Feralpi Siderurgica Opens Its Doors to “Electric Factories”: Electrification as a Driver of Decarbonization

Lonato del Garda. Feralpi Siderurgica hosted the “Electric Factories” initiative at its Lonato del Garda plant, a program promoted by ItalyPost Group with the support of the European Climate Foundation. The event provided a detailed technical insight into the role of electric energy in steelmaking, with a focus on high‑temperature processing and the progressive replacement of fossil fuels. Electric arc furnace steelmaking already relies on electricity as its primary energy input for melting. The current technological frontier concerns downstream thermal processes, where electrification is emerging as a viable alternative to methane‑based heating systems. During the visit, Feralpi presented the engineering upgrades implemented within its broader energy transition and decarbonization roadmap.

Electrification within the company’s decarbonization architecture

Feralpi Group’s decarbonization strategy is structured around three main pillars: electrification of thermal processes, energy efficiency across production lines, and increased procurement of renewable electricity. Short‑term climate targets include a 50% reduction in specific CO₂ emissions (Scope 1, 2 and 3 core boundary) and a 25% reduction in absolute Scope 3 non‑core boundary emissions by 2030. Long‑term targets aim for a 90% reduction in specific CO₂ emissions (Scope 1, 2 and 3 core boundary) and a 90% reduction in absolute Scope 3 non‑core boundary emissions by 2050. All targets have been validated by the Science Based Targets initiative (SBTi), confirming alignment with recognized scientific methodologies for industrial decarbonization pathways.

Engineering upgrades at the Lonato del Garda facility

A key electrification project completed at the Lonato del Garda plant is the replacement of the former methane‑fired billet reheating furnace of Rolling Mill 1. The unit was fully dismantled and replaced in 2023 with induction furnaces powered exclusively by electricity. This upgrade eliminates direct combustion emissions from the reheating phase and enables more precise thermal control, improved energy efficiency and reduced operational variability. Parallel Research & Development activities are underway to evaluate additional electric‑based reheating technologies, with the objective of extending electrification to further high‑temperature processes.

Performance indicators from the Integrated Report 2025

According to Feralpi Group’s Integrated Report 2025, specific CO₂ emissions from production activities (Scope 1, 2 and 3 core boundary) stand at 0.230 tons of CO₂ equivalent per ton of steel produced. This represents a 58% reduction compared to the 2022 baseline. The data confirms the measurable impact of electrification and efficiency measures on the company’s carbon intensity, positioning the Group on a credible trajectory toward its validated climate targets.

Energy mix evolution and renewable integration

Electrification is supported by a progressive shift in the Group’s energy mix. In 2025, renewable electricity accounted for 56% of total electric consumption across Feralpi Group’s operations, already surpassing the 50% target set for 2030. This trend reflects a structural approach to reducing indirect emissions (Scope 2) and ensuring that electrified processes are powered by low‑carbon energy sources.

Industrial implications and sectoral relevance

The “Electric Factories” initiative highlighted how electrification is becoming a decisive technological lever for steelmaking decarbonization. The transition involves not only furnace technology but also process integration, energy procurement strategies, digital monitoring systems and long‑term R&D investment. Feralpi Siderurgica’s case demonstrates how electrification can be deployed at scale within existing industrial infrastructures, offering a replicable model for other steel producers aiming to reduce thermal process emissions.