In a strategic and energy-intensive sector like steelmaking, innovation is not an option but a necessity. This is why Feralpi Group is constantly engaged in numerous Research and Development activities, contributing to the creation of new technologies that further mitigate its environmental impact.

We work tirelessly on process efficiency and decarbonization, exploring the adoption of the best available technologies and clean energy sources to accelerate our journey toward carbon neutrality.

These research activities—often conducted in partnership with universities, research centers, and industrial peers—define our way of 'making steel' today, consolidating our competitiveness and ensuring growth driven by impact reduction. This creates value both for the company and for the communities in which we operate.

 

 

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ENVIRONMENTAL COMMITMENT 

Feralpi Group’s Research and Development (R&D) is deeply focused on reducing the environmental impact of steel production. This commitment translates into targeted initiatives for the recovery and valorization of by-products, transforming waste into valuable resources, eliminating refuse, and significantly reducing emissions. A crucial chapter of the Group’s future strategy is the electrification of production processes, a fundamental strategic move to further curb $CO_2$ emissions.

  • Coralis

    Project CORALIS

    Feralpi Group is a participant in the European CORALIS project, which aims to develop industrial symbiosis initiatives to recover and repurpose residues that would otherwise remain unused. Feralpi Siderurgica focused specifically on the recovery of LF (Ladle Furnace) slag and aluminum oxides for the production of ferroalloys and charge materials. By studying the most effective compaction methods and conducting tests at external pilot plants, the Group successfully validated both the reduction of oxides and the recovery of metallic fractions. This activity led to the definition of the most suitable by-product mixes for recovery and the optimal sizing preparation, integrating technical-economic feasibility studies and environmental impact analyses in collaboration with international partners.

    Network and Partnership

    The success of CORALIS is the result of a high-profile international collaboration:

    • Industrial Partners: 20

    • Universities, Research Institutions, and Associations: 13

    Find out more on the official website

    Status: Completed (2025)
    Implementation Site: Feralpi Siderurgica (Lonato del Garda)
    Start Date: 10/2020
    Framework: HORIZON CSP - European Community
    Goals: Valorization of materials from a circular economy perspective and the development of industrial symbiosis
    ESG Classification: Environmental commitment
    Strategic relevance: ☆☆☆☆☆

  • SteelZeroWaste

    Project STEELZEROWASTE

    The SteelZeroWaste project sets strategic goals for significant emission reductions and waste minimization. The initiative focuses on electrification through induction billet heating and the use of polymers and alternative plastic materials as substitutes for fossil coal in the Electric Arc Furnace (EAF). The circular economy roadmap further integrates slag recovery for the construction industry, sludge dehydration, and the optimization of scrap treatment to maximize melting performance. Rigorous monitoring of environmental KPIs ensures the effectiveness of these innovative technologies, transforming steelmaking processes into models of advanced sustainability.

    Status: Completed (2025)
    Implementation Site: Feralpi Siderurgica (Lonato del Garda)
    Start Date: 04/2021
    Framework: Ministerial Call – Sustainable Growth Fund
    Goals: Improving environmental sustainability through the implementation of innovative technologies to reduce waste and emissions
    ESG Classification: Environmental commitment
    Strategic Relevance: ☆☆☆☆☆

     

  • ModHeaTech

    Project MODHEATECH

    The objective of the ModHeaTech project is to promote, implement, and test the introduction of alternative heating systems to replace gas with electrical power, aiming to drastically reduce $CO_2$ emissions in steel production. In 2024, Feralpi Siderurgica and ESF Elbe-Stahlwerke Feralpi collaborated intensively to define the configuration of an experimental pilot plant. Within the project, Feralpi Siderurgica S.p.A. is working with Feralpi ESF Elbe-Stahlwerke Feralpi GmbH on testing and experimentation activities using its own billet samples, as well as evaluating potential applications within its own plant configuration. During the current year, preliminary studies and assessments were conducted to identify the most viable small-scale experimental pilot solution to be implemented. This project represents a fundamental step toward an increasingly electrified, efficient, and sustainable production layout.

    Network and Partnership

    The success of ModHeaTech is the result of a high-profile international collaboration:

    • Industrial Partners: 4

    • Universities, Research Institutions, and Associations: 2

    Find out more on the official website

     

    Status: Active (2025)
    Implementation site: Feralpi Siderurgica (Lonato del Garda), Elbe-Stahlwerke Feralpi ESF (Riesa)
    Start date: 03/2023
    Framework: European Horizon - CSP
    Goals: Decarbonization and electrification through the use of downstream hybrid technologies
    ESG Classification: Environmental commitment
    Strategic Relevance: ☆☆☆☆☆

  • ModiPlant

    Project MODIPLANT

    The ModiPlant project aims to develop an innovative electric billet heating method as an alternative to induction, leading to the implementation of a full-scale industrial demonstrator. Studies and simulations were conducted to define the plant solution to be adopted. For the plant under study, the component manufacturing, material procurement, and site preparation phases have been launched. The simulation and design phases have been completed, and the construction of components is currently underway alongside site preparation and the development of IT tools for production optimization. In close synergy, ESF Elbe-Stahlwerke is supporting the testing phase by evaluating the repeatability and scalability of the solution within its own rolling mill, taking into account the expertise acquired and the constraints imposed by the plant layout.

