The new furnace boosts efficiency, cuts CO₂ emissions by 40%, and supports the decarbonization of stainless-steel production in Europe.

Tenova, through its Italimpianti business line, is completing the installation of a state-of-the-art Walking Beam Furnace (WBF) for Arvedi AST, part of the Arvedi Group, at its integrated stainless-steel plant in Terni, Italy—one of Europe’s most important production hubs.

With a nominal capacity of 240 tonnes per hour, the new furnace represents a major technological upgrade that improves operational performance while significantly reducing the plant’s carbon footprint and operating costs.

Following the contract award, the project progressed through engineering, supply, and installation under Tenova’s responsibility, excluding civil works. According to Marcello Tomolillo, Reheating Product Line Director at Tenova, the project has advanced at record speed given its complexity. “The project lasted approximately two years from the award of the contract, covering a very broad scope of work,” he explains. “By the end of February, the furnace will reach 100% production for most of the products and will be almost ready for its first trials of performance test.”

Energy efficiency and lower emissions at the core

The main innovation of the new WBF lies in its advanced combustion and heat recovery systems. Unlike conventional furnaces, which typically preheat combustion air to around 500 °C, this solution recovers heat from exhaust gases to reach temperatures of around 700 °C, significantly improving thermal efficiency.

The furnace also integrates a combustion system with oxygen lancing and is hydrogen-ready burners, with the ability to operate with up to 100% hydrogen as fuel. Together, these features enable about a 40% reduction in CO₂ emissions compared to the current Walking Beam Furnace operating on the same hot-rolling mill, while also cutting OPEX.

“In Europe, where decarbonization is becoming a key element of industrial competitiveness, this type of solution makes a tangible difference,” Tomolillo notes. “The High Efficiency Walking Beam Furnace is a strategic product for customers seeking to combine performance, sustainability, and cost efficiency, and Arvedi in particular, is focusing its strategy towards energy efficiency and reduction of direct emissions.”

Ensuring operational continuity

Beyond technology, one of the main challenges of the project was maintaining operational continuity at the Terni plant. To minimize disruptions, the new furnace was built on existing foundations with minor civil works activities, allowing production activities to continue safely throughout the construction phase.

“The real challenge was the joint management of the client, resources, and the project,” Tomolillo adds. “This was not just about introducing technological innovation, but about finding the right balance between performance, cost, and what best serves the customer’s operational needs. Achieving that balance is a major accomplishment.”

Digitalization and smart furnace management

The new WBF is equipped with Tenova’s advanced digital packages, Vulcan and Atlas, which enhance combustion control, process optimization, and predictive maintenance. Vulcan focuses on reducing fuel consumption and scale formation through optimized combustion management, while Atlas enables plant-wide monitoring using predictive analytics.

The new WBF will be equipped with Tenova’s advanced digital packages Vulcan, Terminus, Atlas, and Hurcan, designed to monitor and enhance energy efficiency, process control and plant reliability. Vulcan focuses on optimizing combustion by advanced monitoring and control of pressure and oxygen. Terminus supervises the cooling circuits, detecting anomalies that may impact efficiency and energy consumption. Atlas enables predictive maintenance on hydraulic systems, increasing plant reliability and availability. Hurcan uses machine learning models to forecast emissions.

In parallel, the Tenova Dynamic Furnace system and its Level 2 online mathematical model provide fully automated furnace management, ensuring optimal heating practices, stable operation, and optimized energy consumption.

Together, these technological and digital innovations position the Walking Beam Furnace as a concrete example of how industrial-scale solutions can advance the energy transition in hard-to-abate sectors such as steelmaking, delivering measurable emissions reductions while safeguarding productivity and competitiveness.

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