Optimise Furnace Performance with Inferno

Use our Adaptive Intelligence to maximise production for the least amount of energy. Inferno's advanced simulation will help you cut costs, reduce emissions, improve yield, and reduce furnace variability.

Stop guessing, start optimising.

Master Furnace Complexity
with Data-Driven Precision

Optimising Aluminium furnaces involves navigating inherent process complexity, unpredictable feed stock variability, and measurement difficulties. Balancing competing goals like energy savings, yield maximisation, and throughput requires moving beyond intuition towards data-driven precision.

Your Digital Furnace Testbed

Inferno is digital twin software providing advanced simulation and optimization for Aluminium Furnaces. Leveraging physics-based modelling and adaptive intelligence, it accurately represents complex furnace dynamics. Predict energy consumption and yield, receive operational guidance, or implement automated control. Master Furnace Complexity with Data-Driven Precision.

Sustainable Operations

Unlock Measurable Results with Inferno

Translate deep process understanding into tangible energy savings and maximized metal yield with Inferno’s adaptive intelligence

Reduce Energy Consumption by 10%

Optimize burner profiles & shutdown timing for approximately 8-10% or more potential savings

Improved Yield by 0.75%

Prevent overheating & minimise dross with optimized control for around 0.5-0.75% gains on average

Increase Throughput by 10%

Achieve consistent melt times & optimized sequences for 5-10% faster cycles on average

De-Risk Changes

Validate improvements virtually using “what-if” analysis before live implementation

Visualise and Track Performance

Go beyond basic KPIs. Inferno enables detailed analysis to deliver actionable recommendations. For example, explore the impact of burner demand on gas consumption, evaluate how configuration changes affect melt rates, correlate tapping temperatures with yield loss, and optimise operational timing like skimming or stirring. Compare scenarios visually and understand prediction accuracy to truly master your furnace dynamics. Download examples of the insights you can generate below.

How Inferno Delivers Optimisation

Physics-informed AI simulation

Accurately models core furnace physics like heat transfer and combustion for reliable predictions. Grounded in science, proven in practice.

"What-If" Analysis

Safely explore unlimited scenarios offline including charge mix, burners, and timings to find optimal strategies without risk.

Predictive Analytics

Forecast key KPIs such as melt time, energy use, and dross, enabling data-driven decisions and optimized shutdowns.

AI-Enabled Control

Integrates Adaptive Intelligence for real-time operator guidance or automated control, driving peak efficiency.

Product Suite

The AI Advantage

Inferno | Engine: Physics-Informed AI

Our core engine combines deep physics-based understanding with machine learning, forming a robust Physics-Informed AI foundation. It simulates furnace behavior based on fundamental principles, ensuring exceptional accuracy and adaptability. We calibrate Inferno | Engine against your real-world Furnace to ensure close alignment between simulated and real results.

Inferno | Expert: De-risk Decisions, Unlock Potential

Unlock deep process insights with Inferno | Expert, your digital twin for scenario exploration and optimisation. Virtually simulate different charges, burner settings, or operating strategies before live implementation. Empower your furnace experts to perform sensitivity analyses, analyze historical performance, and identify optimal strategies to enhance efficiency and de-risk operational changes.

Inferno | Assist: Real-Time Guidance, Consistent Results

Empower your operators with Inferno | Assist for dynamic, real-time operational guidance. Our system predicts melt time changes during the cycle and advises on the optimal timing for critical actions like skimming or alloying. Achieve greater consistency across shifts, maximize efficiency, and improve throughput by standardizing best practices directly on the plant floor.

Inferno | Control: AI-Powered Autonomous Optimisation

Experience autonomous furnace management with Inferno | Control, leveraging Physics-Informed Machine Learning. Our Adaptive Neural Controllers (ANCs) continuously adjust setpoints, guided by both real-time data and core physical principles from the engine. This AI-driven system intelligently handles process variations, ensuring your furnace consistently operates at peak energy efficiency and optimal melt profiles with enhanced robustness and adaptive control.

Find Out More

Download technical resources covering our Physics-based, ML-enhanced Digital Twin approach and the practical steps for effective furnace implementation and calibration. Explore the Product Specification for more information about scope, impact and configuration options.

Product Downloads

Get in Touch

On-Premise
/ On-Board

No cloud or remote connectivity

No Historical
Data Needed

Uses 1 principles model approach and generates own training data

Fits Into
Small Spaces

Very compute efficient

Flexible
Embodiment

Deploy into embedded controllers, or in PLC/DCS/Motion/SCADA products

Get in Touch

We work with your team to develop system models and a training curriculum that accommodates physical tolerances, safety limits, process scenarios and control uncertainties, while simultaneously and continuously optimising around your value drivers.

Technology explanation

We would like to help you learn as much as possible about Adaptive Intelligence. To help you understand as quickly as possible, we have written a technical description for control engineers and another one for computer scientists from an artificial intelligence background.

Download the 2 white papers here:

Luffy AI is the most credible team on the market.”

– Surface Generation CEO

Arrange a Demonstration

Get in touch to arrange a demonstration at your site of the capabilities of Inferno.

Master Furnace Complexity
with Data-Driven Precision

Your Digital Furnace Testbed

Sustainable Operations