Future Forgeworks and SMS Group: First sustainable CMT steel mill of Australia

Future Forgeworks, a Brisbane-based steel manufacturer, has awarded SMS group the contract to supply Australia’s first Continuous Mill Technology (CMT® 350) mill. This pioneering project, the Swanbank Green Steel Mill, will produce rebar steel using an endless process, positioning Future Forgeworks at the forefront of sustainable steel production in Queensland and across Australia.

Following regulatory approvals, construction is set to commence in early 2025, with the first steel bar expected within 24 months. The mill is projected to be fully operational by the end of 2027. Future Forgeworks emphasizes that this initiative is a crucial step towards producing low-carbon, green steel for the construction sector.

The innovative CMT® technology enhances energy efficiency by directly feeding liquid steel into a high-speed caster, eliminating the need for a traditional fossil fuel-fired reheating furnace. This process significantly reduces energy consumption and aligns with global decarbonization efforts. Future Forgeworks estimates the project will cut carbon emissions by approximately 90% compared to current Australian market levels.

“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,” said Rohan Richardson, Managing Director of Future Forgeworks. “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.”

The CMT® 350 mill eliminates the need for natural gas in billet reheating, achieving a 30% reduction in CO2 emissions compared to conventional rebar mill processes. SMS group will oversee the entire project, supplying engineering and procurement services for state-of-the-art steelmaking facilities, including an electric arc furnace designed to maximize efficiency while minimizing environmental impact.

Additionally, the facility will include a fume treatment plant, a ladle furnace, a caster, and a rolling mill with an annual production capacity of 350,000 tons. The integration of SMS Elotherm inductive heating furnaces, powered by green electricity, further supports the mill’s sustainability objectives.

To ensure quality and efficiency, the mill will incorporate TBK REBARgauge, an advanced laser measurement system that enables real-time detection of dimensional anomalies. This precision technology minimizes waste and ensures compliance with stringent quality standards. The digital-ready infrastructure will facilitate seamless integration with cutting-edge automation systems, enhancing productivity and operational efficiency.

Future Forgeworks and SMS group have collaborated closely on optimizing operational expenditures, reinforcing the company’s competitive edge in the rebar market. The integration of mechanical, electrical, and automation systems will ensure seamless operations, contributing to Future Forgeworks’ ambition to lead the shift toward low-carbon steel production in Australia.

“Through the application of 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,” Richardson added.

Source and Photo: SMS Group