Rolling Mill B: a story of a steel revolution
In the heart of Saxony, in Riesa, the steel industry is undergoing a radical transformation, driven by the need for a transition towards climate neutrality. Feralpi Group has embraced this challenge with a project that redefines production and environmental standards: the new Rolling Mill B at the FERALPI STAHL plant in Riesa.
This plant stems from a clear idea: to make a technological leap by combining innovation and sustainability, marking a turning point in low-impact steel production.
The vision
The project was born from the desire to meet market needs by producing the so-called Spooler, and to do so with an innovative, digitalised plant with a reduced environmental impact. Launched in 2022 as part of its multi-year industrial plan, Feralpi Group allocated over €220 million for a plant that stands as the first rolling mill in Germany capable of producing Spooler, as well as the first to create coils weighing up to 8 tonnes.
The objectives
- Sustainability > to build a plant with zero direct emissions (Scope 1).
- Employment > to create over 100 new skilled industrial jobs in Saxony.
- Innovation > to introduce a unique product and unique processes to the market.
Achieving all this was not simple: the implementation of Rolling Mill B, carried out in collaboration with Danieli, required over 700 days and involved more than 30 partners.
Innovation
The main innovation is process-related. Rolling Mill B operates with zero direct emissions (Scope 1). This is a breakthrough for the sector. Unlike traditional plants that use natural gas-fired reheating furnaces, FERALPI STAHL "won" this technological challenge by creating a direct link from the existing continuous casting plant via a 300-metre roller table. Induction furnaces were inserted within this table, allowing the billets to be heated using electricity. This process generates no direct CO₂ emissions.
The innovative aspects extend beyond the environment. Rolling Mill B has set two records:
- It is the first plant in Germany to produce Spooler (hot-rolled reinforcing steel in coils)
- It is the fist plant in the world capable of producing Spooler up to 8 tonnes in weight
Everything is maneged by Big Data and artificial intelliogence systems, which connect the plant in real-time to optimise energy consumption and ensure maximum product quality. This impressive technological effort has been complemented by a major general modernisation plan (scrap metal, logistics, electrical substation).
This new plant in Riesa testifies to our long-term vision and our constant commitment to investing in advanced technologies to strangthen our competitiveness in the global market and pursue ever more sustainable production. We firmly believe in Germany's growth potential and want to be a driving force in this economic revival.
- Giuseppe Pasini, President of Feralpi Group
The story of FERALPI STAHL's Rolling Mill B
The Riesa Rolling Mill B project was officially presented during Wire 2022 in Düsseldorf. The international steel trade fair provided the opportunity to share the first details and renderings of the new plant.
The project simbolically kicked off with the official "ground-breaking" ceremony. This moment marked the official start of work and was attended by key figures: Feralpi Group President Giuseppe Pasini, Eng. Giacomo Danieli-Mareschi (CEO of Danieli), Saxony's Prime Minister Michael Kretschmer and the President of the German Steel Federation, Mr Kerkhoff.
Their presence immediately highlighted the strategic importance of the investment, not just for the company, but for the entire region.
A key moment of the project team. On this date, the first tests were carried out to verify the connection between the continuous casting and the new transfer system, allowing the billets to proceed along the 300-metre roller table.
The rolling of the first billet was celebrated internally by the teams as the culmination and success of over 700 days of work. A small celebration also attended by an emotional President Giuseppe Pasini.
15 May 2025 marks a historic date for Feralpi Group: the official inauguration of Rolling Mill B. Over 500 people attended the celebratory event. The ceremony included high-level institutional representatives, such as Italian Minister Tommaso Foti, Saxony's Prime Minister Michael Kretschmer, and the Italian Ambassador to Germany, Fabrizio Bucci.
