Hybar lowers output forecast, owning up to EAF startup delay

“We’re melting scrap as we speak,” he said. “We’ll be producing and fulfilling our orders in the coming days and weeks.”

Aura system: First in the world, first in frustration

Originally slated to be the second Aura-equipped mill globally, Hybar inherited the “world’s first” title after a project in Vietnam was postponed. The result: no prior lessons from which to learn or benefit.

The SMS group’s X-Pact Aura (advanced unit rectifier assembly) technology utilizes a compact, modular system for supplying DC arc furnaces, like Hybar’s, with efficient and stable power in all power network configurations, including weak grids.

Hybar had hoped to strike the first arc on its EAF in June/July, but that was delayed while working out the kinks in the world’s first application of the technology.

“We lost six to eight weeks of production, which pisses me off,” Stickler said bluntly, adding, “We’re not pointing fingers – we take full responsibility.”

During the delay, Hybar reheated and rolled purchased billets, a process Stickler dismissed as “the boring, old-fashioned way to make rebar.” He emphasized that Hybar was built to be anything but conventional.

Stickler noted that the mill is also still working to dial in on the production of some of the smaller sizes of rebar.

Solar facility: 100% renewable when the sun shines

Hybar’s 105 MW behind-the-meter solar facility – paired with 160 MWh of battery storage – is fully constructed and integrated with the mill’s operations. The plant comprises 186,000 solar panels covering 400 acres.

Stickler stressed the distinction from grid-tied solar: “When the sun is shining, I can point to the sun, the solar panel, and our own private transmission line – and without question, that electron is coming into our mill,” without ever touching the grid.

However, the full solar operation awaits final approval by the Federal Energy Regulatory Commission (FERC), which is expected by December. Until then, the mill is running on grid power.

Revised production forecast

Hybar’s initial production target of 200,000 short tons (st) of rebar this year has been downwardly revised to 150,000 st due to the Aura-related delay.

“I’ll never get that production back,” Stickler lamented. “But the order book is solid – we just need to get the steel produced.”

Hybar’s rated production capacity is 630,000 st annually, but Stickler believes the newest player in the rebar game can push it up to 700,000 st per year.