Abstract
The energy-intensive industry, heavily reliant on heat generation processes, faces the critical challenge of drastically reducing greenhouse gas emissions. This study reviews the potential of digital twin technology in decarbonizing combustion-dependent manufacturing processes. While primarily focusing on scholarly articles, our analysis may not cover all current industrial practices and digital twin implementations. This paper highlights challenges and opportunities in deploying practical digital twins for industrial furnaces within the Industry 4.0 framework. Digital twins, integrating real-time simulation models with predictive capabilities, aim to enhance industrial furnaces’ design, operation, and maintenance by combining high-fidelity simulations with data-driven modelling techniques. The findings indicate that digital twins can facilitate the transition to furnace electrification and adopting zero-carbon fuels, significantly reducing emissions and optimizing overall furnace performance. However, challenges like model reliability and high upfront investments in IT and connectivity infrastructures limit their widespread adoption. Despite these limitations, ongoing technological advancements predict a rapid expansion of digital twin applications in industrial furnaces, making them indispensable for achieving decarbonization goals in energy-intensive industries.
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