Future Forgeworks awards SMS group contract for Australia’s first sustainable CMT® mill to produce rebar steel in an endless process

• The new mill positions Future Forgeworks as pioneer in the production of low-carbon green steel rebar products for the construction sector in Queensland and across Australia
• This greenfield project includes lower-emission CMT^® technology, reducing reliance on fossil fuels
• The project will contribute significantly to decarbonization efforts by cutting emissions by approximately 90 percent compared to current Australian market figures

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.

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.

The TBK REBARgauge, an autonomous laser measurement system, 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.

SMS has partnered with Future Forgeworks on the mill design to optimize operational expenditure, providing Future Forgeworks with a competitive edge in the rebar market. The integration of mechanical, electrical and automation systems will guarantee seamless operations and enhanced productivity.

“We are very proud to be partnering with SMS group, a global leader in the manufacture of equipment for steel production, renowned worldwide for its future-oriented technologies. Bringing this proven technology to Queensland significantly underpins the development of our landmark Swanbank project, in line with our goal to build 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.

“The partnership between SMS group and Future Forgeworks is set to initiate a fruitful and innovative collaboration. Our project will strengthen Australia’s position at the forefront of sustainable steel production.” Bernhard Steenken, CSO APAC & MEA, SMS group.