Rebar mill modernization, Feralpi (Italy)

Feralpi Group commissioned SMS group to modernize its existing rebar mill in Lonato, Italy, to enable environmentally friendly rebar production. The gas-fired furnaces were replaced with energy-efficient induction heating. Feralpi's modernization shows how integrating modern technology in existing plants can enable the shift towards fossil-free steel manufacturing.

How the process is made more sustainable

SMS dismantled the billet reheating furnace and replaced it with new energy-powered induction heating furnaces. These furnaces utilize electromagnetic induction to heat steel, allowing for precise temperature control and reduced energy consumption compared to traditional gas-fired furnaces.

Moreover, the modernized plant features a new transfer device that reduces energy losses by transporting hot billets from the continuous casting site to the rolling mill more efficiently. The inductors in the new system operate only when billets pass through, avoiding energy consumption during inactive periods. Additionally, the new billet welding machine joins multiple billets into a single semi-finished product for continuous rolling, increasing productivity and reducing waste.

Electrification as enabler of sustainable production

Electricity can be generated from renewable sources such as wind and solar power. This capability allows steel plants to transition from fossil fuels to cleaner energy alternatives, significantly reducing their carbon footprint. Electric systems often achieve higher efficiency compared to fossil fuel-based systems, leading to reduced energy waste. 

This modernization project demonstrates that retrofitting brownfield plants with modern technology can significantly reduce CO₂ emissions. Feralpi has set a benchmark for other brownfield plant operators aiming to implement fossil free solutions in steel manufacturing.

The role of electrification

Electrification is important for sustainable steel production, especially when combined with renewable energy sources to significantly cut CO₂ emissions. Even in areas lacking renewable energy infrastructure, energy-efficient technologies from SMS group can reduce energy consumption. As a foundational strategy, electrification, combined with other innovations and waste reduction measures, enhances sustainable production in both greenfield and brownfield plants.