System and method of operating a batch melting furnace

A method of controlling a batch metal melting process in a melting furnace, comprising:

• determining at least one furnace parameter characterizing a melting furnace;
• adding a charge containing solid metal into the melting furnace;
• detecting at least one charge parameter characterizing the charge;
• firing a burner into the melting furnace to provide heat to melt the charge, and exhausting combustion products from the furnace through a passage;
• detecting at least one process parameter characterizing progress of melting the charge;
• calculating a furnace efficiency based on the at least one furnace parameter;
• calculating a predicted process pour readiness time based on the at least one charge parameter, the at least one process parameter, and the furnace efficiency by:
• calculating a theoretical energy requirement based on the at least one charge parameter;
• calculating a target fuel consumption based on the theoretical energy requirement and the overall furnace efficiency;
• calculating an actual fuel consumption based on the at least one process parameter;
• and
• calculating the predicted process pour readiness time based on comparing the target fuel consumption with the actual fuel consumption;
• and
• controlling the metal melting process based on the predicted process pour readiness time;
• wherein the passage to exhaust burner combustion products includes a flue;
• and
• wherein the at least one process parameter includes one or more of:
• burner firing rate, reactant enthalpy rate, exhaust enthalpy rate, flue temperature, furnace wall temperature, fuel heating value, flue exit combustion intensity, baghouse temperature, flue gas composition, flue duct temperature, furnace door temperature, furnace door gap size, furnace shell temperature, furnace chamber temperature, charge melt rate, furnace heat loss, elapsed melt operation time, and charge visual appearance.