     

    Network and Partnership

    The success of ModiPlant is the result of a high-profile international collaboration:

    • Industrial Partners: 4

    • Universities, Research Institutions, and Associations: 2

    Find out more on the official website

     

     

    Status: Active (2025)
    Implementation Site: Feralpi Siderurgica (Lonato del Garda), Elbe-Stahlwerke Feralpi ESF (Riesa)
    Start Date: 03/2023
    Framework: RFCS-CSP-Big Tickets - European Community
    Goals: Decarbonization and electrification through the use of hybrid technologies in downstream processes
    ESG Classification: Environmental commitment
    Strategic Relevance: ☆☆☆☆☆

  • iSlag

    Project iSLAG

    The iSlag project aims to enhance the valorization of steelmaking slag by developing and testing innovative devices for the rapid, on-line characterization of slag in both liquid and solid states. These devices are integrated with simulation models and intelligent decision-support tools. To achieve the best possible process correction indicators and optimize downstream slag management, real-time process simulators have been developed for both the melting area and secondary metallurgy, complemented by a dedicated Decision Support System (DSS).


    Network and Partnership

    The success of iSlag is the result of a high-profile international collaboration:

    • Industrial Partners: 6

    • Universities, Research Institutions, and Associations: 4

    Find out more on the official website

     

    Status: Completed (2024)
    Implementation Site: Acciaierie di Calvisano
    Start Date: 07/2020
    Framework: RFCS (Research Fund for Coal and Steel) – European Community
    Goals: Valorization of steelmaking slag through intelligent systems and digital models
    ESG Classification: Environmental commitment
    Strategic Relevance: ☆☆☆☆☆

  • Biorecast

    Project BIORECAST

    The Biorecast project aims to reduce the impacts of the melting process through the innovative use of biocarbon and conjugated polymers within a circular economy framework. Acciaierie di Calvisano is targeting the replacement of fossil anthracite with these innovative materials in the special steels supply chain. The project seeks to demonstrate the introduction of this material into the steelmaking process as both a slag foaming agent and a reducing agent. To this end, initial operational tests and result analyses are currently underway, supported by a new storage and propulsion system.

    Network and Partnership

    The success of Biorecast is the result of a high-profile international collaboration:

    • Industrial Partners: 5

    • Universities, Research Institutions, and Associations: 4

    Find out more on the official website

    Status: Active (2025)
    Implementation Site: Acciaierie di Calvisano (Calvisano)
    Start Date: 11/2023
    Framework: RFCS (Research Fund for Coal and Steel) – European Community
    Goals:  Decarbonization of the electric arc furnace (EAF) through circular economy and waste biomass
    ESG Classification: Environmental commitment
    Strategic Relevance: ☆☆☆☆☆

impegno industriale

INDUSTRIAL COMMITMENT

Beyond environmental sustainability, Feralpi is shaping its future by merging energy efficiency with enhanced product quality. The introduction and adoption of new technologies—particularly those based on Artificial Intelligence (AI) and Machine Learning (ML)—are driving advanced process optimization. These innovations are essential for significantly boosting productivity and achieving standards of operational excellence.

  • DeepQuality

    Project DEEPQUALITY

    The Deep Quality project was established to evolve decision-making processes within the steel industry through a synergistic approach that integrates deep learning, advanced data management, and cutting-edge sensing technologies. By developing a predictive model focused on mechanical strength (the primary KPI), the system monitors process parameters to detect anomalies and ensure the highest quality standards. Concluding in 2024 with the completion of testing and technological validation, the initiative has optimized production efficiency while maximizing system reliability and final product quality.

     

    Network and Partnership

    The success of Deep Quality is the result of a high-profile international collaboration:

    • Industrial Partners: 6

    • Research Partners and Universities: 3

    Find out more on the official website

    Status: Completed (2024)
    Implementation Site: Arlenico (Lecco)
    Start Date: 07/2021
    Framework:  RFCS (Research Fund for Coal and Steel) – European Community
    Goals: Quality optimization through Deep Learning technologies
    ESG Classification: Industrial commitment 
    Strategic Relevance: ☆☆☆☆☆

  • Sunshine

    Project SUNSHINE

    The Sunshine project addresses non-uniform in-mould solidification in long and flat products, which causes shape and surface defects. One of the primary goals of the project is the early detection and prediction of these defects through the use of on-line sensors, combined with simulation models and Artificial Intelligence (AI) tools. Feralpi’s activities are directed toward increasing the quality and efficiency of the continuous casting process and minimizing shape defects in billets.

     

    Network and Partnership

    The success of Sunshine is the result of a high-profile international collaboration:

    • Industrial Partners: 4

    • Universities, Research Institutions, and Associations: 3

    Find out more on the official website

     

    Status: Active (2025)
    Implementation Site: Feralpi Siderurgica (Lonato del Garda)
    Start Date 10/2024
    Framework: RFCS (Research Fund for Coal and Steel) – European Community
    Goals: Improving quality control through the support of Artificial Intelligence
    ESG Classification: Industrial commitment
    Strategic Relevance: ☆☆☆☆☆

  • MultiSensEAF

    Project MULTISENSEAF

    The MultiSensEAF project aims to develop and test multi-sensor systems and machine learning-based soft sensors for optimized process control in the Electric Arc Furnace (EAF).

     

    Network and Partnership

    The success of MultiSensEAF is the result of a high-profile international collaboration:

    • Industrial Partners: 6

    • Universities, Research Institutions, and Associations: 2

    Find out more on the official website

     

    Status: Active (2025)
    Implementation Site: Acciaierie di Calvisano (Calvisano)
    Start Date: 07/2023
    Framework: RFCS (Research Fund for Coal and Steel) – European Community
    Goals: Optimization of process control through advanced sensing and machine learning
    ESG Classification: Industrial commitment
    Strategic relevance: ☆☆☆☆☆