For Feralpi innovation is the engine of growth and as such it is an important element of its business policy, being aware that the search for competitiveness requires projects pursuing tangible sustainability. This entails achieving the best technical performance by reducing energy consumption and CO2 emissions and increasing the safety standards in a continuous progression.

GREEN STONE 2+ project”

The transformation of EAF slag from waste into Green Stone 2+ by-product

The processing of dross, entrusted to a specialist independent company with whom the treatment process
was developed together, makes it possible to transform it into by-products known commercially as “Green Stone”, which are used in the construction industry in place of materials of natural origins and therefore generate overall savings in terms of non-renewable sources.
In June 2014, following controls by an external certification body, all Green Stone by-products were given the CE 2+ marking, according to specific UNI EN standards (aggregates for unbound and hydraulically bound materials for use in civil engineering work and road construction, concrete aggregates, aggregates for bituminous mixtures and surface treatments for roads).

HOT CHARGE project

More energy efficiency to optimise the production process

The Hot Charge project was conceived to optimise the production process thanks to increased energy efficiency and involved both rolling mills at Feralpi Siderurgica.

Major investments were made on Rolling mill 1 in Lonato del Garda to install a roller system for conveying billets from continuous casting straight to the heating furnace (in addition to complete remaking of the heating furnace). This makes it possible to considerably reduce the holding times of the billets leaving the continuous casting machine awaiting to be fed to the rolling mill heating furnace, and fed them at a temperature of around 650°C (instead of ambient temperature).

The final result is:

  • a reduction of natural gas consumption
  • a reduction of electricity consumption
  • increased productivity
  • reduced need for handling material using a crane, with consequent reduced risks for operators
  • a reduction of direct CO2 emissions.

Rolling mill 2 at the Lonato del Garda plant processes billets coming from the Acciaierie di Calvisano plant, which are delivered at the Lonato plant at an ambient temperature. Before being taken to the rolling mill, billets need to be heated to about 1150°C in the dedicated heating furnace, so as to ensure a correct hot plastic deformation process. Now, thanks to the Hot Charge project, billets reach the heating furnace at Rolling Mill still warm, which results in less energy used to return them to the initial temperature.

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