OSCEOLA, Ark. — Hybar LLC, a startup steel producer based in Osceola, Arkansas, announced that its rolling mill is officially producing steel rebar from billets, marking a major milestone just 22 months after breaking ground at its 1,300-acre greenfield site.

CEO Dave Stickler declared the company “open for business” following the successful start of production at the facility. He explained that the company is now preparing to commission its 105-ton electric arc furnace (EAF) and continuous caster in the coming month. Alongside that, commissioning of the rolling mill and an innovative solar and battery storage facility will also be finalized soon.

Hybar’s website describes the EAF melt shop as capable of consuming up to 700,000 tons of ferrous scrap annually to produce approximately 630,000 tons of recycled-content steel rebar per year. The operation aims to emphasize sustainability and reduce the carbon footprint associated with steel production.

“Hybar’s first day as a company was August 1, 2023,” Stickler said. “We had $1 billion of financing, three employees and huge ambitions. Our plan was to build the world’s most technically advanced environmentally sustainable rebar steel minimill, along with our own Mississippi River port, and the largest behind-the-meter solar and battery storage facility in the United States.”

He added, “I am extremely proud to say, ‘mission accomplished.’ Hats off to the Hybar team and our construction contractors for a job well done.”

The company credits Germany-based SMS Group GmbH for supplying the electric arc furnace, continuous caster, rolling mill, and water treatment plant. Arizona-based Depcom Power Inc. is designing and constructing the solar and battery storage system. Primetals Technologies USA LLC, a business unit of London-based Primetals, provided key components for the onsite electrical infrastructure, including a substation and power distribution network.

Hybar plans to operate North America’s only steel production facility capable of using 100 percent renewable power during daylight hours, thanks to its behind-the-meter solar and battery storage system. This technology allows the company to drastically reduce its carbon emissions compared to traditional steel manufacturing.

“We’re proud that this facility can lead the way in sustainable steelmaking,” said Stickler.

Rebar products and incoming scrap materials will be transported using multiple logistics modes, including barge shipments on the Mississippi, Tennessee, Ohio, and Arkansas Rivers; rail transport via BNSF Railway and other networks; and trucks on nearby highways.

Chief Financial Officer Ari Levy highlighted the efficiency of the project development: “Being able to build three projects in 22 months using our $1 billion, which included our contingency, is a testament to the great team assembled at Hybar, and the partnership Hybar formed with [Arkansas-based] Lexicon Inc., the construction manager for all three projects.”

Hybar and its related entities, including Green & Clean Holdings LLC (parent company), Green & Clean Power LLC (solar and battery storage), and Green & Clean Terminals LLC (river port), are owned by a consortium of companies and funds. This consortium includes the San Francisco-based TPG Rise Climate fund; Koch Minerals & Trading LLC of Kansas; Global Principal Partners LLC, an investment group owned by Hybar’s senior management; and Houston-based energy services firm Quanta Services Inc.

With production underway and key facilities coming online, Hybar positions itself as a pioneering force in sustainable steel production, aiming to reshape the industry’s environmental impact while supporting regional economic growth in Arkansas.

Originally reported by Brian Taylor in CD Recycler.