The aim of this project was to simulate a large industrial furnace and its operation with the purpose of identifying ways to reduce energy consumption and reduce its carbon footprint. The project was completed in 2 different stages and an accurate 3D model was built which included all the details of the furnace, heaters, nozzle output, cooling jackets and ventilation, etc. The results focused on temperature and melting profiles across the furnace and different heater locations were modelled to identify any potential savings. A parametric study was conducted to find the optimum location of the heaters. The simulations included complex heat transfer models and multiphase flow and the results were successfully compared against the experimental data provided by the client. Ultimately the new optimised design enabled the client to save significant amount of energy in running the furnace.