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The secondary non-ferrous metals meltingMelting route requires considerably less energyEnergy compared to primary production, making it currently the most sustainable production method. Industry 4.0Industry 4.0 tools, e.g., digital twin, artificial intelligenceArtificial intelligence/machine learningMachine learning, and networked devices (smart burners), make reverb and rotary furnaceRotary furnace operations more energyEnergy-efficient, improve metal yield, and can help predict furnace maintenance needs. This paper presents field data of implementing the proprietary smart Transient Heating burner in reverb furnacesReverb furnace as well as a ‘digital twin process advisor’ technology and its continuous improvement using machine learningMachine learning in rotary furnacesRotary furnace. Results on production increase, energy savingsEnergy saving, and yield improvement when compared with conventional oxy-fuel technologies (rotary furnaceRotary furnace) and air–fuel (reverb furnaceReverb furnace) are discussed. These Industry 4.0Industry 4.0 tools, combined with next-generation oxy-fuel burner technologies, provide a practical means to make secondary production routes more efficient.

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Industry 4.0: Implementation of Smart Combustion Technology and Process Advisor in Secondary Melting Furnaces

  • 会议论文

  • 发表日期：

    2026年

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  • Anandkumar Makwana,
  • Daniel Merino Allue,
  • Valmiro Sa,
  • Edson Escudeiro Basilio,
  • Reed Hendershot,
  • Eric Seo

摘要

The secondary non-ferrous metals meltingMelting route requires considerably less energyEnergy compared to primary production, making it currently the most sustainable production method. Industry 4.0Industry 4.0 tools, e.g., digital twin, artificial intelligenceArtificial intelligence/machine learningMachine learning, and networked devices (smart burners), make reverb and rotary furnaceRotary furnace operations more energyEnergy-efficient, improve metal yield, and can help predict furnace maintenance needs. This paper presents field data of implementing the proprietary smart Transient Heating burner in reverb furnacesReverb furnace as well as a ‘digital twin process advisor’ technology and its continuous improvement using machine learningMachine learning in rotary furnacesRotary furnace. Results on production increase, energy savingsEnergy saving, and yield improvement when compared with conventional oxy-fuel technologies (rotary furnaceRotary furnace) and air–fuel (reverb furnaceReverb furnace) are discussed. These Industry 4.0Industry 4.0 tools, combined with next-generation oxy-fuel burner technologies, provide a practical means to make secondary production routes more efficient.