With the new mill, Future Forgeworks aims to position itself as a pioneer in the production of low-carbon reinforcing steel for the Australian construction sector. The greenfield project, which is being implemented by SMS, includes an innovative rolling process to reduce dependence on fossil fuels. This will enable the plant to achieve a reduction in emissions of around 90 percent compared to the current Australian market.
Future Forgeworks, a steel manufacturer based in Brisbane, Australia, has commissioned SMS group to supply the nation’s first Continuous Mill Technology (CMT 350) mill. Future Forgeworks’ landmark project, the Swanbank Green Steel Mill Project, will produce rebar steel in an endless process, thus guaranteeing low carbon emissions and highly efficient production. Following statutory project approvals, work is scheduled to start in early 2025. The project is expected to produce its first bar within 24 months from the commencement date, with full completion anticipated by the end of 2027. Future Forgeworks’ new mill aims to set new benchmarks in sustainable steel production in Australia, reflecting a commitment to environmentally-conscious manufacturing. It also seeks to meet the increasing demand for sustainable construction materials. The innovative CMT technology facilitates an energy-efficient steelmaking process by supplying liquid steel directly to a high-speed caster, which seamlessly feeds the rebar rolling mill. This direct integration eliminates the need for a traditional fossil fuel-fired reheating furnace, significantly reducing energy consumption and carbon emissions. By minimizing reliance on fossil fuels, the technology aligns with global efforts to mitigate industrial emissions.
No natural gas is required for billet reheating
According to SMS, the CMT 350 mill is designed such that no natural gas is required for billet reheating, thereby achieving a reduction in CO2 emissions of up to 30 percent compared to other rebar mill processes. SMS will supply the entire plant from a single source, ensuring streamlined delivery and integration. This includes the engineering and procurement of new steelmaking facilities, featuring an electric arc furnace that is focused on efficiency and sustainability and equipped with technologies to minimize emissions and enhance safety. Additionally, the project comprises a fume treatment plant, a ladle furnace, a caster, and a rolling mill with a capacity of 350,000 tons per year.
An autonomous laser measurement system (TBK REBARgauge) enables early detection of dimensional anomalies, allowing adjustments to be made during production to meet specified standards and reduce material waste. This high measurement accuracy provides for full exploitation of production tolerances, ensuring every product meets stringent quality standards. SMS Elotherm inductive heating furnaces will reheat the steel billets, using green electricity. The CMT mill will be digital-ready and enables seamless integration with state-of-the-art digital systems.
“Bringing this proven technology to Queensland significantly underpins the development of our landmark Swanbank project, in line with our goal to deliver Queensland’s first green steel mill. Through the application of the SMS technology, Future Forgeworks’ project will make a considerable contribution to decarbonization efforts by reducing emissions by approximately 90 percent when compared to the current domestic market.” Rohan Richardson, Managing Director, Future Forgeworks.
Source: SMS group.
