, enhancing storage and transport efficiency. This innovative technology optimizes production processes, significantly reducing handling costs and improving overall operational performance.
HSD®: High-Speed Delivery System
Learn moreHSD® High Speed Delivery is an innovative system for producing round and deformed bars at very high speeds. It enables single‑strand rolling from 6 to 43 mm, improves material yield, reduces short bars, and delivers significant cost savings with consistent product quality.
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EAFXpert™
Learn moreEAFXpert™is an advanced tool designed to optimize electric arc furnace (EAF) operations by transforming data into actionable insights. It enhances safety, efficiency, and reliability through predictive and prescriptive optimization techniques.
Genius Condition Monitoring
Learn moreGenius CM® provides real-time condition monitoring for metallurgical plants using sensor networks and AI-supported analysis. It delivers early alerts and supports predictive maintenance to reduce downtime and false alarms. Modular integration across equipment improves reliability, safety, and efficiency.