Feralpi Stahl Achieves Record-Setting Production at Riesa Mill with Danieli Technology
In a groundbreaking achievement for the steel industry, Feralpi Stahl, one of Germany’s leading steel manufacturers, has set an impressive new record at its "Walzwerk A" bar and wirerod mill in Riesa. The mill, which has been in operation since 1994, has consistently performed at a high level, but recent upgrades have propelled it to even greater success. Thanks to the use of Danieli billet welder technology and hot-charge equipment, Feralpi Stahl has increased its throughput, achieving an average production rate of 180 metric tons per hour (tph), with peak rates reaching 190 tph.
Technological Advancements Powering Production Gains
The key to this remarkable feat lies in the integration of Danieli billet welder technology. Installed in 2022, the billet welder has allowed for the continuous welding of billets at an exceptionally high capacity. This technology enables the production of high-quality billets that are efficiently processed through the mill, ensuring consistent performance even at higher output levels.
Additionally, the hot-charge equipment, which was installed in January 2024 and also supplied by Danieli, has further optimized the production process. By feeding billets into the mill at an elevated temperature, the hot-charge system reduces energy consumption and boosts throughput. The synergy between these advanced technologies has been instrumental in enabling Feralpi Stahl to exceed the 165 tph design capacity of the Walzwerk A mill.
Breaking the Design Capacity
The Walzwerk A mill was originally designed with a capacity of 165 tph, a standard that was regularly met but never surpassed, until now. By exceeding this threshold, Feralpi Stahl has demonstrated the effectiveness of its investment in advanced technology. The integration of the billet welder and hot-charge system has allowed the mill to surpass its design specifications, setting a new benchmark for performance in the steel industry.
This achievement reflects a broader trend in the industry, where steelmakers are increasingly relying on cutting-edge technologies to maximize production efficiency, improve quality, and reduce energy consumption. By surpassing its design capacity, Feralpi Stahl not only proves the reliability of Danieli's equipment, but also shows that continuous innovation is key to maintaining competitive advantage in the global steel market.
Optimized Efficiency and Enhanced Production Capacity
The use of Danieli’s billet welder and hot-charge equipment has resulted in a more efficient and effective steel production process. By welding billets continuously at high speed and feeding them at the optimal temperature, Feralpi Stahl has significantly reduced downtime and energy consumption, which are critical factors in maintaining a high level of throughput. This technological upgrade has allowed the mill to operate at a level previously thought to be beyond its capacity.
Moreover, the integration of these systems supports Feralpi Stahl's long-term commitment to sustainability and operational excellence. With energy consumption reduced and throughput increased, the company is not only achieving record production rates but also contributing to a more environmentally responsible approach to steel manufacturing.
Future Prospects for the Riesa Mill
Given the success of these technological advancements, Feralpi Stahl is well-positioned to continue its path of innovation and growth. The combination of Danieli's billet welder and hot-charge technology has shown that it is possible to achieve extraordinary production outputs while maintaining the highest standards of quality and efficiency. With further optimization in the future, the Riesa mill could set even higher records, contributing to Feralpi Stahl’s reputation as a leader in the global steel industry.
The continued success at the Walzwerk A mill highlights the potential for future advancements in the steel production sector, where the adoption of cutting-edge technology plays a pivotal role in driving industry performance.
