Furnace Studies & Audits

FurnXpert performs detailed furnace studies and operational audits to improve thermal efficiency, productivity, fuel consumption, controllability, and product quality.

Our analysis includes combustion evaluation, heat balance calculations, refractory review, cycle optimization, and process recommendations tailored to customer operations.

Furnace Process Simulation

You provide us with the basic information. We will evaluate the problem and gather all required information to perform the analysis. If the information is not readily available, we will conduct the necessary research to obtain it.

We Will Deliver:

• Furnace Setup
• Product Modeling
• Profile Generation
• Process Settings
• Multiple simulation cases as required for final recommendations
• Reports in PDF, Excel, and/or PowerPoint format

Custom Software Development

FurnXpert has been developing custom thermal software applications for Industrial Furnaces since early eighties. We provide both Web-based applications and Desktop programs to serve customers' specific needs.

Our specialty is working with technical products that typically require application design and thermal calculations as part of the selection and specification process. Our development team includes Mechanical, Metallurgical, Electrical and Software Engineers, with experience in a variety of industries. This unique combination means that we already understand customer's products and applications, saving them valuable time and resources.

Customization could be either adding Graphical User Interfaces to an existing software or develop new applications based on customers' specifications. We can also embed third party software on our software to enhance features and add functionality.

Level II Automation & Digital Twin

FurnXpert develops customized Level 2 Automation and Digital Twin solutions for industrial reheating furnaces and thermal processing systems.

Our Digital Twin software creates a virtual replica of a specific furnace to simulate furnace operations in real time. The system can be deployed on a local PC or cloud server and is tailored to the customer’s furnace design, process conditions, production requirements, and operating practices.

The software continuously models furnace behavior, product heating, fuel consumption, temperature profiles, and material movement to provide accurate process predictions and operational insights.

Using the Digital Twin environment, engineers can evaluate various operating scenarios without disrupting actual production. This enables optimization of furnace settings, heating profiles, throughput rates, combustion conditions, and energy usage — leading to improved process efficiency, reduced fuel consumption, enhanced product quality, and better operational decision-making.

FurnXpert Level 2 solutions can also be integrated with plant automation systems to support advanced supervisory control, process monitoring, setpoint generation, and real-time production analysis.